ABB ACS880-604 User manual

ABB industrial drives
Hardware manual
ACS880-604 1-phase brake chopper units as modules
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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
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Electrical planning instructions for ACS880 multidrive
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Safety instructions for ACS880 multidrive cabinets and
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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
EN
EFFECTIVE: 2013-12-05
©2013 ABB Oy. All Rights Reserved.
3. Mechanical installation
5. Electrical installation
Table of contents
7. Start-up
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5
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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6
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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7
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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8
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Introduction to the manual 9
1
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.
Related documents
The user documentation of a multidrive module delivery includes a USB memory stick with
all manuals of the product series.
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 Explanation
Control board Circuit board in which the control program runs
Brake chopper Conducts the surplus energy from the intermediate circuit of the
drive to the brake resistors when necessary. The chopper operates
when the DC link voltage exceeds a certain maximum limit. The
voltage rise is typically caused by deceleration (braking) of a high
inertia motor.
Brake chopper module Brake chopper enclosed inside a metal frame or enclosure.
Intended for cabinet installation. See Brake chopper.
Brake chopper unit Brake chopper modules under control of one control board and
related accessories. The control board is considered part of the unit.
Brake resistor Dissipates the drive surplus braking energy conducted by the brake
chopper to heat. Essential part of the brake circuit. See Brake
chopper.
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