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SR5K100V25R
Smart 2500W
Shunt Regulator
The SR5K100V25R Shunt Regulator has been designed to Standard Features
work in conjunction with a wide variety of power sources
• Dissipates Excess EMF and Regeneration voltage to
and motor controllers. Over voltage shunting may be
prevent system failure or damage.
required when braking or drastically reducing DC motor
• Simple on-the-fly adjustment of nine preset shunt
speeds which creates Back Electro-Motive Force (EMF),
or Regeneration and is used to prevent damage to the voltages.
power supply and associated electronics. This voltage • Full Auto shunt threshold set for a full range of voltages
can equal to or even exceed the supply voltage in some from 12 to 100 volts.
cases depending on the rotational inertia of the mechanical • Over heating protection can be cycled repeatedly
system, causing system failures or permanent damage. The without replacing an inline fuse or circuit breaker.
Roboteq SR5K100V25R Shunt Regulator applies a heavy • Fast easy connection to unit using Fast-On type
two-level resistive load during overvoltage conditions to connectors and standard crimp style lugs.
bring voltages back to safe levels. • Voltage loop through connections makes the use of
“Y” cables unnecessary.
Applications
• Solid 6061 aluminum base plate for easy mounting and
• Automatic Guided Vehicles superb heatsinking.
• Small Electric Vehicles, Electric Bikes • 5000 Watt instantaneous, 200 Watts continuous load
• Police and Military Robots capability.
• Hazardous Material Handling Robots • Flashing Status Lamp to indicate the operational mode
• Automated Delivery Robots including Scan, Relay ON, and Resistor Cooling modes.
• Motorized Factory Machinery • Active relay switching indication lamps during shunting
operation.
• Compact, Low Cost with Simple Operation.
Ordering Information
Reference Channels Watts Volts Presets Max Load R
SR5K100V25R 1 200 100 10 2.5 Ohm
SR5K100V25R Datasheet 1
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Operation
The Shunt Regulator is connected across the DC power source to the operating electronics. It then monitors
the line continuously, and when the voltage exceeds the clipping preset the microcontroller activates the
switching which connects the shunt resistor across the load. For the time that the measured voltage exceeds
the preset value, the shunt remains connected. When the voltage levels drop to a level just below the
threshold value minus a preset hysteresis loop value, the shunt disconnects. Constant monitoring of the shunt
resistor temperature ensures that long term shunting does not exceed the thermal limits of the two 100W
load resistors. To ensure that the proper braking load is applied at the correct time, the Shunt Regulator uses a
Dual Resistor configuration. As the voltage rises, the first 100W load resistor is made active, then the second
resistor about 3 volts higher. This allow more accurate control of the overvoltage condition.
FIGURE 1. Block Diagram of Shunt Regulator Assembly
2 SR5K100V25R Datasheet Version 1.0 June 2, 2024
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+ +
0 ~100 V
Power supply Motor
or battery Drive Motor
-
+ +
0 ~100 V + + - -
Power supply Motor
or battery Drive Motor
Shunt
-
Regulator
FIGURE 2. General Connection Diagram
X
+ + - -
The connection to the shunt Shunt
+ regulator is illustrated in figure
+ 2. Please note that if the auxiliary power
0 ~100 V Regulator
connectors are used, the motor drive’s current will constantly flow through the fast-on connectors. Use the
Power
connection supply in Figure 3 only if you can guarantee that
illustrated Motor
the application’s current remains below 40 A,
orthe
battery Drive Motor
which is maximum rating for the fast-on connectors.
-
X
+ +
0 ~100 V + + - -
Power supply Motor
or battery Drive Motor
Shunt
-
Regulator
+ + - -
Shunt
Regulator
FIGURE 3. Improper connection example
SR5K100V25R Datasheet 3
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Compatibility with other Roboteq products
The SRV100 Shunt Regulator module is fully compatible with all Roboteq motor controllers which include both
brushed and brushless types. Loop through connections on the Shunt Regulator allow for easy power pass
through connections.
FIGURE 4. Typical wiring with Roboteq controller
Operation
FIGURE 5. Location of indicator lamps and Rotary switch
4 SR5K100V25R Datasheet Version 1.0 June 2, 2024
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Upon power up the STATUS LED’s will remain off for 3 seconds. During the initial power up delay, the
input voltage applied across the Shunt Regulator is measured and evaluated. The AUTO mode value is set.
The controller then goes into SCAN mode, ready to activate the load if an overvoltage condition occurs.
The STATUS LED flashes twice a second during SCAN mode when there is no overload and conditions are
nominal.
When an over voltage condition occurs, the STATUS LED extinguishes and one or both of the load switches
becomes active, with the corresponding LOAD LED illuminated depending on whether one or both shunt
loads are active. These will stay lit during the overvoltage condition as long as the resistors do not exceed
their power rating. If the duration of the over voltage causes a thermal overload condition in the load resistors
(about 70C), the controller automatically turns off the loads to prevent damage to the Shunt Regulators
electronics. Both LOAD LED’s will then turn off, and the STATUS LED will show a fast double flash spaced
at one second intervals to indicate the unit is in the COOLDOWN mode. Depending on heat sink of the base
metal plate of the Shunt Regulator, this may take up to a minute or more to recover and the temperature of
the 100W load resistors to return to a safe level. The double flash will stop and at that point the loads will be
turned back on if needed. If the over load time period calculated by the i2t protection algorithm exceeds the
load resistors manufacturers specifications, then loading is also discontinued. The STATUS LED will remain on
solid until the time period has elapsed to re-enable loading. Unlike the previous version of the firmware, the
user does not have to hit a reset button to recover. The controller in the Shunt Regulator will release the load
from shutdown after a pre determined period depending on the overload condition and automatically reset and
resume scanning operation.
LED Indicator Lamp Summary
Firmware before January 2022
FIGURE 6. All OFF – Power is OFF
FIGURE 7. Both Loads are Active
SR5K100V25R Datasheet 5
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FIGURE 8. Load Alternating – Equivalent to One Load Active
FIGURE 9. Status ON Solid – i2t overvoltage max limit reached, loads cut off
FIGURE 10. Double Flash Status – Thermal Overload
Firmware after January 2022
(All above except “Status ON Solid” has been replaced)
FIGURE 11. All Three Flickering – Overvoltage, trying to re-connect loads.
This replaces the Solid ON condition, which takes longer to attempt loading recovery.
6 SR5K100V25R Datasheet Version 1.0 June 2, 2024
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Selecting the Clipping Voltage
Voltage selection is accomplished by setting a rotary PCB mounted switch. The following shunting voltages are
preset:
Switch Clip Voltage
0 AUTO
1 20V
2 25V
3 30V
4 35V
5 40V
6 60V
7 80V
8 100V
9 -
The preset voltages for shunting can be set at any time during operation. The selection of a proper shunt clip
voltage above the power supply voltage is crucial for proper operation. Standard shunting voltages from 20
volts to 120 volts maximum are available on the switch.
Auto Mode is active when switch position “0” is selected. The processor reads the power line voltage upon
power up and sets a fixed preset threshold (about 5v) above that value. This will allow for intermediate values
to be obtained for shunting.
Caution
Be aware that if the device is in auto mode and is charging, resistors may connect to the system as the
voltage increases. Despite the built-in I2T protection temporarily disconnecting the resistors, repeated
cycling can lead to their damage. To prevent this, always switch to manual selection mode if the shunt
regulator remains connected during battery charging.
Note: The momentary push button on the status area of the PCB is not currently used and will become
available at a future time to implement additional features.
SR5K100V25R Datasheet 7
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Product Specifications
Electrical Specifications
Absolute Maximum Voltage input range 12 – 120vdc
Typical operating input voltage 20 – 100vdc
Auto Mode input voltage range 12 – 100vdc
Current Consumption at 50vdc 25 ma
Current Consumption at 25vdc 12 ma
Filter Capacitance 1650uF
Maximum Cont. Power Dissipation 200W
Total Load Resistance 2.5 Ohms 200W
SCAN mode Sampling rate Every 1.0 mS
FIGURE 12. Overload vs. Duration for the Shunt Regulator Loading Profile
Max Amperage at various clip level settings
8 SR5K100V25R Datasheet Version 1.0 June 2, 2024
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Case 1: Single 5 ohm primary loading
Clip Voltage Amperage Watts
20 4 80
30 6 180
40 8 320
50 10 500
60 12 720
70 14 980
80 16 1280
90 18 1620
100 20 2000
Case 2: Dual Load 2.5 ohm loading
Clip Voltage Amperage Watts
20 8 160
30 12 360
40 16 640
50 20 1000
60 24 1440
70 28 1960
80 32 2560
90 36 1620
100 40 4000
Mechanical Specifications
Size (H x W x D) 35mm x 100mm x 159mm
Weight 0.54 kg
FIGURE 13. Mounting Plate Hole Location
SR5K100V25R Datasheet 9
