ABB ACS880-607LC User manual

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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

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