AC Drives

Regenerative Energy Solutions

Product Summary
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Regenerative Energy Solutions
• Snubber Resistor Braking Kits
• Line Regeneration Controls
• Synchronous Rectifier Controls
AC Drives and Regenerative Energy
When the rotating element of an AC motor turns faster At this voltage level the energy is transferred to a resistor
than the AC drive’s speed command, the motor begins to (or group of resistors) where the energy is burned off as
act as a generator and pumps (regenerates) energy back heat. Some AC drives already include a built-in braking
into the DC bus of the drive. If the drive cannot absorb this transistor (such as the GV3000/SE Bookshelf drive) and
excess energy, the DC bus voltage will continue to climb only require the addition of a resistor kit. Snubber resistor
until the drive trips on a high bus fault. These regenerative braking kits are a lower cost solution compared to line
conditions can occur when: regeneration controls or synchronous rectifier controls.
Snubber braking resistors, however, require cool down
• quickly decelerating a high inertia load (flywheel,
time, which make them less suitable for highly cyclical
mechanical arm)
operations such as frequent, repetitive starts and stops.
• controlling the speed of a load moving vertically
Line regeneration controls or synchronous rectifier
downward (hoist, declining conveyor)
controls are more suitable for these applications.
• a sudden drop in load torque occurs (machining/drilling
operation or an industrial saw) Line Regeneration Controls use a set of transistors,
• the process requires repetitive acceleration and which pulse “on” at a predetermined DC bus voltage set
deceleration to a stop (indexing) below the AC drive’s trip point. At this voltage level the
• controlling the speed (tension control) of an unwind energy is transferred directly back to the AC power source.
application Line regeneration controls can operate in a continuous
mode up to the transistor current rating. Their ability to
Regenerative Energy Solutions regenerate power back to the power source also makes
them an energy saving device. Over time this energy
A 460 VAC drive operating on 460 VAC line power will
savings can offset the higher cost of these controls.
have a nominal DC bus voltage of 650 VDC (325 VDC for
a 230 VAC drive). When the DC bus exceeds 800 VDC Synchronous Rectifier Controls can be used either as
(400 VDC for a 230 VAC drive) the drive will trip. line regeneration controls or as AC line voltage to DC
voltage converters for powering the DC bus of an AC
There are three technologies available to prevent the AC
drive.
drive from reaching the trip level. Each technology has its
own advantages and disadvantages. The three
technologies are Snubber Resistor Braking, Line
Regeneration Control, and Synchronous Rectifier
Control.

Snubber Resistor Braking kits use a transistor and

circuitry that “turns on” at a predetermined DC bus
voltage, which is set below the AC drive’s trip point.
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In line regeneration control, the synchronous rectifier and Calculating the Regenerative Energy
the AC drive both receive their input power from the AC
1) Determine the speed/cycle profile of the application:
line. The AC drive’s DC bus terminals are also connected
to the DC terminals of the synchronous rectifier. Under N1 = minimum speed
regenerative conditions the synchronous rectifier channels N2 = maximum speed
the excess DC bus voltage, based on a preset level, back to t1 = total cycle time
the AC power line. t2 = deceleration time
In synchronous rectifier control, the AC drive (or a group
of AC drives) is connected directly to the DC output of the
synchronous rectifier control via the drive DC bus
terminals, thus bypassing the AC line and the AC drive’s
diode bridge front-end. With multiple AC drives
connected via a “common bus” to the synchronous
rectifier, regenerative energy is shared between the 2) Calculate or obtain the system inertia data:
motoring and regenerating drives, thus saving power. WK2s = WK2m + (WK2L / GR2)

When Is External Braking Required? Where:

Not every regenerative situation will require external WK2s = total system inertia
braking hardware. If the regenerative energy is small WK2m = motor rotor inertia
enough to be readily absorbed by the DC bus of the drive, WK2L = driven load inertia
then an external brake will not be necessary. A
GR2 = gear ratio (defined as motor revolutions/driven load
combination of extended deceleration time, reduced
revolutions)
change in speed and mechanical system friction will assist
in absorbing the excess energy. 3) Calculate the regeneration or braking torque required to
decelerate the load:
A drive operating on 460 VAC power will have a nominal
bus voltage of 650 VDC (325 VDC for 230 VAC drives). TR = Tdecel. – Tf
460 VAC drives are typically designed to operate with DC
TR = WK2 * (N2 –N1) - Tf
bus voltage levels up to 800 VDC (400 VDC for 230 VAC
308 * 12
drives) before tripping. The regenerative energy may be
small enough for the DC bus to remain under 800 VDC. Where:
Typically, if the regenerative horsepower is 10% or less TR = braking torque in ft-lbs.
than the drive horsepower rating, external braking Tf = friction torque
hardware will not be required.
4) Calculate the braking HP required at top speed:
HPregen = TR * N2
5250

5) The value of HPregen can now be compared to the drive

rating to determine if external braking hardware is needed.
If (HPregen / HPdrive) * 100 > 10%, external braking
hardware is recommended.
Sizing External Braking Hardware Calculating the Regenerative Current
If the results of step 5 indicate the need for external 10) The regenerative current must be compared to the
braking hardware, the following additional steps will current rating of the braking unit. The regenerative current
assist in properly sizing an external brake unit. To must not exceed the rated amps of the braking unit. Using
determine if the brake unit meets the application’s needs, the braking HP from step 4, the following rule-of- thumb
three items must be determined: average power formulas can be used to calculate the regenerative current:
generation, peak power, and peak regeneration current.
460 V Drives Iregen = 1.2 * HP regen
6) Average power generation is calculated as follows,
assuming the deceleration rate is linear: 230 V Drives Iregen = 2.4 * HP regen

HPregen = (TR * (N2+N1) / 2 * t1

5250 * t2

7) Convert the regeneration HP in watts (Average Power).

Wattsregen = HPregen * 746

8) Peak regeneration watts can be obtained by using the

HPregen calculated in step 4 and converting to watts. This
peak regeneration (watts) energy must be less than the
peak watt rating of the braking unit.

Determining the Duty Cycle

9) The braking duty cycle (percentage of time during an
operating cycle when braking occurs), must be
determined. A typical operating cycle consists of an
acceleration mode, a running at set speed mode, a
deceleration mode and finally a rest or zero speed mode.
Braking occurs during the deceleration mode.

Duty Cycle = Braking time

Cycle time

A lower duty cycle percentage will allow more time for

resistor cool-down. This will affect resistor sizing and
selection. A duty cycle of 50% or less makes snubber
brake control a good solution. For duty cycles near or at
100%, line regeneration control is more suitable.
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Snubber Braking Kits – Description and Selection Information
Snubber brakes consist of two components – braking Specifications
transistor circuitry and a resistor or set of resistors. Some • Rated Voltage: 3-phase, +10%, -20%
AC drives are manufactured with built-in snubber • Hertz: 50-60 Hz
transistor circuitry such as the GV3000/SE Bookshelf • Input Current: Rated DC current
drive. These drives only require the addition of a properly • Connections: Drive DC bus, ground,
sized resistor (refer to tables 5 and 6 for resistor kits and input AC line (single phase, rated
sizing information). For drives requiring an external voltage +10%, -20%, 50-60 Hz)
braking transistor, refer to table 1 for complete snubber • Adjustments: None, automatic
braking kits or tables 2 through 5 for separate snubber voltage level
transistor and resistor kits. • Current Limit: To rated DC current
• Maximum On-time: 60 seconds
Complete Snubber Resistor Braking Units • Operating Temperature: 0-50oC
Contains both a Snubber Transistor and Snubber Resistor • Humidity: Below 90%, non-condensing
• For 20-50% Duty Cycles • Atmosphere: Free of corrosive gas or dust
• NEMA 1 Enclosed • Panel Indicators: DC bus lamp, control power lamp,
• 230 V, 460 V, 575 V active braking lamp

Table 1 Complete Snubber Brake Kits Selection Table

Dimensions (in.)
Drive Snubber Brake Resistance Cont. Watt Instant. Watt Continuous
Rating Kit M/N Value Dissipation Dissipation Duty Cycle H W D
1 HP, 230 V 2SR20400 30 400 4000 50% 18.2 8.25 8.5
2SR20400 30 400 4000 30% 18.2 8.25 8.5
2 HP, 230 V
2SR20600 20 600 6000 50% 18.2 8.25 8.5
2SR20400 30 400 4000 20% 18.2 8.25 8.5
3 HP, 230 V 2SR20600 20 600 6000 30% 18.2 8.25 8.5
2SR21200 10 1200 12000 50% 18.2 8.25 8.5
2SR20600 20 600 6000 20% 18.2 8.25 8.5
5 HP, 230 V 2SR21200 10 1200 12000 30% 18.2 8.25 8.5
2SR21800 6 1800 18000 50% 18.2 10.25 10.5
2SR21200 10 1200 12000 50% 18.2 8.25 8.5
7 1/2 HP, 230 V
2SR21800 6 1800 18000 50% 18.2 10.25 10.5
2SR21200 10 1200 12000 50% 18.2 8.25 8.5
10 HP, 230 V
2SR21800 6 1800 18000 50% 18.2 10.25 10.5
1 HP, 460 V 2SR40400 120 400 4000 50% 18.2 8.25 8.5
2SR40400 120 400 4000 30% 18.2 8.25 8.5
2 HP, 460 V
2SR40600 75 600 6000 50% 18.2 8.25 8.5
2SR40400 120 400 4000 20% 18.2 8.25 8.5
3 HP, 460 V 2SR40600 75 600 6000 30% 18.2 8.25 8.5
2SR41200 40 1200 12000 50% 18.2 8.25 8.5
2SR40600 75 600 6000 20% 18.2 8.25 8.5
5 HP, 460 V 2SR41200 40 1200 12000 30% 18.2 8.25 8.5
2SR41800 25 1800 18000 50% 18.2 10.25 10.5
2SR41200 40 1200 12000 50% 18.2 8.25 8.5
7 1/2 HP, 460 V
2SR41800 25 1800 18000 50% 18.2 10.25 10.5
2SR41200 40 1200 12000 50% 18.2 8.25 8.5
10 HP, 460 V
2SR41800 25 1800 18000 50% 18.2 10.25 10.5
15 HP, 460 V 2SR41800 25 1800 18000 50% 18.2 10.25 10.5
20 HP, 460 V 2SR41800 25 1800 18000 50% 18.2 10.25 10.5
2SR50600 105 600 6000 20% 18.2 8.25 8.5
5 HP, 575 V 2SR51200 52 1200 12000 40% 18.2 8.25 8.5
2SR51800 35 1800 18000 50% 18.2 10.25 10.5
2SR51200 52 1200 12000 20% 18.2 8.25 8.5
10 HP, 575 V
2SR51800 35 1800 18000 40% 18.2 10.25 8.5
Note: To properly size a complete snubber resistor braking kit, calculate the peak and average regeneration power of the application, as outlined in
steps 5 through 9. If the peak and average power cannot be calculated due to unknown values for items such as system inertia, select the braking
units above based on the drive horsepower rating and the application duty cycle.
Snubber Transistor Braking Kits IP20 Enclosed - Snubber Transistors Kits
• For 6-20% Duty Cycles
Snubber transistor braking kits provide transistor circuitry
• 230 V, 460 V
for AC drives requiring an external braking transistor.
Snubber transistor kits are available in IP20 enclosures or
Specifications
as open chassis construction. • Input Power: Derived from DC bus
• Fan Input Voltage: 1-phase, 115 VAC
Open Chassis - Snubber Transistors Kits • Hertz: 50-60 Hz
• For 20-100% Duty Cycles
• Input Current: Rated DC current
• 230 V, 460 V
• Connections: Drive DC bus, ground, input
AC line (single phase, 115 VAC, 50-60 Hz),
Specifications
resistor unit
• Input Power: 1-phase (based on rating)
• Adjustments: None, automatic voltage level
• Fan Input Voltage: Derived internally
• Current Limit: To rated DC current
• Hertz: 50-60 Hz
• Maximum On-time: 60 seconds maximum
• Input Current: Rated DC current
• Operating Temperature: 0-50oC
• Connections: Drive DC bus, ground, input AC line
• Humidity: Below 90%, non-condensing
(single phase, rated volts +10, -20% 50-60 Hz), resistor
• Atmosphere: Free of corrosive gas or dust
unit
• Panel Indicators: DC bus lamp, active braking lamp
• Adjustments: None, automatic voltage level
• Current Limit: To rated DC current
• Maximum On-time: See selection table 2
• Operating Temperature: 0-50oC
• Humidity: Below 90%, non-condensing
• Atmosphere: Free of corrosive gas or dust
• Panel Indicators: DC bus lamp, control power lamp,
active braking lamp
Table 3 IP20 Snubber Transistor Kits
Snubber Dimensions (in.)
AC Line Transistor Amps DC Min. UL
Voltage Kit M/N RMS Ohms Labeled H W D
M3575TL15 15 25 No 12.75 3 8.7
230 M3575TL30 30 12.5 No 12.75 3 8.7
M3575TL60 60 6.25 No 12.75 4 8.7
M3575TH15 15 50 No 12.75 3 8.7
M3575TH30 30 25 No 12.75 3 8.7
M3575TH75 75 10 No 12.75 4 8.7
Table 2 Chassis Snubber Transistor Kits 460 M3575TH125 125 6 No 17.75 4 8.7
M3575TH150 150 5 No 17.75 4 8.7
Dimensions
Snubber (in.) M3575TH200 200 3.75 No 17.75 7 9.2
AC Line Transistor Amps DC Min. Maximum UL M3575TH300 300 2.5 No 17.75 7 9.2
Voltage Kit M/N RMS Ohms On-time Labeled H W D
2ST20019 19 20 120 Sec. No 15 6 6.75 Note: When matching a transistor kit with resistors, it is important to
230
2ST20054 54 6 120 Sec. Yes 15 6 6.75 select a resistor with the proper ohmage. The ohmage must be equal to or
2ST40009 9 75 Continuous No 15 6 6.75 greater than the ohmage rating of the transistor. If the resistor ohmage is
2ST40027 27 25 120 Sec. Yes 15 6 6.75 too low, a short of the drive DC bus may occur which can result in dam-
2ST40075 75 10 120 Sec. No 15 12 8
age to the braking transistor or the drive. If the resistor ohmage is too
high, little or no braking will occur.
460 2ST40125 125 6 120 Sec. No 15 12 8
To properly size a snubber transistor kit, calculate the regenerative
2ST40150 150 5 Continuous No 16 15 8
current of the application as outlined in steps 5 through 10. If the regener-
2ST40200 200 3.8 Continuous No 16 15 8
ative current cannot be calculated due to unknown values for items such
2ST40300 300 2.5 Continuous No 16 15 8 as system inertia, the drive horsepower can be multiplied by the rule-of-
thumb formulas in step 10.
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Snubber Resistor Braking Kits
Snubber resistor braking kits consist of a resistor, or a
combination of resistors, packaged in an IP20 enclosure
for easy mounting and matching with a snubber transistor
kit. Tables 4 and 5 list the snubber resistor kits available in
IP20 enclosures, rated for 6 to 20% duty cycles. Loose
resistors or resistors with ratings not listed in tables 4 or 5
(i.e., greater than 20% duty cycle) must be obtained
directly from a third party vendor.

IP20 Snubber Resistor Brake Kits

• For 6-20% Duty Cycles Table 5 460 V Snubber Resistor Kits
• 230 V, 460 V Snubber Braking Watts Dimensions (in.)
Resistor Braking Duty Max. Load
Kit M/N HP Cycle Peak Cont. Amps Ohms H W D
Specifications M3575RH1M 6% 50
1 746 1 780 12.75 4 8.7
• Optional Fan Input Voltage: 1-phase, 60 Hz, 115 VAC M3575RH1MF 20% 150
M3575RH2M 6% 100
• Connections: Drive DC bus, fault contacts, optional fan 2 1492 2 390 12.75 4 8.7
M3575RH2MF 20% 300
AC input line input (single phase, 60 Hz, 115 VAC) M3575RH3M 6% 150
3 2238 3 260 12.75 4 8.7
• Adjustments: None M3575RH3MF 20% 450
• Maximum On-time: 60 seconds M3575RH4M
4
6%
2984
200
4 195 12.75 7 8.7
M3575RH4MF 20% 600
• Operating Temperature: 0-50oC
M3575RH5B 6% 250
• Humidity: Below 90%, non-condensing M3575RH5BF
5
20%
4000
800
5 150 17.75 4 8.7

• Atmosphere: Free of corrosive gas or dust M3575RH6M

6
6%
4476
300
6 130 12.75 7 8.7
• Fault Indicator: 1 N.C. contact rated for 1 A @ 24 VDC M3575RH6MF 20% 900
M3575RH8B 6% 350
or 0.5 A @ 115 VAC. Contact opens on over- M3575RH8BF
8
20%
6000
1200
8 90 17.75 4 8.7

temperature condition (85oC or higher). M3575RH9M 6% 450

9 6714 9 87 12.75 10 8.7
M3575RH9MF 20% 1350

Table 4 230 V Snubber Resistor Kits M3575RH11B

M3575RH11BF
11
6%
20%
8000
450
1600
11 60 17.75 7 9.2

Snubber Braking Watts Dimensions (in.) M3575RH16B 6% 700

Resistor Braking Duty Max. Load 16 12000 16 45 17.75 7 9.2
Kit M/N HP Cycle Peak Cont. Amps Ohms H W D M3575RH16BF 20% 2400
M3575RL1M 6% 50 M3575RH24B 6% 1000
1 746 2 190 12.75 4 8.7 24 18000 24 30 17.75 10 9.7
M3575RL1MF 20% 150 M3575RH24BF 20% 3600
M3575RL2M 6% 100 M3575RH50G1F 50 20% 40000 8000 53 14 41.25 29 22
2 1492 4 95 12.75 4 8.7
M3575RL2MF 20% 300 M3575RH100G2F 100 20% 80000 16000 106 7 50.25 29 22
M3575RL3B 6% 100 M3575RH150G3F 150 20% 24000 24000 159 5 59.25 29 22
3 1989 5 75 17.75 4 8.7
M3575RL3BF 20% 400
M3575RL3M 6% 150
3 2238 6 63 12.75 4 8.7
M3575RL3MF 20% 450
M3575RL4M 6% 200 Note: When matching a resistor kit with a snubber transistor kit or with a
4 2984 8 48 12.75 7 8.7 drive that has a built-in braking transistor, it is important to select a resistor
M3575RL4MF 20% 600
M3575RL5B 6% 200 with the proper ohmage. The ohmage must be equal to or greater than the
5 3979 10 38 17.75 4 8.7 ohmage rating of the transistor. If the resistor ohmage is too low, a short of
M3575RL5BF 20% 800
M3575RL6M 6% 300 the drive DC bus may occur, resulting in damage to the braking transistor or
6 4476 12 32 12.75 7 8.7 the drive. If the resistor ohmage is too high, little or no braking will occur.
M3575RL6MF 20% 900
M3575RL8B 6% 300 To determine the proper size snubber resistor kit, calculate the peak and
8 5968 15 25 17.75 4 8.7 average power regeneration, as well as the braking duty cycle requirement, as
M3575RL8BF 20% 1200
M3575RL9M 6% 450 outlined in steps 5 through 10. If the regenerative braking condition occurs
9 6714 18 21 12.75 10 8.7 infrequently (several times a day, with long periods of rest), the resistor kit
M3575RL9MF 20% 1350
M3575RL11B 6% 400 can be sized using its instantaneous watt rating. If the regenerative braking
11 7967 20 19 17.75 7 9.2 condition is repetitive and frequent, the resistor kit must be sized according to
M3575RL11BF 20% 1600
M3575RL16B 6% 600 the kit’s duty cycle and continuous watts rating.
16 11936 31 13 17.75 7 9.2
M3575RL16BF 20% 2400
M3575RL24B 6% 900
24 17904 47 8 17.75 10 9.7
M3575RL24BF 20% 3600
Snubber Resistor Braking Selection Table 7 Snubber Resistor Size for 20-100%
Information Duty Cycles
Snubber Approx.
Table 6 provides snubber resistor sizing information for Duty Transistor Minimum Maximum Resistor
Ohms Ohms
HP Cycle Kit M/N KW
applications using the GV3000/SE Bookshelf drive.
230 V Drive Snubber Resistor Sizing
Table 7 provides snubber resistor sizing and appropriately 60% 2ST20019 20 58 2
1-5
matched chassis style snubber transistor kits for 100% 2ST20019 20 35 3.75
applications with 20% or greater duty cycles. 60% 2ST20019 20 29 3.75
7.5 - 10
100% 2ST20054 6 17 7.5
60% 2ST20054 6 14 9
15 - 20
100% 2ST20054 6 8.5 15

460 V Drive Snubber Resistor Sizing

60% 2ST40027 25 230 2.5

1-5
100% 2ST40027 25 139 3.75
60% 2ST40027 25 116 5
7.5 - 10
100% 2ST40027 25 70 7.5
20% 2ST40027 25 116 5
15 - 30 60% 2ST40027 25 39 13
100% 2ST40075 10 23 20
20% 2ST40075 10 58 9
40 - 60 60% 2ST40075 10 20 27
Table 6 Snubber Resistor Kit Sizing for 100% 2ST40075 10 12 45
GV3000/SE Bookshelf Drives 20% 2ST40075 10 35 15
75 - 100 60% 2ST40075 10 12 45
Cabinet Dim.
GV3000/SE Snubber (in.) Peak Cont. 100% 2ST40125 6 7 75
Bookshelf Braking Duty Resistor Braking Braking Load Amp
M/N HP Cycle Kit M/N H W D Watts Watts Ohms Rating 20% 2ST40125 6 17 30

31ER/ 1 6% M3575RH1M 12.75 4 8.7 746 50 780 1

125 - 200 60% 2ST40150 5 6 90

31ET4060 1 20% M3575RH1MF 12.75 4 8.7 746 150 780 1 100% 2ST40200 3.8 4 150

38ER/ 2 6% M3575RH2M 12.75 4 8.7 1492 100 390 2 20% 2ST40075 10 14 37

38ET4060 2 20% M3575RH2MF 12.75 4 8.7 1492 300 390 2 40% 2ST40125 6 7 75
55ER/ 3 6% M3575RH3M 12.75 4 8.7 2238 150 260 3 250 60% 2ST40150 5 6 112
55ET4060 3 20% M3575RH3MF 12.75 4 8.7 2238 450 260 3 80% 2ST40200 3.8 4 150
85ER/ 4 6% M3575RH4M 12.75 7 8.7 2984 200 195 4 100% 2ST40300 2.5 3 187
85ET4060 4 20% M3575RH4MF 12.75 7 8.7 2984 600 195 4
20% 2ST40075 10 12 45
5 6% M3575RH5B 17.75 4 8.7 4000 250 150 5
40% 2ST40125 6 6.5 90
5 20% M3575RH5BF 17.75 4 8.7 4000 800 150 5
300 50% 2ST40150 5 5.5 112
6 6% M3575RH6M 12.75 7 8.7 4476 300 130 6
60% 2ST40200 3.8 4 135
6 20% M3575RH6MF 12.75 7 8.7 4476 900 130 6
100% 2ST40300 2.5 3 224
126ER/ 8 6% M3575RH8B 17.75 4 8.7 6000 350 90 8

126ET4060 8 20% M3575RH8BF 17.75 4 8.7 6000 1200 90 8

20% 2ST40125 10 11 62

150ER/ 9 6% M3575RH9M 12.75 10 8.7 6714 400 87 9 40% 2ST40150 5 5.5 104
350
150ET4060 9 20% M3575RH9MF 12.75 10 8.7 6714 1350 87 9 60% 2ST40200 3.8 4 157
240ER/ 11 6% M3575RH11B 17.75 7 9.2 8000 450 60 11 80% 2ST40300 2.5 3 208
240ET4060 11 20% M3575RH11BF 17.75 7 9.2 8000 1600 60 11 20% 2ST40200 3.8 9 60
400
300ER/ 16 6% M3575RH16B 17.75 7 9.2 12000 700 45 16 60% 2ST40300 2.5 3 179
300ET4060 16 20% M3575RH16BF 17.75 7 9.2 12000 2400 45 16

430ER/ 24 6% M3575RH24B 17.75 10 9.7 18000 1000 30 24

430ET4060 24 20% M3575RH24BF 17.75 10 9.7 18000 3600 30 24
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Line Regeneration Controls Specifications
• Rated Voltage: +/- 10%
Line regeneration controls are best suited for applications
• Hertz: 50/60 Hz
requiring frequent, repetitive starts and stops or • Input Current: 100% of rated DC current, inverse time
applications requiring the AC drive to hold back on a overload trip
regenerative load. Line regeneration controls do not • Connections: Input AC line, drive DC bus, ground
radiate the large amounts of heat that can radiate from a • Power Factor: Greater than 90%
snubber resistor. This radiated heat must be considered • Fusing: AC input line, DC drive bus
when applying snubber resistors in small machine rooms • Adjustments: None, automatic voltage level
or near operating personnel. Finally, line regeneration • Maximum On-time: Continuous
controls channel the excess regenerative energy back to • Operating Temperature: 0-50oC
the AC power line, which provides the additional benefit • Humidity: Below 90%, non-condensing
of energy savings. • Atmosphere: Free of corrosive gas and dust
• Internal Indicators: Drive active LED, current limit
Energy Savings Example: active
• External Indicator: Power indicator lamp, DC bus
If a drive rated for 20 HP fully regenerates into a snubber ammeter
resistor grid during 20% of the application duty cycle, the
resistor grid actually dissipates 2,984 watts in heat (20 HP Table 8 Line Regeneration Controls Selection
x 20% x 746 watts/HP), every time the load is stopped. If Tables
the application runs 24 hours a day, 365 days per year, w/o Fan Option
AC Line Regeneration RMS DC
stopping 20% of the time, the wasted energy would total Volts Control Unit M/N Amps 45 sec. KW Cont. KW

26,139 KWH (2984 W x 24 Hrs x 365 Days/1000 watts 1RG22008 10 3 3

1RG22015 20 7 4
per KW). With an assumed energy cost of $.08 per KWH, 230V
1RG22025 30 10 4
this application would save $2,091 per year using a line 1RG22045 45 15 4

regeneration control rather than snubber braking resistors. 1RG42008 10 7 4

1RG42015 20 14 4
1RG42025 30 20 4
Line Regeneration Controls 460V
1RG42045 45 30 4
• For 50-100% Duty Cycle 1RG42060 60 41 37.5
1RG42090 90 61 37.5
• 230 V, 460 V
• NEMA 12 Enclosure
Regeneration Control Dimensions (in.)
• DC Ammeter – Door Mounted
Amp Rating H W D
w/o Fan Option 10,20,30,45 17.5 16.2 8.3
10,20,30,45 17.5 18.5 8.3
with Fan Option
60,90 26 23 10.4

Note: To determine the proper size line regeneration control, calculate the regenerative current of the application, as outlined in steps 5 through
10. If the regenerative current cannot be calculated due to unknown values for items such as system inertia, the drive horsepower can be multi-
plied by the rule-of-thumb formulas in step 10.
Up to four 60 amp or two 90 amp line regeneration control units can be connected in parallel for use with larger amp rated drives. The model
numbers listed in table 8, however, cannot be paralleled. Contact Reliance Electric Drives for more information on regenerative controls config-
ured for parallel operation.
Synchronous Rectifier Controls
• Use as line regeneration control To function properly, each synchronous rectifier control
• Use as a DC bus power supply source unit must have a special input line reactor, varistor, and
- Allows energy to be shared between regenerating and harmonic filter connected at its AC input power terminals.
motoring drives Up to three synchronous rectifiers can be connected in
• IP20 enclosures parallel for higher horsepower applications.

Synchronous Rectifier Control used as common DC bus for three GV3000/SE drives

Specifications • Output Signals: RDY signal, FR signal, instantaneous

• Input Voltage: 200-230 VAC, 380-460 VAC models power loss, main magnetic contactor reference contact
• Hertz: 50/60 Hz • Monitor Display (four, 7-segment LEDs): Input current,
• Output Current: Per rated DC current input power voltage, DC bus voltage, power, and load
• Protection Functions: Overcurrent, overload, ratio
overvoltage, low voltage, phase loss • Ambient Temperature: 0-55oC
• Input Signals: Run, reset, answer-back of main magnetic • Humidity: Below 90%, non-condensing
contactor • Atmosphere: Free of corrosive gas and dust

Table 9 Synchronous Rectifier and Accessory Selection Table

Additional Hardware Required Ahead of Each Synchronous Rectifier
Synch. Rectifier Output
AC Line Voltage Unit M/N Module Type KVA Amps AC Line Reactor Varistor Harmonic Filter EMC Filter Unit
SS4207 Master 9.5 27 MT-B0023 23SAD431 MC-B0002 -
SS4207P Slave 9.5 27 MT-B0023 23SAD431 MC-B0002 -
SS4218 Master 22.5 64 MT-B0014 23SAD431 MC-B0002 -
SS4218P Slave 22.5 64 MT-B0014 23SAD431 MC-B0002 -
200-230V
SS4222 Master 27 76 MB-B0025 23SAD431 MC-B0002 -
SS4222P Slave 27 76 MB-B0025 23SAD431 MC-B0002 -
SS4265 Master 75 200 MB-B0025 (qty 2) - - EM441B
SS4265P Slave 75 200 MB-B0025 (qty 2) - - EM441B
SS4415 Master 19 27 MT-B0023 23SAD102 MC-B0002 -
SS4415P Slave 19 27 MT-B0023 23SAD102 MC-B0002 -
SS4437 Master 45 64 MT-B0013 23SAD102 MC-B0002 -
380-460V
SS4437P Slave 45 64 MT-B0013 23SAD102 MC-B0002 -
SS441B Master 135 200 MB-B0025 (qty 2) - - EM441B
SS441BP Slave 135 200 MB-B0025 (qty 2) - - EM441B

Note: Synchronous Rectifiers SS4265, SS4265P, SS441B, and SS441BP require two MB-B0025 AC line reactors connected in parallel.
EMC Filter Unit consists of: one EMC Filter, one Main Contactor, one Harmonic Filter, & one Varistor.
Synchronous Rectifiers are only sold through Rockwell Automation Regional Drive Centers.
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NOTE: This material is not intended to provide operational instructions.

Appropriate Reliance Electric Drives instruction manuals precautions should be
This document located at: studied prior to installation, operation, or maintenance of equipment.
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