Rockwell Automation 1336-F-E-T-S User Manual

Installation Instructions

Allen-Bradley
1336/1336VT
1336 PLUS/PLUS II/FORCE/IMPACT
Chopper Module

Cat. Nos. 1336 -WA018, WB009 & WC009

-WA070, WB035

-WA115, WB110

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 the Chopper Module Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

How to Select a Chopper Module and Dynamic Brake Resistor. . . . . . . . . . . . . . . . . . . . . . 5

Selecting a Chopper Module and the Dynamic Brake Resistance . . . . . . . . . . . . . . . . . . . 6

Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Ordering Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chopper Module Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chopper Module Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

WA018, WB009 and WC009 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

WA070, WB035 and WC035 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

WA115, WB110 and WC085 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1336 and 1336VT Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1336IMPACT Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1336FORCE Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1336PLUS Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Brake Fault Contact Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Brake Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Brake Module Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

WA018, WB009 and WC009 Terminal Block, Fuse and Jumper Locations . . . . . . . . . . . . 28

WA070, WB035 and WC035 Terminal Block, Fuse and Jumper Locations . . . . . . . . . . . . 29

WA115, WB110 and WC085 Terminal Block, Fuse and Jumper Locations . . . . . . . . . . . . 30

WA018, WB009 and WC009

Single Brake Wiring Scheme 1336F – BRF and 1336S – BRF Drives Only . . . . . . . . . . . . 31

Multiple Brake Wiring Scheme 1336F – BRF and 1336S – BRF Drives Only . . . . . . . . . . 32

WA070, WB035 and WC035 — WA115, WB110 and WC085

Single Brake Wiring Scheme 1336F – BRF Drives Only . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Multiple Brake Wiring Scheme 1336F – BRF Drives Only . . . . . . . . . . . . . . . . . . . . . . . . . 34

WA018, WB009 and WC009

Single Brake Wiring Scheme 1336 (VT, S, F, T, E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Multiple Brake Wiring Scheme 1336 (VT, S, F, T, E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

WA070, WB035 and WC035 — WA115, WB110 and WC085

Single Brake Wiring Scheme 1336 (VT, S, F, T, E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Multiple Brake Wiring Scheme 1336 (VT, S, F, T, E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

& WC035
& WC085

1336-5.65 — March, 2007

Heavy Duty Dynamic Braking

2

What This Option Provides

Where This Option is Used

The brake chopper module is an open style assembly that together with
customer supplied braking resistors can increase the braking torque
capability of a 1336, 1336VT, 1336PLUS, 1336PLUSII, 1336FORCE or
1336IMPACT drive from approximately 10 to 100%.

B003-B250 and C003-C250 1336 Drives.
B003-B250 1336VT Drives.
AQF05-A125, BRF05-B600 and CWF10-C600 1336PLUS and

1336PLUSII Drives.
A001-A125, B001-B600 and C001-C650 1336FORCE and 1336 IMPACT

Drives.

1336 — W

1336
1336VT
1336PLUS
1336PLUS II
1336FORCE
Brake Chopper Module

B 009

Voltage Rating Continuous Amp Rating

A = 230VAC 018 = 375VDC, 18.0ADC

070 = 375VDC, 70.0ADC
115 = 375VDC, 115.0ADC

B = 380/415/460VAC 009 = 750VDC, 9.0ADC

035 = 750VDC, 35.0ADC
110 = 750VDC, 110.0ADC

C = 575VAC 009 = 935VDC, 9.0A DC

035 = 935VDC, 35.0ADC
085 = 935VDC, 85.0ADC

What These Instructions Contain

How Dynamic Braking Works

These instructions contain the necessary information to select, configure
and install dynamic braking. By completing Selecting a Chopper Module
and the Maximum Dynamic Brake Resistance first you will be able to
determine:

1. Whether or not dynamic braking is required for your application.

2. If dynamic braking is required, the rating and quantity of chopper

modules required as well as the size and type of braking resistors
required.

When an induction motor’s rotor is turning slower than the synchronous
speed set by the drive’s output power, the motor is transforming electrical
energy obtained from the drive into mechanical energy available at the drive
shaft of the motor. This process is referred to as motoring. When the rotor
is turning faster than the synchronous speed set by the drive’s output power,
the motor is transforming mechanical energy available at the drive shaft of
the motor into electrical energy that can be transferred back into the utility
grid. This process is referred to as regeneration.

Most AC PWM drives convert AC power from the fixed frequency utility
grid into DC power by means of a diode rectifier bridge or controlled SCR
bridge before it is inverted into variable frequency AC power. Diode and
SCR bridges are cost effective, but can only handle power in the motoring
direction. Therefore, if the motor is regenerating, the bridge cannot conduct

1336-5.65 — March, 2007

Heavy Duty Dynamic Braking 3

the necessary negative DC current, the DC bus voltage will increase and
cause a Bus Overvoltage trip at the drive.

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.

How the Chopper Module Works

Figure 1 shows a simplified schematic of a Chopper Module with Dynamic

Brake Resistor. The Chopper Module is shown connected to the positive
and negative conductors of an AC PWM Drive. The two series connected
Bus Caps are part of the DC Bus filter of the AC Drive.

A Chopper Module contains five significant power components:

Protective fuses are sized to work in conjunction with a Crowbar SCR.
Sensing circuitry within the Chopper Transistor Voltage Control determines
if an abnormal conditions exist within the Chopper Module, such as a
shorted Chopper Transistor. When an abnormal condition is sensed, the
Chopper Transistor Voltage Control will fire the Crowbar SCR, shorting
the DC Bus, and melting the fuse links. This action isolates the Chopper
Module from the DC Bus until the problem can be resolved.

The Chopper Transistor is an Insulated Gate Bipolar Transistor (IGBT). The
Chopper Transistor is either ON or OFF, connecting the Dynamic Brake
Resistor to the DC Bus and dissipating power, or isolating the resistor from
the DC Bus. There are several transistor ratings that are used in the various
Chopper Module ratings. The most important rating is the collector current
rating of the Chopper Transistor that helps to determine the minimum ohmic
value used for the Dynamic Brake Resistor.

Chopper Transistor Voltage Control (hysteretic voltage comparator)
regulates the voltage of the DC Bus during regeneration. The average values
of DC Bus voltages are:

• 375V DC (for 230V AC input)

• 750V DC (for 460V AC input)

• 937.5V DC (for 575V AC input)
Voltage dividers reduce the DC Bus voltage to a value that is usable in signal

circuit isolation and control. The DC Bus feedback voltage from the voltage
dividers is compared to a reference voltage to actuate the Chopper
Transistor.

The Freewheel Diode (FWD), in parallel with the Dynamic Brake Resistor,
allows any magnetic energy stored in the parasitic inductance of that circuit
to be safely dissipated during turn off of the Chopper Transistor.

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Heavy Duty Dynamic Braking

4

Figure 1
Schematic of Chopper Module and Dynamic Brake Resistor

To
Voltage Dividers

Chopper Transistor

Voltage Control

+ DC Bus

Dynamic

Brake

Resistor

Chopper

Transistor

Fuse

FWD

FWD

Voltage
Divider

Voltage
Divider

To
Voltage
Control

Signal
Common

To
Voltage
Control

Bus Caps

Crowbar

SCR

Bus Caps

To
Crowbar
SCR Gate

Chopper Modules are designed to be applied in parallel if the current rating
is insufficient for the application. One Chopper Module is the designated
Master Chopper Module, while any other Modules are the designated
Follower Modules.

Two lights are provided on the front of the enclosure to indicate operation.

• DC Power light illuminates when DC power has been applied to the

• Brake On light flickers when the Chopper Module is operating

Fuse

– DC Bus

Chopper Module.

(chopping).

To
Voltage
Control

1336-5.65 — March, 2007

Heavy Duty Dynamic Braking 5

How to Select a Chopper Module and Dynamic Brake Resistor

As a rule, a Chopper 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 Chopper Module rating
and Dynamic Brake Resistor value to use. If a drive is consistently operating
in the regenerative mode of operation, serious consideration should be given
to equipment that will transform the electrical energy back to the fixed
frequency utility.

In order to select the appropriate Chopper Module and Dynamic Brake
Resistor for your application, the following data must be calculated.

Peak Regenerative Power of the Drive (Expressed in watts of power.)
This value is used to determine:

• The minimum current rating of the Chopper Module
Choose the actual current rating from the selection tables.

• The estimated maximum ohmic value of the Dynamic Brake Resistor
If this value is greater than the maximum imposed by the peak
regenerative power of the drive, the drive can trip off due to transient
DC Bus overvoltage problems.

Minimum Dynamic Brake Resistance

If a Dynamic Brake Resistance value that is less than the minimum imposed
by the choice of the Chopper Module is applied, damage can occur to the
Chopper Transistor.

Dynamic Brake Resistor’s Allowable Ohmic Value Range

(Use the Chopper Module current rating to determine this range.)
These values range between the minimum value set by the Chopper

Transistor current rating and the maximum value set by the peak
regenerative power developed by the drive in order to decelerate or satisfy
other regenerative applications.

Wattage Rating of the Dynamic Brake Resistor

This rating is estimated by applying what is known about the drive’s
motoring and regenerating modes of operation. The average power
dissipation of the regenerative mode must be estimated and the wattage of
the Dynamic Brake Resistor chosen to be greater than the average
regenerative power dissipation of the drive.

Dynamic Brake Resistors with large thermodynamic heat capacities,
defined as thermal time constants less than 5 seconds, are able to absorb a
large amount of energy without the temperature of the resistor element
exceeding the operational temperature rating. Thermal time constants in
the order of 50 seconds and higher satisfy the criteria of large heat capacities
for these applications. If a resistor has a small heat capacity, the temperature
of the resistor element could exceed maximum temperature limits during
the application of pulse power to the element.

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Heavy Duty Dynamic Braking

6

Selecting a Chopper Module and the Maximum Dynamic Brake Resistance

The following calculations are demonstrated using The International
System of Units (SI).

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-m

2

or lb-ft

2

• 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

function of time for a particular cyclic application that is periodic over t

4

seconds. The desired time to decelerate is known or calculable and is within
the drive performance limits. In Figure 2, the following variables are
defined:

ω(t) = Motor shaft speed in radians per second (rps)

Rad

ω ✕

N(t) = Motor shaft speed in Revolutions Per Minute (RPM)

2πN

=

60

s

T(t)

= Motor shaft torque in Newton-meters

1.0 lb-ft = 1.355818 N-m

= Motor shaft power in watts

P(t)

1.0 HP = 746 watts

= Motor shaft peak regenerative power in watts

-Pb

1336-5.65 — March, 2007

Figure 2
Application Speed, Torque and Power Profiles

ω

(t)

ω

b

ω

o

0t

T(t)

1

t

2

Heavy Duty Dynamic Braking 7

t1 + t

t

3

t

4

4

t

0t

1

t

2

P(t)

0t

1

t

2

-Pb

t1 + t

t1 + t

4

4

t

3

t

3

t

4

t

4

t

t

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Heavy Duty Dynamic Braking

8

Step 1 — Determine Gear Ratio

Step 2 — Determine the Total Inertia

Turns of Load

GR=

Turns of Motor

GR = _________

JT = Jm + GR2 ✕ JL JT= Total inertia reflected to the motor shaft (kg-m2 or lb-ft2)

J

= Motor inertia (kg-m2 or lb-ft2)

m

GR = Gear ratio of any gear between motor and load

(dimensionless)

J

= Load inertia (kg-m2 or lb-ft2)

L

1.0 lb-ft

2

= 0.04214011 kg-m

2

JT = [+] ✕ []

Step 3 — Calculate the Peak Braking Power

J

✕ ωb (ωb - ωo)

T

Pb =

(t

- t2)

3

JT= Total inertia reflected to the motor shaft (kg-m2)

ω

= Rated angular rotational speed (Rad / s = 2πNb / 60)

b

ω

= Angular rotational speed,

o

less than rated speed down to zero (Rad / s)

N

= Rated motor speed (RPM)

b

- t2= Deceleration time from ωb to ωo (seconds)

t

3

= Peak braking power (watts)

P

b

1.0 HP = 746 watts

Pb =

[ ✕ (-)]

[–]

JT = __________ kg-m2 or lb-ft

Pb = __________watts

2

Compare the peak braking power to that of the rated motor power. If the
peak braking power is greater that 1.5 times that of the motor, then the
deceleration time (t

- t2) needs to be increased so that the drive does not

3

go into current limit.

1336-5.65 — March, 2007

Heavy Duty Dynamic Braking 9

Step 4 — Calculate the Maximum Dynamic Brake Resistance Value

R

db1 =

2

V

d

P

b

R

= Maximum allowable value for the dynamic brake

db1

resistor (ohms)

= DC Bus voltage the chopper module regulates to

V

d

(375V DC, 750V DC, or 937.5V DC)

P

= Peak braking power calculated in Step 2 (watts)

b

[ ✕ ]

R

db1 =

[]

R

= _________ ohms

db1

The choice of the Dynamic Brake resistance value should be less than the
value calculated in Step 4. If the resistance value is greater than the value
calculated in Step 4, the drive can trip on DC Bus overvoltage.

Step 5 — Calculate the Minimum Chopper Module Current Rating

Id1 =

V

d

R

db1

Id1= Minimum current flow through Chopper Transistor

= Value of DC Bus voltage chosen in Step 3

V

d

= Value of Dynamic Brake Resistor calculated in Step 3

R

db1

[]

Id1 =

[]

The value of I

sets the minimum current rating for the Chopper Module.

d1

Id1 = __________ amps

When choosing a Chopper Module, the current rating for the Chopper
Transistor must be greater than or equal to the value calculated for I

d1

.

Step 6 — Calculate the Minimum Dynamic Brake Resistor Value

R

R

db2 =

R

V

d

0.75 ✕ I

[]

db2 =

[]

d2

= Minimum ohmic value of the Dynamic Brake Resistor

db2

= Value of DC Bus voltage chosen in Step 3

V

d

= Value of Chopper Module current rating

I

d2

R

= __________ ohms

db2

This step calculates the minimum resistance value that the Dynamic Brake
Resistor can have. If a lower resistance were to be used with the Chopper
Module of choice, the IGBT could be damaged from overcurrent.

1336-5.65 — March, 2007

Heavy Duty Dynamic Braking10

Step 7 — Choose the Dynamic Brake Resistance Value

Use to Table 1a, 2a, or 3a to choose the correct table based on the Chopper
Module’s regulating voltage.

1. Find the column that lists the value of Dynamic Brake Resistance for

the various Dynamic Brake Resistor assemblies.

2. Choose the resistor value that lies between R

Preferred resistance values are as close R

and R

db1

as possible.

db1

db2

.

Step 8 — Estimate the Minimum Wattage Requirements for the Dynamic
Brake Resistor

It is assumed that the application exhibits a periodic function of acceleration
and deceleration. If (t

deceleration from rated speed to 0 speed, and t
the process repeats itself, then the average duty cycle is (t

- t2) equals the time in seconds necessary for

3

is the time in seconds before

4

- t2)/t4. The

3

power as a function of time is a linearly decreasing function from a value
equal to the peak regenerative power to 0 after (t

The average power regenerated over the interval of (t
The average power in watts regenerated over the period t

P

ωb + ω

b

(

2

- t2= Deceleration time from ωb to ωo (seconds)

3

= Total cycle time or period of process (seconds)

4

= Peak braking power (watts)

b

= Rated motor speed (Rad / s)

b

= A lower motor speed (Rad / s)

o

o

)

ω

b

Pav =

[t

- t2]

3

✕

t

4

Pav= Average dynamic brake resister dissipation (watts)

t

t

P

ω

ω

- t2) seconds have elapsed.

3

- t2) seconds is Pb/2.

3

is:

4

Example Calculation

1336-5.65 — March, 2007

[–]

Pav =

[]

[]

✕

2

Pav = _________ watts

The Dynamic Brake Resistor power rating, in watts, that is chosen should
be equal to or greater than the value calculated in Step 8.

Application Information

A 100 HP, 460 Volt motor and drive is accelerating and decelerating as
depicted in Figure 2.

• Cycle period (t

) is 60 seconds

4

• Rated speed is 1785 RPM

• Deceleration time from rated speed to 0 speed is 6.0 seconds

• Motor load can be considered purely as an inertia

• 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 9.61 kg-m

2

Heavy Duty Dynamic Braking 11

Calculate Application Values

Use the Application Information to calculate the necessary values to choose
an acceptable Chopper Module and Dynamic Brake Resistor.

Rated Power of Motor = 100 HP × 746 = 74.6 kW

This information is given and must be known before the calculation process
begins. If this rating is given in horsepower, convert to watts before using
in the equations.

Rated Speed = 1785 RPM = 2π × 1785/60 = 186.93 Rad/s = ω

This information is given and must be known before the calculation process
begins. If this rating is given in RPM, convert to radians per second before
using in the equations.

Total Inertia = 9.61 kg-m2 = J

T

If this value is given in lb-ft2 or Wk2, convert to kg-m2 before using in the
equations. Total inertia is given and does not need further calculations as
outlined in Step 2.

Deceleration Time = 6.0 seconds = (t3 - t2)

Period of Cycle = 60 seconds = t

DC Bus Voltage = 750 Volts = V

4

d

This is known because the drive is rated at 460 Volts rms.
If a drive is rated 230 Volts rms, V

If a drive is rated 575 Volts rms, V

= 375 Volts.

d

= 937.5 Volts.

d

Select the Correct Chopper Module

Peak Braking Power = J

2

ω

/(t3 - t2) = 55.96 kW = P

T

b

This is 75% rated power and is less than the maximum drive limit of 150%
current limit. This calculation is the result of Step 3 and determines the peak
power that must be dissipated by the Dynamic Brake Resistor.

Maximum Dynamic Brake Resistance = V

2

/Pb = 10.5 ohms = R

d

db1

This calculation is the result of Step 4 and determines the maximum ohmic
value of the Dynamic Brake Resistor. Note that a choice of V

= 750 Volts

d

DC was made based on the premise that the drive is rated at 460 Volts.

Minimum Current Flow = V

= 74.62 amps = I

d/Rdb1

d1

This calculation is the result of Step 5. This is the minimum value of current
that will flow through the Dynamic Brake Resistor when the Chopper
Module Transistor is turned on. Refer to Table 2b in the Installation
Instructions for the Brake Chopper Module, Publication 1336-5.65. Choose
the Brake Chopper Module whose peak current capacity is greater than

74.62 amps. The correct choice must be the WB035 Chopper Module
because it has a current rating greater than 74.62 amps.

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Heavy Duty Dynamic Braking12

Ordering Resistors

Minimum Dynamic Brake Resistance = Vd/Id2 = 10 ohms = R

db2

This is the result of Step 6 and is also included as a value in Table 2b.

Choose the 10.4 ohms resistor, type T10F4R2K97, rated at 2.97 kW from
Tabl e 2 a.

Average Power Dissipation = [(t3 - t2)/t4]Pb/2 = 2.8 kW = P

av

This is the result of calculating the average power dissipation as outlined
in Step 8. Verify that the power rating of the Dynamic Brake Resistor chosen
in Step 7 is greater than the value calculated in Step 8. Note that the actual
resistor wattage rating is much greater than what is needed. The type
T10F4R2K97 assembly is the best choice based on resistance and wattage
values.

Resistor assemblies listed are manufactured by IPC Power Resistors
International Incorporated and Powerohm Resistors Incorporated and have
been tested with Allen-Bradley Chopper Modules.

Available resistor assembly options include an overtemperature switch (see
Wiring Schemes), auxiliary terminal blocks and custom enclosures.

For purchase information, contact:

IPC Power Resistors International Inc.
167 Gap Way
Erlanger, KY 41018
Tel. [phone] Fax. [phone]
www.ipcresistors.com

Powerohm Resistors Inc.
5713 13th Street
Katy, TX 77493
Tel. [phone] Fax. [phone]
www.powerohm.com

1336-5.65 — March, 2007