Related Manuals for ABB ACS880-604
Summary of Contents for ABB ACS880-604
- Page 1 ABB industrial drives Hardware manual ACS880-604 1-phase brake chopper units as modules...
- Page 2 3AUA0000104271 ACS880 primary control program firmware manual 3AUA0000085967 ACS880 primary control program quick start-up guide 3AUA0000098062 Brake module manuals ACS880-604 1-phase brake chopper units as modules 3AUA0000106244 hardware manual Option manuals and guides ACS-AP-x Assistant control panels user's manual 3AUA0000085685 Drive composer start-up and maintenance PC tool user’s...
- Page 3 Hardware manual ACS880-604 1-phase brake chopper units as modules Table of contents 3. Mechanical installation 5. Electrical installation 7. Start-up © 2013 ABB Oy. All Rights Reserved. 3AUA0000106244 Rev B EFFECTIVE: 2013-12-05...
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Page 5: Table Of Contents
Table of contents 1. Introduction to the manual Contents of this chapter ..........9 Safety instructions . - Page 6 Protecting the system against thermal overload ......31 Operation principle ..........31 Protecting the resistor cable against short-circuits .
- Page 7 ACS880-604-0640-3 brake unit, follower ........
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Page 9: Introduction To The Manual
Introduction to the manual 9 Introduction to the manual Contents of this chapter This chapter introduces this manual. Safety instructions Obey all safety instructions delivered with the drive. Read the complete safety instructions before you install, start up, or use the drive. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). -
Page 10: Contents Of The Manual
You can find instructions on equipment kits on the Internet. Go to https://www151.abb.com/spaces/lvacdrivesengineeringsupport/content. For other manuals, see the inside of the front cover. If needed, contact your local ABB representative. Terms and abbreviations Term/Abbreviation... - Page 11 Introduction to the manual 11 Term/Abbreviation Explanation Brake unit Brake chopper and resistors Cubicle One section of a cabinet-installed drive. A cubicle is typically behind a door of its own. DC link DC circuit between rectifier and inverter Drive Frequency converter for controlling AC motors Electromagnetic compatibility IGBT Insulated gate bipolar transistor;...
- Page 12 12 Introduction to the manual...
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Page 13: Operation Principle And Hardware Description
Contents of this chapter This chapter describes the operation principle and construction of the brake chopper. Product overview ACS880-604 is an air-cooled brake chopper unit. It includes an NBRA brake chopper module or two parallel-connected NBRA brake chopper modules. Operation principle The brake chopper handles the energy generated by a decelerating motor. -
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. In this example, the supply unit consists of one supply module. DC link Inverter DC fuses Inverter units. -
Page 15: Layout Drawing
Operation principle and hardware description 15 Layout drawing The components of the brake chopper module are shown below. Four fastening points at the back of the unit Four front panel fastening screws Front panel Chopper control board (NBRC) with control terminals (see page 16) Voltage selection jumper (see page 34) PE (protective earth) clamp Grounding clamp... -
Page 16: Overview Of Power And Control Connections
16 Operation principle and hardware description Overview of power and control connections The diagram below shows the power and control connections of the brake chopper module. NBRA NBRC t° UDC- UDC+ t° Item Description Additional information Chopper enable input Protecting the system against thermal overload (page 31) Fault indication relay output... -
Page 17: Type Designation Label
Operation principle and hardware description 17 Type designation label Each brake chopper module is equipped with a type designation label. An example label is shown below. Description Type designation Brake chopper module order code Serial number • The first digit of the serial number refers to the manufacturing plant. •... - Page 18 18 Operation principle and hardware description...
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Page 19: Mechanical Installation
Mechanical installation 19 Mechanical installation Contents of this chapter This chapter contains installation instructions and examples. Checking the installation site The brake chopper module must be installed in an upright position. The degree of protection of the module is IP00. Take this into account when selecting the installation site. Installation in a cabinet is highly recommended. -
Page 20: Installing The Brake Chopper Module
20 Mechanical installation Installing the brake chopper module 1. Mark the locations of the four mounting holes onto the installation surface. For the module dimensions, see chapter Dimension drawings. 2. Drill the mounting holes. Make sure that dust and burr from drilling does not enter the module or other equipment at the installation site. -
Page 21: Examples: Installing The Brake Chopper Module And A Cooling Fan
Brake chopper cubicle, side view Brake chopper cubicle, front view Brake chopper module, front view DC fuses Brake chopper module Power connection terminals Cooling fan mounting plate* Cooling fan * Not available from ABB For more information on the dimensions, see chapter Dimension drawings. -
Page 22: Example 2: Installation Into Rittal Ts8 Enclosure
Attenuator (optional) Brake chopper module Cooling fan Cooling fan mounting plate* Plastic bars on both sides to block airflow** * Not available from ABB. For an illustration, see 3AXD50000007886. ** Not available from ABB. For an illustration, see 3AXD50000008190 and 3AXD50000008209. -
Page 23: Examples: Installing Brake Resistors And A Cooling Fan
Brake resistor cubicle, front view Brake resistor cubicle, side view Mounting rails* Thermal circuit breakers Brake resistors Power connection terminals Cooling fan mounting plate* Cooling fan * Not available from ABB For more information on the dimensions, see chapter Dimension drawings. -
Page 24: Example 2: Installation Into Rittal Ts8 Enclosure
Air flow out. Use open roof. Brake resistors Cooling fan mounting plate* Cooling fan Plastic bars on both sides to block airflow** * Not available from ABB. For an illustration, see 3AXD50000008316. ** Not available from ABB. For an illustration, see 3AXD50000008190 and 3AXD50000008209. -
Page 25: Planning The Electrical Installation
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: Equipping The Drive With A Main Contactor And Manual Control Switch(Es)
26 Planning the electrical installation Equipping the drive with a main contactor and manual control switch(es) It is highly recommended to equip the drive with a main contactor and wire it to fault indication relay output X3 on the chopper control board. This configuration also requires a manual start/stop switch(es) for system start-up. - Page 27 Planning the electrical installation 27 For connection examples, see the diagrams below. Example 1 NBRC Example 2 NBRC...
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Page 28: Selecting The Brake Circuit Components
28 Planning the electrical installation Selecting the brake circuit components 1. Calculate the maximum power generated by the motor during braking (P 2. Select a suitable brake chopper and brake resistor combination for the application from the rating table on page 57. This condition must be met: >... -
Page 29: Calculating The Maximum Braking Power
Planning the electrical installation 29 Calculating the maximum braking power The P value for each standard brake chopper and brake resistor combination is given brmax in the rating table on page 57. The rated value is specified for a reference braking cycle (10 s of braking, 50 s of rest). -
Page 30: Example 3
The maximum cable length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user- defined brake resistors and cabling. The EMC compliance of the complete installation... -
Page 31: Placing The Brake Resistors
Planning the electrical installation 31 Placing the brake resistors Install the resistors in a place where they will cool. Arrange the cooling of the resistor in a way that: • no danger of overheating is caused to the resistor or nearby materials •... -
Page 32: Controlling The Brake Chopper From An External Control Location
32 Planning the electrical installation 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 33: Electrical Installation
Electrical installation 33 Electrical installation Contents of this chapter This chapter contains instructions on wiring the brake chopper unit. Safety Obey the safety instructions for the drive. See Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]. WARNING! If you ignore these instructions, physical injury or death, or damage to the equipment can occur. -
Page 34: Checking The Insulation Of The Resistor Circuit
34 Electrical installation Checking the insulation of the resistor circuit Do not make any voltage tolerance or insulation resistance tests on the brake chopper modules. Every brake chopper module has been tested for insulation between the main circuit and the chassis at the factory. Check the insulation of the brake resistor assembly as follows: 1. -
Page 35: Synchronizing Multiple Brake Choppers
Electrical installation 35 WARNING! An incorrect jumper setting or missing jumper may cause brake chopper malfunctioning or damage to the chopper or resistor. Synchronizing multiple brake choppers When several brake choppers are in use, the first chopper in the chain acts as the master for the other choppers. -
Page 36: Connecting The Dc And Resistor Cables
36 Electrical installation Connecting the DC and resistor cables WARNING! Never connect the output terminals of the brake chopper together. It short-circuits the chopper and will damage it. Connection diagram DC link and brake unit in separate cabinets DC link and brake unit in the same cabinet * The brake unit can be grounded to the frame through the mounting screws if the galvanic connection to PE (protective earth) is good enough. -
Page 37: Connection Procedure
Electrical installation 37 Connection procedure 1. If the DC link and the brake unit are located in separate cabinets, ground the DC cable 360 degrees at the cabinet lead-throughs. 2. At the brake chopper end, connect the twisted shields (protective earth conductor) of the DC and resistor cables and the third conductors to the grounding terminals. -
Page 38: Connecting The Thermal Switch
38 Electrical installation Connecting the thermal switch Connect the thermal switches of the resistors in series to chopper enable input X1 as shown in the power and control connections diagram on page 16. -
Page 39: Installation Checklist
Installation checklist 39 Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the brake chopper. Checklist Check the mechanical and electrical installation of the brake chopper before start-up. Go through the checklist together with another person. WARNING! Only qualified electricians are allowed to carry out the work described below. - Page 40 40 Installation checklist Check that … The setting of the voltage selection jumper is correct. See section Selecting the voltage on page 34. The DC cable has been connected to the appropriate terminals, and the terminals have been tightened. (Pull the conductors to check.) Appropriate DC fuses have been installed.
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Page 41: Start-Up
Start-up 41 Start-up Contents of this chapter This chapter contains the start-up procedure of a brake unit. WARNING! Only qualified electricians are allowed to perform the work described in this chapter. Obey all safety instructions in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]. -
Page 42: Power Switch-On
42 Start-up Action Additional information Check that the drive is ready for the brake chopper start-up: See the supply and inverter module hardware manuals and • The supply and inverter units have been installed according other appropriate manuals on the to the instructions given in their hardware manuals. -
Page 43: Fault Tracing And Maintenance
Fault tracing and maintenance 43 Fault tracing and maintenance Contents of this chapter This chapter describes the fault tracing possibilities and maintenance of a brake unit. Maintenance If installed into an appropriate environment, the brake chopper module does not require maintenance, except for regular cleaning. -
Page 44: Fault Indications
Short circuit in power cables or Check power cables and resistor. resistor. Chopper control board failure. Contact local ABB representative. Chopper damaged; it is not able to disconnect resistor from intermediate circuit. Chopper does not function. Chopper voltage setting too high. -
Page 45: Nred Voltage Reducer Selection For Nbra-669
Fault tracing and maintenance 45 NRED voltage reducer selection for NBRA-669 The NRED voltage reducer can be used to protect the NBRC-61 chopper control board from overvoltage peaks. Jumper X6 on the chopper control board defines if the NRED voltage reducer is used. By default, the NRED voltage reducer is used and the jumper is set to OFF (recommended). - Page 46 46 Fault tracing and maintenance...
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Page 47: Ordering Information
Ordering information 47 Ordering information Contents of this chapter This chapter lists the components and accessories for the brake chopper unit. -
Page 48: Brake Chopper Modules
48 Ordering information Brake chopper modules ACS880-604- Module type Ordering code = 400 V (Range 380…415 V) 0210-3 NBRA-658 59006428 0320-3 NBRA-659 59006436 0640-3 2×NBRA-659 59006436 0960-3 3×NBRA-659 59006436 1280-3 4×NBRA-659 59006436 1600-3 5×NBRA-659 59006436 1920-3 6×NBRA-659 59006436 = 500 V (Range 380…500 V) -
Page 49: Brake Chopper Cooling Fans
Ordering information 49 Brake chopper cooling fans ACS880-604- Module type Ordering code Additional information = 400 V (Range 380…415 V) 0210-3 NBRA-658 64114158 0320-3 NBRA-659 64114158 0640-3 2×NBRA-659 64114158 230 V fan kit 0960-3 3×NBRA-659 64114158 (G2E140-PI51-09 + wire) 1280-3 4×NBRA-659... -
Page 50: Fuses
50 Ordering information Fuses ACS880-604- Module type Ordering code Fuse type Ratings = 400 V (Range 380…415 V) 0210-3 NBRA-658 10028183 170M5142 400 A, 1250 V 0320-3 NBRA-659 10028191 170M5146 630 A, 1250 V 0640-3 2×NBRA-659 10028191 170M5146 630 A, 1250 V 0960-3 3×NBRA-659... -
Page 51: Fuse Bases
Ordering information 51 Fuse bases ACS880-604- Module type Ordering code Base type = 400 V (Range 380…415 V) 0210-3 NBRA-658 10028205 170H3005 0320-3 NBRA-659 10028205 170H3005 0640-3 2×NBRA-659 10028205 170H3005 0960-3 3×NBRA-659 10028205 170H3005 1280-3 4×NBRA-659 10028205 170H3005 1600-3 5×NBRA-659... -
Page 52: Brake Resistors
52 Ordering information Brake resistors ACS880-604- Module type Ordering code Resistor type Ratings = 400 V (Range 380…415 V) 0210-3 NBRA-658 68759391 SAFUR210F575 575 V, 210 kW, R = 3.4 ohm 0320-3 NBRA-659 68759315 SAFUR180F460 460 V, 180 kW, R = 2.4 ohm 0640-3 2×NBRA-659... -
Page 53: Brake Resistor Cooling Fans
Ordering information 53 Brake resistor cooling fans One cooling fan is sufficient for two of the above resistors when the resistors are installed side by side. ACS880-604- Module type Ordering code Additional information = 400 V (Range 380…415 V) 0210-3... -
Page 54: Attenuator
54 Ordering information Attenuator Attenuator (optional) for suppressing voltage spikes at the chopper input. Must be fitted if it is possible to disconnect all inverter units from the DC link with the supply unit on. ACS880-604- Module type Ordering code Type = 400 V (Range 380…415 V) -
Page 55: Technical Data
Technical data 55 Technical data Contents of this chapter This chapter contains the technical specifications of the brake chopper module, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Standard brake resistor and cooling fan specifications are also included where applicable. -
Page 56: Ratings
56 Technical data Ratings Only chopper ACS880- Module type Duty cycle Duty cycle 604- (1 min/5 min) (10 s/60 s) brmax cont. = 400 V (Range 380…415 V) 0210-3 NBRA-658 – 0320-3 NBRA-659 1.20 – 0640-3 2×NBRA-659 0.60 1090 1090 –... -
Page 57: Chopper With Standard Resistors
Technical data 57 Chopper with standard resistors ACS880- Module Resistors Duty cycle Duty cycle 604- type (1 min/5 min) (10 s/60 s) Type Qty* P brmax cont. = 400 V (Range 380…415 V) 0210-3 NBRA-658 2×SAFUR210F575 2×21 8400 0320-3 NBRA-659 2×SAFUR180F460 2×30 1.20 444 12000... -
Page 58: Definitions
58 Technical data Definitions Brake unit Example: ACS880-604-0640-3 Maximum braking power per brake unit allowed brmax momentarily Nominal resistance of the brake resistors connected to one brake chopper unit Total recommended brake resistor resistance of the listed resistor assembly Peak brake current (DC) per chopper Continuous braking power per brake unit. -
Page 59: Dc Fuses
Technical data 59 DC fuses ACS880-604- Module type Fuse type* = 400 V (Range 380…415 V) 0210-3 NBRA-658 170M5142 1250 0320-3 NBRA-659 170M5146 1250 0640-3 2×NBRA-659 170M5146 1250 0960-3 3×NBRA-659 170M5146 1250 1280-3 4×NBRA-659 170M5146 1250 1600-3 5×NBRA-659 170M5146 1250 1920-3 6×NBRA-659... -
Page 60: Dimensions, Weights And Free Space Requirements
60 Technical data Dimensions, weights and free space requirements Device Height Width Depth Weight Brake chopper module 538.5 21.20 13.15 9.45 NBRA-658/659/669 Brake resistor SAFUR180F460 1320 51.97 11.81 13.58 Brake resistor SAFUR125F500 1320 51.97 11.81 13.58 Brake resistor SAFUR200F500 1320 51.97 11.81 13.58... -
Page 61: Losses, Cooling Data And Noise
Technical data 61 Losses, cooling data and noise The heat loss of a brake chopper is one percent of the braking power. Only chopper ACS880-604- Module type Air flow Noise /min dB(A) = 400 V (Range 380…415 V) 0210-3 NBRA-658... -
Page 62: Chopper With Standard Resistors
62 Technical data Chopper with standard resistors ACS880-604- Module type Resistor type Air flow Noise /min dB(A) = 400 V (Range 380…415 V) 0210-3 NBRA-658 2×SAFUR210F575 2500 1472 0320-3 NBRA-659 2×SAFUR180F460 2500 1472 0640-3 2×NBRA-659 2×(2×SAFUR180F460) 5000 2943 0960-3 3×NBRA-659 3×(2×SAFUR180F460) -
Page 63: Brake Circuit Cable Sizes
Technical data 63 Brake circuit cable sizes Resistor cable (Cu)** ACS880-604- Module type Chopper cable (Cu)* Multicore Single-core Multicore Single-core = 400 V (Range 380…415 V) 0210-3 NBRA-658 3×95+50 3×50+25 0320-3 NBRA-659 3×185+95 3×95+50 0640-3 2×NBRA-659 2×120 2×(3×185+95) 2×70 2×(3×95+50) 0960-3 3×NBRA-659... -
Page 64: Brake Chopper Terminal Data
64 Technical data Brake chopper terminal data ACS880-604- Module type UDC+, UDC-, R+, R- Grounding clamps Hole Screw Tightening Max. wire Tightening diameter torque size torque N·m N·m = 400 V (Range 380…415 V) 0210-3 NBRA-658 0320-3 NBRA-659 0640-3 2×NBRA-659 2×M10... -
Page 65: Brake Resistor Terminal Data
Technical data 65 Brake resistor terminal data ACS880-604- Module type Resistor type R+, R- and grounding terminals Hole Screw Tightening diameter torque N·m = 400 V (Range 380…415 V) 0210-3 NBRA-658 2×SAFUR210F575 0320-3 NBRA-659 2×SAFUR180F460 0640-3 2×NBRA-659 2×(2×SAFUR180F460) 2×M6 0960-3 3×NBRA-659... -
Page 66: Ce Marking
66 Technical data CE marking A CE mark is attached to the brake chopper module to verify that the unit follows the provisions of the European Low Voltage and EMC Directives. Compliance with the European Low Voltage Directive The compliance with the European Low Voltage Directive has been verified according to standards EN 61800-5-1 and EN 60204-1. -
Page 67: Dimension Drawings
Dimension drawings 67 Dimension drawings Contents of this chapter This chapter contains the dimension drawings of the brake chopper module, as well as the standard brake resistors and cooling fans. The dimensions are in millimeters. To convert to inches, use the formula: 25.4 mm = 1 in. -
Page 68: Brake Chopper Modules Nbra-658, Nbra-659, Nbra-669
68 Dimension drawings Brake chopper modules NBRA-658, NBRA-659, NBRA- Brake chopper cooling fan G2E140-PI51-09 Weight: 3 kg... -
Page 69: Brake Resistors Safur180F460, Safur125F500, Safur200F500, Safur210F575
Dimension drawings 69 Brake resistors SAFUR180F460, SAFUR125F500, SAFUR200F500, SAFUR210F575 R+ R- Ø Brake resistor cooling fan D4E225-CC01-39... - Page 70 70 Dimension drawings...
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Page 71: Example Circuit Diagrams
Example circuit diagrams 71 Example circuit diagrams Contents of this chapter This chapter contains example circuit diagrams of a brake unit. The installation consists of two parallel units both including a brake chopper and two brake resistors. One chopper – the first in the chain – acts as the master for the other. The switching of the follower chopper is controlled by the master via a fiber optic link. - Page 72 72 Example circuit diagrams...
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Page 73: Acs880-604-0640-3 Brake Unit, Master
ACS880-604-0640-3 brake unit, master... -
Page 74: Acs880-604-0640-3 Brake Unit, Follower
ACS880-604-0640-3 brake unit, follower... -
Page 75: 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 76 Contact us www.abb.com/drives www.abb.com/drivespartners 3AUA0000106244 Rev B (EN) 2013-12-05...