Manual

ManualsBrandsRockwell Automation ManualsEquipment1336_S_F_T Allen-Bradley Dynamic Braking

Installation Data

1336-5.64 — July, 2005

Allen-Bradley

1336/1336VT/1336 PLUS/PLUS II/IMPACT

1336 FORCE Drives

Dynamic Braking

Series D Cat. No. 1336-MOD-KA005, KB005 and KC005

Series D Cat. No. 1336-MOD-KA010, KB010 and KC010

Series D Cat. No. 1336-MOD-KB050 and KC050

Table of Contents

What This Option Provides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Where This Option Is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

What These Instructions Contain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

How Dynamic Braking Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

How to Select a Dynamic Brake Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Table 1a — 200-240V AC Drive Brake Assembly Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 2a — 380-480V AC Drive Brake Assembly Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 3a — 500-600V AC Drive Brake Assembly Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

KA005-KA010, KB005-KB010 and KC005-KC010

Dimensions, Weights and Conduit Entry Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

KB050 and KC050

Dimensions, Weights and Conduit Entry Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Recommended Brake Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Brake Fault Contact Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Brake Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Brake Module Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

KA005-KA010, KB005-KB010 and KC005-KC010

Terminal Block, Fuse and Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

KB050 and KC050

Terminal Block, Fuse and Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

KA005-KA010, KB005-KB010 and KC005-KC010

Wiring Scheme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

KB050 and KC050

Wiring Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DC Power Wiring Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table 1b — DC Brake Power Wiring for 200-240V AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table 2b — DC Brake Power Wiring for 380-480V AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table 3b — DC Brake Power Wiring for 500-600V AC Drives . . . . . . . . . . . . . . . . . . . . . . . . . 27

Summary of content (28 pages)

PAGE 1
Installation Data Allen-Bradley 1336/1336VT/1336 PLUS/PLUS II/IMPACT 1336 FORCE Drives Dynamic Braking Series D Cat. No. 1336-MOD-KA005, KB005 and KC005 Series D Cat. No. 1336-MOD-KA010, KB010 and KC010 Series D Cat. No. 1336-MOD-KB050 and KC050 Table of Contents What This Option Provides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Where This Option Is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2
Heavy Duty Dynamic Braking What This Option Provides The Heavy Duty Dynamic Braking Option provides a self contained NEMA Type 1 enclosed assembly that is wired to a 1336 AC Drive. Dynamic braking can increase the braking torque capability of a drive up to 100%.
PAGE 3
Heavy Duty Dynamic Braking 3 Expensive bridge configurations use SCRs or transistors that can transform DC regenerative electrical energy into fixed frequency utility electrical energy. A more cost effective solution is to provide a Transistor Chopper on the DC Bus of the AC PWM drive that feeds a power resistor which transforms the regenerative electrical energy into thermal energy. This is generally referred to as Dynamic Braking.
PAGE 4
Heavy Duty Dynamic Braking Figure 1 Simplified Schematic of Dynamic Brake Module + DC Bus Fuse Bus Caps FWD To Voltage Dividers Voltage Divider Dynamic Brake Resistor To Voltage Control Signal Common Chopper Transistor FWD Chopper Transistor Voltage Control Crowbar SCR Voltage Divider Fuse To Crowbar SCR Gate To Voltage Control Bus Caps To Voltage Control – DC Bus Dynamic Brake Modules are designed to be applied in parallel if the current rating is insufficient for the application.
PAGE 5
Heavy Duty Dynamic Braking How to Select a Dynamic Brake Module 5 As a rule, a Dynamic Brake Module can be specified when regenerative energy is dissipated on an occasional or periodic basis. In general, the motor power rating, speed, torque, and details regarding the regenerative mode of operation will be needed in order to estimate what Dynamic Brake Module rating to use.
PAGE 6
Heavy Duty Dynamic Braking How to Select a Dynamic Brake Module Gather the following information: • Power rating from motor nameplate in watts, kilowatts, or horsepower • Speed rating from motor nameplate in rpm or rps (radians per second) • Motor inertia and load inertia in kg-m2 or lb-ft2 • Gear ratio (GR) if a gear is present between the motor and load • Motor shaft speed, torque, and power profile of the drive application Figure 2 shows the speed, torque, and power profiles of the drive as a functi
PAGE 7
Heavy Duty Dynamic Braking 7 Figure 2 Application Speed, Torque and Power Profiles ω(t) ωb ωo 0 t1 t2 t3 t4 t 1 + t4 t 0 t1 t2 t3 t4 t 1 + t4 t t1 t2 t3 t4 t 1 + t4 t T(t) P(t) 0 -Pb 1336-5.
PAGE 8
Heavy Duty Dynamic Braking Step 1 — Determine the Total Inertia JT = Jm + (GR2 ✕ JL) 1.0 lb-ft2 = 0.04214011 kg-m2 = Total inertia reflected to the motor shaft (kg-m2) JT Jm = Motor inertia (kg-m2) GR = Gear ratio for any gear between motor and load (dimensionless) Note: For 2:1 gear ratio, GR = 0.5.
PAGE 9
Heavy Duty Dynamic Braking 9 Step 3 — Calculate the Maximum Dynamic Brake Resistance Value Rdb1 = 0.9 ✕ Vd2 Vd Pb Pb = DC Bus voltage the chopper module regulates to (375V DC, 750V DC, or 937.5V DC) = Peak braking power calculated in Step 2 (watts) Rdb1 = Maximum allowable value for the dynamic brake resistor (ohms) Rdb1 = [ ] ✕ [ Rdb1 = _________ ohms ] The choice of the Dynamic Brake resistance value should be less than the value calculated in Step 3.
PAGE 10
Heavy Duty Dynamic Braking The average power in watts regenerated over the period t4 is: Pav = [t3 - t2] t4 Pb ✕ 2 ( ωb + ωo ωb ) Pav = Average dynamic brake resister dissipation (watts) t3 - t2 = Deceleration time from ωb to ωo (seconds) t4 = Total cycle time or period of process (seconds) Pb = Peak braking power (watts) ωb = Rated motor speed (Rad / s) ωo = A lower motor speed (Rad / s) Pav = [ – ] [ ] ✕ [ ] 2 ✕ ( + ) Pav = _________ watts The Dynamic Brake Resistor power rat
PAGE 11
Heavy Duty Dynamic Braking 11 Step 7 — Calculate the Percent Peak Load of the Dynamic Brake Resistor Pb PL = Pdb ✕ 100 PL = Peak load in percent of Dynamic Brake Resistor Pb = Peak braking power calculated in Step 2 (watts) Pdb = Steady state power dissipation capacity of dynamic brake resistors obtained from Table 1a, 2a, or 3a (watts) PL = [ [ ] ✕ 100 ] PL = __________ % The calculation of PL in percent gives the percentage of the instantaneous power dissipated by the Dynamic Brake Resistors re
PAGE 12
Heavy Duty Dynamic Braking If the line you drew lies to the left of the constant temperature power curve of the Dynamic Brake Resistor, then there will be no application problem. If any portion of the line lies to the right of the constant temperature power curve of the Dynamic Brake Resistor, then there is an application problem.
PAGE 13
Heavy Duty Dynamic Braking Example Calculation 13 A 50 HP, 4 Pole, 460 Volt motor and drive is accelerating and decelerating as depicted in Figure 2. • Cycle period (t4) is 60 seconds • Rated speed is 1785 RPM and is to be decelerated to 0 speed in 6.0 seconds • Motor load can be considered purely as an inertia, and all power expended or absorbed by the motor is absorbed by the motor and load inertia • Load inertia is directly coupled to the motor • Motor inertia plus load inertia is given as 9.
PAGE 14
Heavy Duty Dynamic Braking Rdb1 = 0.9Vd2/Pb = 9.05 ohms This calculation is the result of Step 3 and determines the maximum ohmic value of the Dynamic Brake Resistor. Note that a choice of Vd = 750 Volts DC was made based on the premise that the drive is rated at 460 Volts. The most cost-effective combination of Dynamic Brake Modules chosen in Step 4 is one 1336-MOD-KB050 and one 1336-MOD-KB010 operated in parallel. This results in an equivalent Dynamic Brake Resistance of 8.76 ohms.
PAGE 15
Heavy Duty Dynamic Braking 15 Figure 4 Power Curve Out of Range KA, KB, KC Transient Power Capacity PL = 617% 600 500 Power (%) 400 300 200 100 AL = 32% 0 Point 1 1 2 3 4 5 6 7 8 9 10 t (time in seconds) Figure 4 is the result of Step 8. Note that a portion of the motor power curve lies to the right of the constant temperature power curve of the Dynamic Brake Resistor. This means that the resistor element temperature is exceeding the operating temperature limit.
PAGE 16
Heavy Duty Dynamic Braking Table 1a Maximum Ratings for 230V AC Drives, 375 Volts Turn-on Voltage Dynamic Brake Module Catalog No. 1336-MOD- Resistance Value of Dynamic Brake Resistor (Ohms) Average Wattage Dissipation of Dynamic Brake Resistor (Watts) KA 005 KA 010 28.0 13.2 666 1650 Table 2a Maximum Ratings for 380-460V AC Drives, 750 Volts Turn-on Voltage Dynamic Brake Module Catalog No.
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Heavy Duty Dynamic Braking 17 KA005-KA010, KB005-KB010 and KC005-KC010 Dimensions, Weights and Conduit Entry Locations G R2 E B FOR USE WITH 380/460 DC POWER BRAKE ON A–B P\N 151076 REV 01 BULLETIN 1336 DYNAMIC BRAKE 1336–MOD–KB005 SER C 680–750 VDC. 2.5 ADC (RMS) CAT INPUT VAC BULL. 1336 A.F. DRIVES (OUTPUT) HEAT DISSIPATION 375 WATTS MAXIMUM MADE IN U.S.A. R1 F A (4 places) D F C H (Side) (Front) K Conduit Entry 28.5mm (1.12") Dia.
PAGE 18
Heavy Duty Dynamic Braking KB050 and KC050 Dimensions, Weights and Conduit Entry Locations G R2 E2 B DC POWER BRAKE ON INPUT FOR USE WITH 500/600 A–B P\N 151081 REV 01 BULLETIN 1336 DYNAMIC BRAKE 1336–MOD–KC050 SER B 935 VDC. 10 ADC (RMS) CAT VAC BULL. 1336 A.F. DRIVES (OUTPUT) HEAT DISSIPATION 3750 WATTS MAXIMUM MADE IN U.S.A. E1 R1 (6 places) F A (Front) D F G C (Side) J Conduit Entry 28.5mm (1.12") Dia.
PAGE 19
Heavy Duty Dynamic Braking Specifications Braking Torque 100% torque for 20 seconds (typical). Duty Cycle 20% (typical). Input Power DC power supplied from DC Bus. 19 Customer supplied 115V AC, 1∅, 50/60 Hz required for KB050 & KC050 brake operation. Enable Signal: 50 mA Fan Power: 600 mA Optional Brake Fault Contact (1) N.O. contact, TTL compatible, closed when 115V AC is applied, open when a brake fault or loss of power occurs.
PAGE 20
Heavy Duty Dynamic Braking Mounting Requirements Dynamic brake enclosures must only be installed in the vertical position. Select a location using the guidelines below and information provided in the Recommended Brake Configurations section. • Each dynamic brake enclosure must be mounted outside of any other enclosure or cabinet and exposed to unrestricted circulating air for proper heat dissipation. Allow a minimum of 304.8 mm (12 in.
PAGE 21
Heavy Duty Dynamic Braking 21 Recommended Brake Configurations Brake Enclosure 304.8 mm (12 In.) Minimum Drive 304.8 mm (12 In.) Minimum 3.0 m (10 ft.) Maximum 304.8 mm (12 In.) Minimum 304.8 mm (12 In.) Minimum Brake Enclosure 304.8 mm (12 In.) Minimum Drive 1.5 m (5 ft.) Maximum User Supplied Terminal Block 3.0 m (10 ft.) Maximum 304.8 mm (12 In.) Minimum 304.8 mm (12 In.) Minimum 1.5 m (5 ft.
PAGE 22
Heavy Duty Dynamic Braking Brake Fault Contact Monitoring For all brake ratings a fault contact has been provided to provide a remote output signal to an Allen-Bradley 1336-MOD-L3, L6 or PLC. Should a brake fuse fail, the brake thermostat trip (or for KB050 & KC050 units the brake enable signal be lost), the brake fault contact will open. Interconnection wiring for remote brake monitoring is provided in the Wiring Schemes.
PAGE 23
Heavy Duty Dynamic Braking 23 KA005-KA010, KB005-KB010 and KC005-KC010 Terminal Block, Fuse and Jumper Locations Side View Front View W1 S Slave/Master Jumper W1 1 2 3 M Input Voltage Select Jumper W2 KB005-KB010 Units Only W2 460V 1 2 3 380V Brake Module Board Relay Option Board Fuse F1 KA005-KA010 and KC005-KC010 Units Only W1 S 1 2 3 W2 460V 1 2 3 M 380V DS1 1 2 3 4 DS1 DC Power ON Light DS2 TB3 1 2 3 4 5 6 SLAVE IN.
PAGE 24
Heavy Duty Dynamic Braking KB050 and KC050 Terminal Block, Fuse and Jumper Locations Brake Module Board DC Power ON Light DS1 Brake Fault Contact Terminal Block TB3 TB3 2 Brake ON Light DS2 1 DS1 DS2 TB3 M 380V V. SEL 460V 3 2 1 S W1 W2 Fuse F1 Input Voltage Select Jumper W2 KB050 Units Only 380V V SELECT 460V 3 2 1 W2 1 2 3 4 5 6 7 8 9 10 Slave/Master Jumper W1 M Power and Control Terminal Block TB1 SLAVE IN.
PAGE 25
Heavy Duty Dynamic Braking 25 KA005-KA010, KB005-KB010 and KC005-KC010 Wiring Scheme Important: Series A 1336 PLUS (A4 frames) 380-480V, 5.5-7.5 kW/7,5-10 HP, do not use the -DC terminal for brake connection. A separate -BRK terminal is supplied for proper brake connection. L1 115V AC L2 L3 +DC -DC 1 (+) SLAVE IN. 2 (–) SLAVE IN.
PAGE 26
Heavy Duty Dynamic Braking KB050 and KC050 Wiring Scheme 115V AC ➌ (user supplied) Auxiliary Term Block ➋ (user supplied) -DC -DC L1 115V AC L2 L3 +DC -DC -DC TB1 1 (+) SLAVE IN. 2 (–) SLAVE IN. TB1 +DC +DC MOD-L3 or L6 START STOP 19 START 20 STOP 21 COM TB3 5 (–) DC BUS 6 7 (+) DC BUS 8 9 120VAC POWER 10 120VAC ENABLE 120VAC ENABLE Master Brake ➏ 1 (+) SLAVE IN. 2 (–) SLAVE IN.
PAGE 27
Heavy Duty Dynamic Braking DC Power Wiring Tables 27 Required Minimum DC Power Wiring Sizes in mm2 and (AWG) Table 1b — DC Brake Power Wiring for 200-240V AC Drives for drive rating AQF05-AQF50 with (1) KA005 A007-A010 (1) KA010 Drive – Master or Drive – Auxiliary Term Block Auxiliary Term Block - Master Master – Slave wire size wire size wire size — 6 (10) — — 6 (10) — Slave – Slave wire size — — A015 (1) KA005 + (1) KA010 — 6 (10) 6 (10) — A020 (2) KA010 — 6 (10) 6 (10) — Table 2b
PAGE 28
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