ABB ACS880-607LC User manual

—
ABB INDUSTRIAL DRIVES
ACS880-607LC 3-phase dynamic brake units
Hardware manual

ACS880-607LC 3-phase dynamic
brake units
Hardware manual
Table of contents
4. Electrical installation
7. Start-up
3AXD50000581627 Rev B
EN
Original instructions
EFFECTIVE: 2023-08-22

Table of contents
1 Introduction to the manual
11Contents of this chapter ........................................................................
11Applicability ........................................................................................
11Safety instructions ...............................................................................
11Target audience ...................................................................................
12Categorization by frame size and option code ............................................
12Use of component designations ..............................................................
12Quick installation flowchart ....................................................................
13Related documents ..............................................................................
14Terms and abbreviations .......................................................................
2 Operation principle and hardware description
15Contents of this chapter ........................................................................
15Product overview .................................................................................
15Operation principle ..............................................................................
15When is resistor braking necessary? .........................................................
16Overview diagram of the drive system .......................................................
17Overview drawing of the drive system .......................................................
18Layout drawings – brake module cubicle ....................................................
21Layout drawing – brake module R8i ..........................................................
21Module layout ..................................................................................
21Coolant connectors ...........................................................................
22Connectors X50…X59 ........................................................................
23Fiber optic connectors .......................................................................
23LEDs ..............................................................................................
24Overview of power and control connections ...............................................
25Brake unit control devices ......................................................................
25Overview of the control connections of the BCU control unit ....... .... .... .... ....
26The control panel ..............................................................................
26Control by PC tools ...........................................................................
26Fieldbus control ...............................................................................
26DC switch and charging switch ............................................................
27Type designation labels .........................................................................
27Type designation label of the brake unit .................................................
28Type designation key ............................................................................
28Basic code ......................................................................................
28Option codes ...................................................................................
3 Guidelines for planning the electrical installation
31Contents of this chapter ........................................................................
31Limitation of liability .............................................................................
31North America .................................................................................
31Generic guidelines ................................................................................
32Selecting the brake resistor ....................................................................
Table of contents 5

32Selecting and routing the brake resistor cables ... .... .... .... .... .... .... .... .... .... ....
32Resistor cable sizes and length ............................................................
32Minimizing electromagnetic interference ...............................................
33Selecting the installation location for the brake resistors . ... . ... . ... . ... . ... . ... . ... . ..
33Selecting the resistor thermal switch circuit cable . .... .... .... .... .... .... .... .... .... ...
33Protecting the system against thermal overload .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . ...
33Protecting the system against short-circuits ..............................................
4 Electrical installation
35Contents of this chapter ........................................................................
35Electrical safety precautions ...................................................................
37General notes ......................................................................................
37Printed circuit boards ........................................................................
37Handling fiber optic cables .................................................................
38Measuring the insulation resistance of the brake resistor circuit ... ... . ... . ... . ... . ..
39Connecting the brake resistor cables and thermal switch .... .... .... .... .... .... .... ..
39Connection diagram ..........................................................................
40Connection procedure of the resistor cables ...........................................
40Removing shrouds ........................................................................
40Connecting the cables ....................................................................
42Installing shrouds .........................................................................
43Use of fasteners in cable lug connections ...........................................
44Connection procedure of the thermal switch cable .... .... .... .... .... .... .... .... ...
45Connecting the control cables .................................................................
45Control cable connection procedure ......................................................
45Grounding the outer shields of the control cables 360° at the cabinet entry .
47Routing the control cables inside the cabinet .... .... .... .... .... .... .... .... .... ...
47Connecting control cabling .............................................................
49Connecting a PC ..................................................................................
5 The control unit
51Contents of this chapter ........................................................................
51General ..............................................................................................
52BCU-x2 layout ......................................................................................
54Default I/O diagram of the brake control unit .............................................
57Additional information on the connections .................................................
57Power supply for the control unit (XPOW) ...............................................
57The X485 connector ..........................................................................
57Safe torque off (XSTO, XSTO OUT) ........................................................
57FSO safety functions module connection (X12) .... .... .... .... .... .... .... .... .... ....
57SDHC memory card slot .....................................................................
58Connector data ...................................................................................
61BCU-x2 ground isolation diagram .........................................................
6 Installation checklist
63Contents of this chapter ........................................................................
63Checklist ............................................................................................
7 Start-up
65Contents of this chapter ........................................................................
66Start-up procedure ...............................................................................
6 Table of contents

8 Operating instructions
69Contents of this chapter ........................................................................
69Disconnecting the brake unit from the drive DC bus .... .... .... .... .... .... .... .... .... .
69Connecting the brake unit to the drive DC bus ............................................
9 Fault tracing
71Contents of this chapter ........................................................................
71LEDs .................................................................................................
71Control panel and panel platform/holder LEDs .... .... .... .... .... .... .... .... .... ....
72Control unit LEDs .............................................................................
72R8i module LEDs ..............................................................................
727-segment display of the brake control unit ................................................
72Warning and fault messages ...................................................................
10 Maintenance
73Contents of this chapter ........................................................................
73Maintenance intervals ...........................................................................
73Description of symbols ......................................................................
73Recommended maintenance intervals after start-up .... .... .... .... .... .... .... .... .
75Maintenance timers and counters ............................................................
75Cabinet .............................................................................................
75Cleaning the interior of the cabinet .......................................................
76Cleaning the exterior of the drive .........................................................
77Fan replacement ..................................................................................
77Brake chopper module cubicle .............................................................
78Fan in the output cubicle, top cable entry (option +H351) ..... .... .... .... .... .... ..
79Brake module ......................................................................................
79Assembling the service platform ..........................................................
80Removing the module ........................................................................
83Reinstalling the module ......................................................................
83Capacitors .........................................................................................
84Reforming the capacitors ...................................................................
85Fuses ................................................................................................
85Replacing the brake chopper fuses .......................................................
87Replacing the resistor fuses ................................................................
88Control panel ......................................................................................
89Memory unit .......................................................................................
89Replacing the memory unit .................................................................
11 Internal cooling circuit
91Contents of this chapter ........................................................................
91Applicability ........................................................................................
91Internal cooling system .........................................................................
93Connection to a cooling unit ...................................................................
93Connection to an ACS880-1007LC cooling unit .... .... .... .... .... .... .... .... .... ....
93Connection to a custom cooling unit .....................................................
93General requirements ....................................................................
93Coolant temperature control ...........................................................
94Filling up and bleeding the internal cooling circuit ... . ... . ... . ... . ... . ... . ... . ... . ... . ... .
94Drive line-ups with an ACS880-1007LC cooling unit .. . ... . ... . ... . ... . ... . ... . ... . ... .
Table of contents 7

94Drive line-ups with a custom cooling unit ...............................................
95Draining the internal cooling circuit ..........................................................
95Maintenance intervals ...........................................................................
96Technical data .....................................................................................
96Coolant specification ........................................................................
96Coolant type ................................................................................
96Temperature limits ...........................................................................
98Pressure limits .................................................................................
98Coolant flow rate limits ......................................................................
98Cooling circuit materials ....................................................................
12 Technical data
99Contents of this chapter ........................................................................
99Ratings ..............................................................................................
100Definitions ......................................................................................
101Derating ............................................................................................
101Surrounding air temperature derating ...................................................
101Coolant temperature derating .............................................................
101Antifreeze content derating ................................................................
102Altitude derating ..............................................................................
102Frame sizes and modules used ................................................................
102Fuses ................................................................................................
102DC fuses (IEC) ..................................................................................
103DC fuses (UL) ..................................................................................
103Resistor fuses (IEC and UL) .................................................................
103Dimensions, weights and free space requirements ... .... .... .... .... .... .... .... .... ....
104Losses, cooling data and noise ................................................................
104Terminal and cable entry data for the resistor cables .. ... . ... . ... . ... . ... . ... . ... . ... . ..
105Bottom entry and exit of cables ...........................................................
107Top entry and exit of cables ................................................................
108Tightening torques ...............................................................................
108Electrical connections ........................................................................
108Mechanical connections .....................................................................
108Insulation supports ...........................................................................
108Cable lugs .......................................................................................
108Typical resistor cable sizes .....................................................................
109Maximum cable length .......................................................................
109Resistor connection ..............................................................................
109........................................................................................................
109Control unit (board) connection data ........................................................
109Auxiliary circuit current consumption ........................................................
109Energy efficiency data (ecodesign) ...........................................................
109Efficiency ...........................................................................................
110Protection classes ................................................................................
110Ambient conditions ..............................................................................
111Materials ............................................................................................
111Color .................................................................................................
111Package .............................................................................................
112Disposal ............................................................................................
112Applicable standards ............................................................................
112Markings ............................................................................................
8 Table of contents

113Disclaimers .........................................................................................
113Generic disclaimer ............................................................................
113Cyber security disclaimer ...................................................................
13 Dimension drawings
115Contents of this chapter ........................................................................
116Brake unit with bottom exit ....................................................................
117Brake unit with top exit .........................................................................
Further information
Table of contents 9

10

Introduction to the manual
Contents of this chapter
This chapter contains information on the manual.
Applicability
The manual is applicable to the cabinet-installed ACS880-607LC 3-phase brake units
that form a part of an ACS880 multidrive system.
Safety instructions
Obey all safety instructions of the drive.
• Read the complete safety instructions before you install, commission, use or
service the drive. The complete safety instructions are given in ACS880
liquid-cooled multidrive cabinets and modules safety instructions
(3AXD50000048633 [English]).
• Read the warnings of the software function before you take the function in use
or change its default parameter settings. Read the warnings of the parameter
before you change its default setting. Refer to the firmware manual.
Target audience
This manual is intended for people who plan the installation, install, commission and
do maintenance work on the drive, or create instructions for the end user of the drive
concerning the installation and maintenance of the drive.
Read the manual before you work on the drive. You are expected to know the
fundamentals of electricity, wiring, electrical components and electrical schematic
symbols.
1
Introduction to the manual 11

Categorization by frame size and option code
The frame size identifies information which concerns only a certain frame size of the
drive. The frame size is shown on the type designation label. All frame sizes are listed
in the technical data.
The option code (A123) identifies information which concerns only a certain optional
selection. The options included in the drive are listed on the type designation label.
Use of component designations
Some device names in the manual include the component designation in brackets (for
example, [Q20]). This will help you to identify the components in the circuit diagrams
of the drive.
Quick installation flowchart
SeeTask
Guidelines for planning the electrical installa-
tion (page 31)
Plan the electrical installation and acquire the ac-
cessories needed (cables, fuses, etc.).
Technical data (page 99)
Check the ratings, required coolant flow, and other
technical data. Selecting the brake resistor (page 32)
Select the brake resistor (if custom resistor is used).
ACS880 liquid-cooled multidrive cabinets mechan-
ical installation instructions (3AXD50000048635
[English])
Examine the installation site.
ACS880 liquid-cooled multidrive cabinets mechan-
ical installation instructions (3AXD50000048635
[English])
Unpack and examine the drive (only intact units may
be started up).
Make sure that all necessary optional modules and
equipment are present and correct. If the drive has been non-operational for more than
one year, the DC link capacitors need to be re-
formed. See Capacitor reforming instructions
(3BFE64059629 [English]).
ACS880 liquid-cooled multidrive cabinets mechan-
ical installation instructions (3AXD50000048635
[English])
Fasten the cabinet and join cabinet sections togeth-
er.
Selecting and routing the brake resistor
cables (page 32)
Route the resistor cables (if customer resistor is
used).
Measuring the insulation resistance of the brake
resistor circuit (page 38)
Measure the insulation of the resistor circuit (if
customer resistor is used).
Electrical installation (page 35)
Connect the resistor cables and thermal switch (if
customer resistor is used).
Connect the control cables (if customer resistor is
used).
Installation checklist (page 63)
Check the installation.
12 Introduction to the manual

SeeTask
Start-up (page 65)
Start the brake unit up.
ACS880 brake control program firmware manual
(3AXD50000020967 [English])
Operating instructions (page 69)
Operate the brake unit.
ACS880 brake control program firmware manual
(3AXD50000020967 [English])
Related documents
You can find manuals on the Internet. See below for the relevant code/link. For more
documentation, go to www.abb.com/drives/documents.
Manuals for ACS880 multidrives cabinets
Introduction to the manual 13

Terms and abbreviations
DescriptionTerm
Type of control boardBCON
Type of control unitBCU
Module internal power supply boardBDPS
Conducts the surplus energy from the intermediate circuit of the drive to the
brake resistor when necessary. The chopper operates when the DC link voltage
exceeds a certain maximum limit. The voltage rise is typically caused by decel-
eration (braking) of a high inertia motor.
Brake chopper
Brake chopper enclosed in a metal frame or housing. Intended for cabinet in-
stallation.
Brake chopper module
Dissipates the drive surplus braking energy conducted by the brake chopper
to heat
Brake resistor
Brake chopper modules and the necessary auxiliary equipment, such as control
electronics, fusing and cabling
Brake unit
I/O module for controlling cooling fansCIO
The part in which the control program runs.Control unit
One section of a cabinet-installed drive. A cubicle is typically behind a door of
its own.
Cubicle
DC circuit betweenDC link
Frequency converter for controlling AC motorsDrive
Electromagnetic compatibilityEMC
Physical size of the drive or power moduleFrame, frame size
DC circuit between rectifier and inverterIntermediate circuit
Inverter module(s) under control of one control unit, and related components.
One inverter unit typically controls one motor.
Inverter unit
Drive for controlling several motors which are typically coupled to the same
machinery. Includes one supply unit, and one or several inverter units.
Multidrive
In the drive control program, user-adjustable operation instruction to the
drive, or signal measured or calculated by the drive.
In some (for example fieldbus) contexts, a value that can be accessed as an
object. For example, variable, constant, or signal.
Parameter
Supply module(s) under control of one control unit, and related components.Supply unit
Type of memory unit, attached to the control unitZMU
14 Introduction to the manual

Operation principle and hardware
description
Contents of this chapter
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 external, and customer must acquire and install them separately.
Operation principle
The brake chopper handles the extra energy generated by motor during a quick
deceleration. The extra energy increases the drive DC link voltage. The chopper connects
the brake resistor to the DC link whenever the voltage is greater than the limit defined
by the control program. Energy consumption by the resistor losses lowers the voltage
until the resistor can be disconnected.
When is resistor braking necessary?
Resistor braking is necessary for high capacity braking of the motor and machinery
if a regenerative drive cannot be used.
2
Operation principle and hardware description 15

Overview diagram of the drive system
The diagram that follows shows an example of a multidrive. The supply unit connects
the drive to the AC supply network. It converts the AC voltage into DC. The DC voltage
is distributed through the DC bus to all inverter units and optional brake units. The
inverter unit converts the DC back to AC that rotates the motor. The brake unit
(optional) conveys energy to brake resistors whenever needed.
1
3
4
6
5
88
7
9
10
12
1113
7
2
A
B C C D
7 7
Incoming unitA
Supply unitB
Inverter unitC
Brake unit (optional)D
AC supply1
Main breaker, or main contactor and main switch-disconnector2
Input (AC) fuses3
Supply module4
DC bus5
Supply and inverter module DC fuses6
DC switch/disconnector (optional)7
Inverter modules8
Brake chopper fuses9
3-phase brake chopper module (optional)10
Brake resistors (optional or acquired by user)11
Fuses for the brake resistors12
Motor(s) (acquired by user)13
16 Operation principle and hardware description

Overview drawing of the drive system
This drawing shows an example of a drive system.
A B C D E
Auxiliary control cubicle. Contains control electronics and customer I/O connections.A
Incoming cubicle. Contains the power input cable terminals and switchgear.B
Diode supply unit cubicle. Contains diode supply modules.C
Inverter unit cubicle. Contains inverter modules.D
3-phase dynamic brake unit cubicle. Contains brake chopper modules.E
Operation principle and hardware description 17

Layout drawings – brake module cubicle
The drawing below shows the components of the brake chopper cubicle with bottom
entry and exit of cables (shrouds removed).
A B C
1
2
3
4
6
7
9
11
14
16
17
20
5
8
10
12
13
18
19
21
22
15
CIO-01 I/O module for fan monitoring (A115)11Door closedA
BCU control unit (A41)12Door openB
Coolant inlet manifold with stop and drain
valves
13Door open, swing-out frame removedC
Coolant outlet manifold with stop and drain
valves
14DC switch/disconnector handle (part of op-
tion +F286, Q11)
1
PE busbar15Charging circuit switch fuse handle (part of
option +F286, Q10)
2
Cable entries16Control panel (A49)3
Brake resistor fuses (F11.xx)17Indicator light (P11)4
Brake chopper module (T11)18DC fuses (F11.xx)5
Heat exchanger (between the module and the
cooling fan)
19DC switch/disconnector (behind the fuses,
part of option +F286, Q11)
6
18 Operation principle and hardware description

Incoming resistor connection busbars (R1.2,
R2.2 R3.2)
20Charging controller (part of option +F286,
A11)
7
Outgoing resistor connection busbars (be-
hind cooling fan, R1.1, R2.1 R3.1)
21Charging mechanics (part of option +F286)8
Cooling fan (G115)22Charging resistors (obscure, R10.x)9
Swing-out frame10
The drawing below shows the components of the brake chopper cubicles with top
entry and exit of cables (shrouds removed).
A B
1
2
3
4
5
20
19
21
22
23
18
17
7
8
6
9
10
11
12
13
14
15
16
17
18
19
Swing-out frame12Doors closedA
CIO-01 I/O module for fan monitoring (A115)13Doors openB
BCU control unit (A41)14DC switch/disconnector handle (part of op-
tion +F286, Q11)
1
Heat exchanger (between the module and the
cooling fan)
15Charging circuit switch fuse handle (part of
option +F286, Q10)
2
Operation principle and hardware description 19

Cooling fan (G115)16Control panel (A49)3
Coolant inlet manifold with stop and drain
valves
17Indicator light (P11)4
Coolant outlet manifold with stop and drain
valves
18Cable entries5
PE busbar19DC fuses (F11.xx)6
Outgoing resistor connection busbars (R1.1,
R2.1 R3.1)
20DC switch/disconnector (behind the fuses,
part of option +F286, Q11)
7
Incoming resistor connection busbars (R1.2,
R2.2 R3.2)
21Charging controller (part of option +F286, ,
A11)
8
Brake resistor fuses (F11.xx)22Charging mechanics (part of option +F286)9
Cooling fan (G115)23Charging resistors (obscure, R10.x)10
Brake chopper module (behind the swing-out
frame, T11)
11
20 Operation principle and hardware description