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Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
The voltage must be zero for all three measurements. DC+ DC- Additional Resources You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page. To place an order for paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation® sales representative. Rockwell Automation Publication PFLEX-AT001L-EN-P - September 2017...
Preface Summary of Changes This manual contains new and updated information as indicated in the following table. Topic Page Added 200…240V AC definitions to Appendix A Rockwell Automation Publication PFLEX-AT001L-EN-P - September 2017...
Chapter Understanding How Dynamic Braking Works How Dynamic Braking Works When an induction motor’s rotor turns 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.
Chapter 1 Understanding How Dynamic Braking Works Dynamic Brake Components A Dynamic Brake consists of a Chopper (the chopper transistor and related control components are built into PowerFlex® drives) and a Dynamic Brake Resistor. Figure 1 shows a simplified Dynamic Braking schematic. Figure 1 - Simplified Dynamic Brake Schematic + DC Bus Voltage...
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Understanding How Dynamic Braking Works Chapter 1 Chopper Transistor Voltage Control regulates the voltage of the DC bus during regeneration. The average values of DC bus voltages are: Drive Input Voltage Transistor Turn-On Maximum Power Calculation Voltage Voltage 375V DC 395V DC 375V DC 395V DC...
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Chapter 1 Understanding How Dynamic Braking Works Notes: Rockwell Automation Publication PFLEX-AT001L-EN-P - September 2017...
Chapter Determining Dynamic Brake Requirements How to Determine Dynamic When a drive is consistently operating in the regenerative mode of operation, serious consideration should be given to equipment that transforms the electrical Brake Requirements energy back to the fixed frequency utility grid. As a rule, Dynamic Braking can be used when the need to dissipate regenerative energy is on an occasional or periodic basis.
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Chapter 2 Determining Dynamic Brake Requirements • Speed rating from motor nameplate in rpm or rps (radians per second) • Required decel time (per Figure 2, t ). This time is a process – t requirement and must be within the capabilities of the drive programming. •...
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Determining Dynamic Brake Requirements Chapter 2 Figure 2 - Application Speed, Torque, and Power Profiles Speed ω(t) ω b ω o t 2 t 3 t 1 + t 4 Torque T(t) t 2 t 3 t 1 + t 4 Power P(t) t 2 t 3...
Chapter 2 Determining Dynamic Brake Requirements Determine Values of Step 1 – Total Inertia Equation Variables = Total inertia reflected to the motor shaft (kg•m or WK in lb•ft = Motor inertia (kg•m or WK in lb•ft = Gear ratio for any gear between motor and load (dimensionless) Load Speed ---------------------------- -...
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Determining Dynamic Brake Requirements Chapter 2 Step 2 – Peak Braking Power – ------------------------------------------ - – = Peak braking power (watts) 1.0 Hp = 746 watts = Total inertia reflected to the motor shaft (kg•m 2N ...
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Chapter 2 Determining Dynamic Brake Requirements Record Rated Regenerative Power: For the purposes of this document, it is assumed that the motor used in the application is capable of producing the required regenerative torque and power. Step 3 – Minimum Power Requirements for the Dynamic Brake Resistors It is assumed that the application exhibits a periodic function of acceleration and deceleration.
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Determining Dynamic Brake Requirements Chapter 2 The Average Power in watts regenerated over the period – ----------------- - ----- - ----------------------- - Calculate Average Power in watts regenerated over the period ...
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Chapter 2 Determining Dynamic Brake Requirements minimum dynamic brake resistance table in Appendix A. This will give a data point for a line to be drawn on one the curves provided in Chapter Step 5 – Percent Peak Load of the Internal Dynamic Brake Resistor Skip this calculation if an external dynamic brake resistor will be used.
Determining Dynamic Brake Requirements Chapter 2 Example Calculation A 10 Hp, 4 Pole, 480 Volt motor and drive is accelerating and decelerating as depicted in Figure • Cycle period t4 is 40 seconds • Rated speed is 1785 rpm and is to be decelerated to 0 speed in 15.0 seconds •...
Chapter 2 Determining Dynamic Brake Requirements – ------------------------------------------ - Peak Braking Power – – 0.261 186.92 186.92 0 ----------------------------------------------------- - 607.9 watts Note that this is 8.1% of rated power and is less than the maximum drive limit of 150% current limit.
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Determining Dynamic Brake Requirements Chapter 2 -------- - Percent Average Load --- - 100% Important: The value of should not exceed 100%. This is the result of the calculation outlined in Step 5. Record this value on page ...
Chapter Evaluating the PowerFlex 7-Class Internal Resistor Evaluating the Capability of To investigate the capabilities of the internal resistor package, the values of (Average Percent Load) and (Peak Percent Load) are plotted onto a graph of the Internal Dynamic Brake the Dynamic Brake Resistor’s constant temperature power curve and connected Resistor with a straight line.
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Chapter 3 Evaluating the PowerFlex 7-Class Internal Resistor 2B. If P is greater than R you will need to extend the cycle time (in cont. seconds) by the result of the following equation. ----- - Decel ...
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Evaluating the PowerFlex 7-Class Internal Resistor Chapter 3 If the line connecting lies entirely to the left of the Power Curve, then the capability of the internal resistor is sufficient for the proposed application. Figure 3 - Example of an Acceptable Resistor Power Curve 3000 480V Frame C 2800...
Chapter Selecting An External Resistor for PowerFlex 7-Class Drives How to Select an External In order to select the appropriate External Dynamic Brake Resistor for your application, the following data must be calculated. Dynamic Brake Resistor for PowerFlex 7-Class Drives Peak Regenerative Power (Expressed in watts) This value is used to determine the maximum resistance value of the Dynamic...
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Chapter 4 Selecting An External Resistor for PowerFlex 7-Class Drives Protecting External Resistor Packages ATTENTION: PowerFlex drives do not offer protection for externally mounted brake resistors. A risk of fire exists if external braking resistors are not protected. External resistor packages must be self-protected from over temperature or the protective circuit show below, or equivalent, must be supplied.
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Selecting An External Resistor for PowerFlex 7-Class Drives Chapter 4 Record the Values Calculated in Section 2 Calculate Maximum Dynamic Brake Resistance Value When using an internal Dynamic Brake Resistor, the value is fixed. However, when choosing an external resistor, the maximum allowable Dynamic Brake resistance value (R ) must be calculated.
Chapter 4 Selecting An External Resistor for PowerFlex 7-Class Drives Select Resistor Select a resistor bank from the following tables or from your resistor supplier that has all of the following: • a resistance value that is less than the value calculated (R in ohms) •...
Appendix A Minimum Dynamic Brake Resistance Table 3 - Minimum Dynamic Break Resistance 400V…690V (continued) Drive Normal Regen DC Bus Minimum Ohms, Rated Continuous Power, Internal Resistors (P Duty Rating Voltage (V External Resistors PowerFlex PowerFlex 70 PowerFlex 700 PowerFlex Product 750-Series Frame Watts Frame Watts Frame Watts Resistance (Ω) 4...
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