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Summary of Contents for ABB ACS880-607LC
- Page 1 — ABB INDUSTRIAL DRIVES ACS880-607LC 1-phase brake units Hardware manual...
- Page 3 ACS880-607LC 1-phase brake units Hardware manual Table of contents 3. Mechanical installation 5. Electrical installation 7. Start-up © 2019 ABB Oy. All Rights Reserved. 3AXD50000481491 Rev A EFFECTIVE: 2019-06-28...
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Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ................Applicability ..................Safety instructions ................Target audience ................... Related documents ................Use of component designations ..............Terms and abbreviations ................. 2 Operation principle and hardware description Contents of this chapter ................ - Page 6 6 Table of contents Protecting the system against thermal overload ..........Operation principle ................Protecting the system against short-circuits ..........5 Electrical installation Contents of this chapter ................Electrical safety precautions ..............Checking the insulation of brake resistor and resistor cable ....... Connecting the brake resistor cables and thermal switch ........
- Page 7 Table of contents 7 Technical data ..................Coolant specification ................Coolant type ................Temperature limits ................Pressure limits ................. Coolant flow rate limits ............... Cooling circuit materials ..............11 Technical data Contents of this chapter ................Ratings ..................... Brake chopper only ................Brake chopper with factory-installed brake resistors (option +D151) ....
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Page 9: Introduction To The Manual
Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to ACS880-607LC 1-phase brake units that form a part of a liquid-cooled ACS880 multidrive system. Safety instructions Follow all safety instructions delivered with the drive. -
Page 10: Related Documents
Drive composer start-up and maintenance PC tool user’s manual 3AUA0000094606 Manuals for I/O extension modules, fieldbus adapters, safety options etc. You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals not available in the document library, contact your local ABB representative. Use of component designations Some device names in the manual include the item designation in brackets, for example [Q20], to make it possible to identify the components in the circuit diagrams of the drive. - Page 11 Introduction to the manual 11 Term/ Description Abbreviation Brake resistor Dissipates the drive surplus braking energy conducted by the brake chopper to heat Brake unit Brake chopper modules under control of one control board, and related accessories I/O module for controlling cabinet fans Cubicle One section of a cabinet-installed drive.
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Page 13: Operation Principle And Hardware Description
This chapter describes the operation principle and construction of the brake unit. Product overview ACS880-607LC is a liquid-cooled cabinet-installed brake unit, which forms a part of an ACS880 multidrive system. As standard, it includes brake chopper(s). Brake resistors are available as an option (+D151). -
Page 14: Single-Line Diagram Of The Drive System
14 Operation principle and hardware description Single-line diagram of the drive system The diagram below shows a typical common DC link drive system. AC supply Input (AC) fuses Supply unit DC link Inverter DC fuses Inverter units. In this example, one of the units consists of two inverter modules connected in parallel. Brake chopper DC fuses Attenuator. -
Page 15: Layout
Operation principle and hardware description 15 Layout ￭ Brake chopper cubicle The figure below shows the components of the brake chopper cubicle. DC fuses [F121.xx] Attenuator [R121.x] CIO-01 I/O module [A115.x] Brake chopper module [T121] Cooling fan [G115.xx] and heat exchanger... -
Page 16: Brake Resistor Cabinet
16 Operation principle and hardware description ￭ Brake resistor cabinet The figure below shows the components of the brake resistor cabinet. Brake resistors [R121.xx] Door position indication switch [S121.7] Brake resistor cooling fans... -
Page 17: Brake Chopper Module
Operation principle and hardware description 17 ￭ Brake chopper module The components of the brake chopper module are shown below. UDC+ R+ UDC- Fastening points on back plate (two at the top, Clamp for drive cable two at the bottom) Front cover fastening screws Clamp for resistor cable Front cover... - Page 18 18 Operation principle and hardware description Coolant connections behind main mounting plate (side view).
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Page 19: Overview Of Power And Control Connections
Operation principle and hardware description 19 Overview of power and control connections The diagram below shows the power and control connections of the brake unit. t ° UDC- UDC+ Brake chopper cubicle Brake chopper module [T121] Brake chopper control board (NBRC) Brake resistor cabinet Brake resistors [R121.xx] Brake resistor monitoring circuit with a thermal switch and a door position indication switch [S121.7]... -
Page 20: Controlling The Brake Chopper From An External Control Location
20 Operation principle and hardware description ￭ Controlling the brake chopper from an external control location The brake chopper can be controlled from an external control location via a fiber optic link (terminals V22 and V23 on the chopper control board). Using the link, it is possible to synchronize several brake choppers. -
Page 21: Brake Chopper Module Type Designation Label
6426OO49 1 / 5 min Irms 267 ADC Serno 8 1 8 3 9 0 1 2 3 4 2.72 Ohm ABB Oy Hiomotie 13 00380 Helsinki Finland Type designation Brake chopper module order code Serial number • The first digit of the serial number refers to the manufacturing plant. -
Page 23: Mechanical Installation
Mechanical installation 23 Mechanical installation Contents of this chapter This chapter describes the mechanical installation of the brake units. Brake unit The ACS880 multidrive - the brake unit as one part of the complete drive - is transported in sections. See ACS880 liquid-cooled multidrive cabinets mechanical installation instructions (3AXD50000048635 [English]). -
Page 25: Planning The Electrical Installation
The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover. -
Page 26: Selecting And Routing The Brake Resistor Cables
26 Planning the electrical installation • The resistor must withstand the specified brake cycles. • The ventilation of the space/room in which the resistors are located must meet the air flow amounts specified. • The resistor assembly must be equipped with a thermal switch. ￭... -
Page 27: Selecting The Resistor Thermal Switch Circuit Cable
Planning the electrical installation 27 ￭ Selecting the resistor thermal switch circuit cable Make sure that the cable in the resistor thermal switch circuit meets the following requirements: • shielded cable • operating voltage 450 V / 750 V (U / U) •... -
Page 29: Electrical Installation
Electrical installation 29 Electrical installation Contents of this chapter This chapter describes the electrical installation of the brake unit. Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. - Page 30 30 Electrical installation • Open the auxiliary voltage switch-disconnector (if present), and all other possible disconnecting devices that isolate the drive from dangerous voltage sources. • In the liquid cooling unit (if present), open the motor protective circuit breaker(s) of the cooling pumps.
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Page 31: Checking The Insulation Of Brake Resistor And Resistor Cable
Electrical installation 31 Checking the insulation of brake resistor and resistor cable WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do installation or maintenance work. 1. -
Page 32: Connecting The Brake Resistor Cables And Thermal Switch
32 Electrical installation Connecting the brake resistor cables and thermal switch ￭ Connection diagram 11 12 X121.1 11 12 X121.7 Brake chopper cubicle (all connections done at the factory) Brake chopper module Brake resistor cabinet ￭ Connection procedure WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. - Page 33 Electrical installation 33 1. Stop the drive and do the steps in section Electrical safety precautions (page 29) before you start the work. 2. Open the door of the brake chopper cubicle and remove the shrouding. 3. Connect the resistor cables: •...
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Page 35: Installation Checklist Of The Drive
Installation checklist of the drive 35 Installation checklist of the drive Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. - Page 36 36 Installation checklist of the drive Make sure that … The input power cable has been connected to the appropriate terminals, the phase order is right, and the terminals have been tightened to the proper torque. There is an adequately sized protective earth (ground) conductor between the motor and the drive, and the conductor has been connected to appropriate terminal, and the terminal has been tightened to the proper torque.
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Page 37: Start-Up
Start-up 37 Start-up Contents of this chapter This chapter contains the start-up procedure of the brake unit. The symbols in brackets, for example [Q1], refer to the item designations used in the circuit diagrams. If a task is valid only for a certain option device or feature, the option code is given in brackets, for example, (option +F286). - Page 38 38 Start-up Tasks Make sure that the supply unit is stopped, and the drive system has been isolated from the supply network. Powering up the DC bus Make sure that all cabinet doors are closed. Close the disconnector of the supply transformer. Close the drive auxiliary voltage switch [Q21] to power up the control units.
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Page 39: Fault Tracing
Check that enable input is on. control system. per control board. Short circuit in resistor or power Check power cables and resistor. cables. Chopper control board failure. Contact local ABB representative. Chopper damaged; it is not able to disconnect resistor from intermedi- ate circuit. -
Page 40: Fan Supervision
40 Fault tracing Fault indication/Fault Cause Remedy Chopper does not function. Chopper voltage setting too high. Check voltage setting. Inverter overvoltage control is on. Check parameters of all inverters. Check that enable input is on. Chopper starts to function at too low Chopper voltage setting too low. - Page 41 Fault tracing 41 Drive supply voltage 380…415 V Drive supply voltage 440…500 V Drive supply voltage 525…690 V Note: If you have parallel choppers which are synchronized through the fiber optic link (master-follower connection): • select the voltage in the master chopper only •...
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Page 43: Maintenance
This chapter describes the maintenance of a brake unit. Maintenance intervals The table below shows the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). -
Page 44: Cooling System
Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components. -
Page 45: Replacing Cooling Fans
See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. ￭ Brake chopper cubicle WARNING! Wear protective gloves and long sleeves. -
Page 46: Brake Resistor Cabinet (Option +D151)
46 Maintenance ￭ Brake resistor cabinet (option +D151) WARNING! Wear protective gloves and long sleeves. Some parts have sharp edges. 1. Stop the drive and do the steps in section Electrical safety precautions (page 29) before you start the work. 2. -
Page 47: Internal Cooling Circuit
Internal cooling circuit 47 Internal cooling circuit Contents of this chapter The cooling system of a liquid-cooled drive consists of two circuits: the internal cooling circuit and the external cooling circuit. The internal cooling circuit covers the heat-generating electrical components of the drive and transfers the heat to the cooling unit. In the cooling unit, the heat is transferred to the external cooling circuit which is usually part of a larger external cooling system. - Page 48 48 Internal cooling circuit Supply modules Inverter modules To/From cooling unit Air-to-liquid heat exchanger Heat sink Inlet valve Inlet-side drain valve Outlet valve Outlet-side drain valve The coolant used with ACS880 liquid-cooled drive systems is Antifrogen® L 25% or 50% water mixture.
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Page 49: Connection To A Cooling Unit
Internal cooling circuit 49 Connection to a cooling unit ￭ Connection to an ACS880-1007LC cooling unit Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]). ￭ Connection to a custom cooling unit General requirements Equip the system with an expansion tank to damp pressure rise due to volume changes when the temperature varies. -
Page 50: Filling Up And Bleeding The Internal Cooling Circuit
50 Internal cooling circuit Filling up and bleeding the internal cooling circuit Both the drive and coolant must be at room temperature before filling up the cooling circuit. WARNING! Make sure that the maximum permissible operating pressure is not exceeded. When necessary regulate the pressure to appropriate level by draining excess coolant out of the system. - Page 51 Internal cooling circuit 51 13. Start the coolant pump. Let any air remaining in the system out through the bleed valve at the cooling unit. 14. After one to two minutes, stop the pump or block the coolant flow with a valve. 15.
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Page 52: Draining The Internal Cooling Circuit
Coolant type Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% water mixture, available from Clariant distributors and ABB Service representatives. Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F). Antifrogen® L 50% mixture is usable in storage temperatures down to -40 °C (-40 °F). - Page 53 Internal cooling circuit 53 The higher the concentration of heat transfer fluid, the higher the viscosity of the coolant. This results in a higher pressure loss in the system. See Pressure limits (page 54). The nominal current ratings of drive system modules apply to an Antifrogen® L / water solution of 25/75% (volume).
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Page 54: Pressure Limits
54 Internal cooling circuit Min. T (°C) coolant (°C) RH = 95% RH = 80% RH = 65% RH = 50% RH = 40% -0.1 -3.0 14.2 11.5 19.2 16.5 13.2 24.1 21.4 17.9 13.8 10.5 29.1 26.2 22.7 18.4 15.0 34.1 31.1... - Page 55 Internal cooling circuit 55 • rubber gasketing NBR (nitrile rubber). WARNING! If connecting external piping to the internal cooling circuit, use only materials that are specified above. Copper, brass or bronze must not be used under any circumstances. Even minor dissolution of copper can cause copper precipitation on aluminum and subsequent galvanic corrosion.
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Page 57: Technical Data
Technical data 57 Technical data Contents of this chapter This chapter contains the technical specifications of the brake unit, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Ratings ￭ Brake chopper only These brake units are not equipped with brake resistors or fans. -
Page 58: Brake Chopper With Factory-Installed Brake Resistors (Option +D151)
58 Technical data ￭ Brake chopper with factory-installed brake resistors (option +D151) Duty cycle Duty cycle (1/5 min) (10/60 s) ACS880- Module brmax brcont Resistor type 607LC-… type 0400-7 NBRW- 2 × 1.35 10800 669C SAFUR200F500 0800-7 2 × 2 × (2 × 1.35 1670 21600... -
Page 59: Definitions
Technical data 59 ￭ Definitions Example: ACS880-607LC-0800-7 Brake unit – Energy pulse that all the resistors of the unit put together will withstand (400 s duty cycle). This energy will heat the resistor elements from 40°C to the maximum allow- able temperature. -
Page 60: Dc Fuses
60 Technical data DC fuses ACS880-607LC-… Fuse type = 690 V (Range 525…690 V) 0400-7 170M5146 1250 0800-7 170M5146 1250 1200-7 170M5146 1250 1600-7 170M5146 1250 2000-7 170M5146 1250 2400-7 170M5146 1250 Dimensions, weights and free space requirements ￭ Brake chopper only ACS880-607LC-…... -
Page 61: Losses, Cooling Data And Noise
Losses, cooling data and noise ￭ Brake chopper only Power loss Coolant Noise Pres- Volume Flow rate sure Into Into ACS880-607LC-… Module type loss coolant dB(A) US gal l/min gal/min (PSI) = 690 V (Range 525…690 V) 0400-7 NBRW-669 0.68 0.42... -
Page 62: Terminal And Lead-Through Data For The Resistor Cable For Brake Units With User-Defined Brake Resistors
62 Technical data Terminal and lead-through data for the resistor cable for brake units with user-defined brake resistors ACS880-607LC-… R+, R-, grounding terminals Number of Hole Screw Tightening torque dia- holes N·m meter = 690 V (Range 525…690 V) 0400-7 0800-7 2×M10... -
Page 63: Protection Classes
Installation site altitude 0…2000 m (0…6562 ft) above sea level. For alti- tudes over 2000 m, contact ABB. Output derated above 1000 m (3281 ft). Air temperature 0 … +45 °C -40 to +70 °C (- -40 to +70 °C (-... - Page 64 64 Technical data Operation Storage Transportation installed for stationary in the protective package in the protective package Vibration IEC/EN 60721-3-3:2002 IEC/EN 60721-3-1:1997 IEC/EN 60721-3-2:1997 IEC/EN 61800-5-1 10…57 Hz: max. 0.075 mm 10…57 Hz: max. 0.075 mm 2…9 Hz: max. 3.5 mm amplitude amplitude amplitude...
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Page 65: Materials
IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations. -
Page 66: Cybersecurity Disclaimer
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized... -
Page 67: 12. Example Circuit Diagrams
Example circuit diagrams 67 12. Example circuit diagrams Contents of this chapter This chapter contains example circuit diagrams of a brake unit. In an installation with parallel-connected brake chopper modules, one chopper acts as the master for the others. The switching of the follower chopper(s) is controlled by the master via a fiber optic link. -
Page 68: Brake Unit With One Brake Chopper Module
18.03.2019 Brake chopper&resistor Circuit diagram EFS2 Prep. Title Item Des. Cust. Doc. No. Cust. Ref. No. App. SAP Doc. No. +60.1 JOLU ACS880-607LC ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 001a ABB Ref. No. Rev. Sheet Resp. Dept. No. of Sheets... -
Page 69: Brake Chopper Control
18.03.2019 Brake chopper control Circuit diagram EFS2 Prep. Title Item Des. Cust. Doc. No. Cust. Ref. No. App. SAP Doc. No. +60.1 JOLU ACS880-607LC ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 005a ABB Ref. No. Rev. Sheet Resp. Dept. -
Page 70: External Fan Voltage Supply
18.03.2019 External supplies Circuit diagram EFS2 Cust. Doc. No. Prep. Title Item Des. Cust. Ref. No. App. SAP Doc. No. +60.1 JOLU ACS880-607LC ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 020a ABB Ref. No. Rev. Sheet Resp. Dept. No. of Sheets... -
Page 71: Fan Control For Brake Chopper Cubicle
Fan control for Brake chopper cabinet Circuit diagram EFS2 Cust. Doc. No. Prep. Title Item Des. Cust. Ref. No. App. SAP Doc. No. +60.1 JOLU ACS880-607LC ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 026a ABB Ref. No. Rev. Sheet Resp. -
Page 72: Fan Control For Resistor Cabinet
Fan control for Brake resistor cabinet Circuit diagram EFS2 Cust. Doc. No. Prep. Title Item Des. Cust. Ref. No. App. SAP Doc. No. +60.2 JOLU ACS880-607LC ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 027a ABB Ref. No. Rev. Sheet Resp. -
Page 73: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels. - Page 74 3AXD50000481491A © 2019 ABB Oy. All Rights Reserved. Specifications subject to change without notice.