ABB ACS880-604 Bedienungsanleitung

ABB industrial drives

Hardware manual

ACS880-604 1-phase brake chopper units as modules

EN_ACS880_604_1ph_brake.book Page 1 Thursday, December 19, 2013 3:06 PM

List of related manuals

You can find manuals and other product documents in PDF format on the Internet. See section

Document library on the Internet on the inside of the back cover. For manuals not available in the

Document library, contact your local ABB representative.

General drive manuals Code (English)

Cabinet design and construction instructions for ACS880

multidrive modules

3AUA0000107668

Electrical planning instructions for ACS880 multidrive

cabinets and modules

3AUA0000102324

Safety instructions for ACS880 multidrive cabinets and

modules

3AUA0000102301

Supply module manuals

ACS880-204 IGBT supply units as modules hardware

manual

3AUA0000131525

ACS880 IGBT supply control program firmware manual 3AUA0000131562

ACS880-304 diode supply modules (+A003) hardware

manual

3AUA0000102452

ACS880 diode supply control program firmware manual 3AUA0000103295

Inverter module manuals and guides

ACS880-104 inverter modules hardware manual 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

hardware manual

3AUA0000106244

Option manuals and guides

ACS-AP-x Assistant control panels user's manual 3AUA0000085685

Drive composer start-up and maintenance PC tool user’s

manual

3AUA0000094606

Manuals and quick guides for I/O extension modules,

fieldbus adapters, etc.

EN_ACS880_604_1ph_brake.book Page 2 Thursday, December 19, 2013 3:06 PM

Hardware manual

ACS880-604 1-phase brake chopper units as

modules

3AUA0000106244 Rev B

EFFECTIVE: 2013-12-05

3. Mechanical installation

5. Electrical installation

Table of contents

7. Start-up

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EN_ACS880_604_1ph_brake.book Page 4 Thursday, December 19, 2013 3:06 PM

Table of contents

1. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Single-line diagram of the drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Installing the brake chopper module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Examples: Installing the brake chopper module and a cooling fan . . . . . . . . . . . . . . . . . 21

Example 1: Installation into generic closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Example 2: Installation into Rittal TS8 enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Examples: Installing brake resistors and a cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Example 1: Installation into generic enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Example 2: Installation into Rittal TS8 enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4. Planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Generic guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Equipping the drive with a main contactor and manual control switch(es) . . . . . . . . . . . 26

Selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Calculating the maximum braking power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Selecting the chopper enable input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Controlling the brake chopper from an external control location . . . . . . . . . . . . . . . . . . 32

5. Electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Checking the insulation of the resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Selecting the voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Synchronizing multiple brake choppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Connecting the DC and resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Connecting the thermal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7. Start-up

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Preliminary actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Power switch-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operational checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8. Fault tracing and maintenance

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

NRED voltage reducer selection for NBRA-669 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9. Ordering information

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Brake chopper modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Brake chopper cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fuse bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Brake resistor cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Attenuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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10. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Only chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Chopper with standard resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Only chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Chopper with standard resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Brake circuit cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Brake chopper terminal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Brake resistor terminal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . 66

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

More information on standards and markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

11. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Brake chopper modules NBRA-658, NBRA-659, NBRA-669 . . . . . . . . . . . . . . . . . . . . . 68

Brake chopper cooling fan G2E140-PI51-09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Brake resistors SAFUR180F460, SAFUR125F500, SAFUR200F500, SAFUR210F575 69

Brake resistor cooling fan D4E225-CC01-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

12. Example circuit diagrams

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

ACS880-604-0640-3 brake unit, master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

ACS880-604-0640-3 brake unit, follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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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]).

Read the task-specific safety instructions before starting the task. See the subsection

describing the task.

Target audience

The manual is intended for people who plan the installation of, install, start up and use the

brake chopper units. Read the manual before working on the units. You are expected to

know the fundamentals of electricity, wiring, electrical components, and electrical

schematic symbols.

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10 Introduction to the manual

Contents of the manual

This manual consists of the following chapters:

•Introduction to the manual introduces this manual.

•Operation principle and hardware description describes the operation principle and

construction of the brake chopper.

•Mechanical installation contains installation instructions and examples.

•Planning the electrical installation contains instructions on selecting, placing and

protecting the brake circuit components and cables.

•Electrical installation contains instructions on wiring the brake chopper unit.

•Installation checklist contains a list for checking the mechanical and electrical

installation of the brake chopper.

•Start-up contains the start-up procedure of a brake unit.

•Fault tracing and maintenance describes the fault tracing possibilities and

maintenance of a brake unit.

•Ordering information lists the components and accessories for the brake chopper unit.

•Technical data contains the technical specifications of the brake chopper module, eg,

the ratings, sizes and technical requirements, provisions for fulfilling the requirements

for CE and other markings.

•Dimension drawings contains the dimension drawings of the brake chopper module,

as well as the standard brake resistors and cooling fans.

•Example circuit diagrams contains example circuit diagrams of a brake unit.

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