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ABB ACS880-604LC, Hardware Manual

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Table of contents

1

Introduction to the manual

9

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

9

Safety instructions ................................................................................

9

Target audience ...................................................................................

10

Related manuals ..................................................................................

11

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

2

Operation principle and hardware description

13

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

13

Product overview ..................................................................................

13

Operation principle ................................................................................

15

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

16

Layout ..............................................................................................

18

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

19

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

3

Planning the installation

21

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

21

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

21

Generic guidelines ................................................................................

22

Equipping the drive with a main contactor and manual control switch or switches .....

24

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

24

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

25

Example 1 ...................................................................................

25

Example 2 ...................................................................................

26

Example 3 ...................................................................................

26

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

26

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

26

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

27

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

27

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

27

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

27

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

27

Operation principle ............................................................................

28

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

28

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

4

Mechanical installation

29

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

29

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

29

Required tools .....................................................................................

30

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

31

Examples: Installing the brake chopper module and related components ...............

31

Example: Installation into a Rittal TS 8 or VX25 enclosure .............................

31

Layout drawing .............................................................................

Table of contents 5

Summary of Contents for ACS880-604LC

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 604LC 1 phase brake units as modules Hardware manual ...

Page 2: ......

Page 3: ...04LC 1 phase brake units as modules Hardware manual Table of contents 4 Mechanical installation 5 Electrical installation 7 Start up 2018 ABB Oy All Rights Reserved 3AXD50000184378 Rev A EN EFFECTIVE 2018 12 31 ...

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Page 5: ...s 24 Calculating the maximum braking power 25 Example 1 25 Example 2 26 Example 3 26 Selecting and routing the brake resistor cables 26 Minimizing electromagnetic interference 26 Maximum cable length 27 EMC compliance of the complete installation 27 Placing the brake resistors 27 Selecting the chopper enable input cable 27 Protecting the system against thermal overload 27 Operation principle 28 Pr...

Page 6: ...ral notes 43 Printed circuit boards 43 Optical components 44 Selecting the voltage 45 Synchronizing multiple brake choppers 46 Connecting the DC and resistor cables 46 Connection diagram 47 Connection procedure 48 Connecting the thermal switch 6 Installation checklist 49 Contents of this chapter 50 Checklist 7 Start up 51 Contents of this chapter 51 Start up procedure 8 Fault tracing 53 Contents o...

Page 7: ...eding the internal cooling circuit 68 Drive line ups with an ACS880 1007LC cooling unit 68 Drive line ups with a custom cooling unit 70 Draining the internal cooling circuit 70 Maintenance intervals 70 Technical data 70 Coolant specification 70 Coolant type 70 Temperature limits 71 Pressure limits 72 Cooling circuit materials 12 Technical data 73 Contents of this chapter 73 Ratings 73 Chopper only...

Page 8: ...pper module Sheet 001a 91 Brake unit with one chopper module Sheet 005a 92 Brake unit with one chopper module Sheet 026a 93 Brake unit with one chopper module Sheet 027a 94 Brake unit with four chopper modules Sheet 001a 95 Brake unit with four chopper modules Sheet 001b 96 Brake unit with four chopper modules Sheet 005a 97 Brake unit with four chopper modules Sheet 005b 98 Brake unit with four ch...

Page 9: ...software function specific warnings and notes before changing the default settings of a function For each function the warnings and notes are given in the section describing the related user adjustable parameters Read the task specific safety instructions before starting the task See the section describing the task Target audience The manual is intended for people who plan the installation of or s...

Page 10: ...3AUA0000098062 ACS880 primary control program quick start up guide Brake module manuals 3AXD50000184378 ACS880 604LC 1 phase brake chopper modules hardware manual Option manuals 3AUA0000085685 ACX AP x assistant control panels user s manual 3AUA0000094606 Drive composer start up and maintenance PC tool user s manual 3AXD50000129607 ACS880 1007LC liquid cooling unit user s manual 3AUA0000127808 Dri...

Page 11: ... rectifier and inverter DC link Frequency converter for controlling AC motors Drive Electromagnetic compatibility EMC Insulated gate bipolar transistor IGBT DC circuit between rectifier and inverter Intermediate circuit Converts direct current and voltage to alternating current and voltage Inverter Drive for controlling several motors which are typically coupled to the same machinery Includes one ...

Page 12: ...12 ...

Page 13: ...orced through an air to liquid heat exchanger The two resistors are installed in a separate air cooled cubicle and share another cooling fan An optional attenuator mounted in the chopper module cubicle suppresses voltage spikes at chopper input The attenuator must be installed if it is possible to disconnect all inverter units from the DC link with the supply unit on Chopper resistor combinations ...

Page 14: ... drive system is equipped with a brake chopper or brake choppers if high capacity braking is needed and the drive cannot be equipped with a regenerative supply unit a backup for the regenerative supply unit is needed Standard resistors are available from ABB for each brake chopper module 14 Operation principle and hardware description ...

Page 15: ...Inverter units In this example one of the units ocnsists of two inverter modules connected in parallel 6 Brake chopper DC fuses 7 Attenuator Suppresses voltage spikes at chopper input Must be installed if it is possible to disconnect all inverter units from the DC link with the supply unit on otherwise optional 8 Brake chopper 9 Brake resistors 10 Motors 11 Operation principle and hardware descrip...

Page 16: ...r 3 Chopper control board NBRC with control terminals See section Overview of power and control connections page 18 4 Voltage selection jumper see Selecting the voltage page 44 5 PE protective earth clamp 6 Grounding clamp 7 Clamp for drive cable 8 Clamp for resistor cable 9 Enable input terminal block see section Overview of power and control connections page 18 X1 16 Operation principle and hard...

Page 17: ...connection terminals UDC UDC R R Coolant connections behind main mounting plate side view A length of 1 5 m 4 9 ft of 6 4 mm pipe is attached to each connector Operation principle and hardware description 17 ...

Page 18: ...section Protecting the system against thermal overload page 27 Chopper enable input X1 Fault indication relay output X3 See section Controlling the brake chopper from an external control location page 28 Fiber optic cable connection Chopper control sig nal to another chopper Transmitter V22 Fiber optic cable connection Chopper control sig nal from another chopper Receiver V23 18 Operation principl...

Page 19: ...ABB Oy Hiomotie 13 00380 Helsinki Finland 1 2 3 4 5 Description No Type designation 1 Brake chopper module order code 2 Serial number 3 The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing year and week respectively The remaining digits complete the serial number so that there are no two units or modules with the same number ...

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Page 21: ...lity 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 Generic guidelines See Electrical planning instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048634 English for the generic guidelines for planning...

Page 22: ...cates chopper faults for example in a thermal overload situation see section Protecting the system against thermal overload page 27 The changeover switch opens when a failure is detected or the chopper is unpowered WARNING In a chopper failure always switch off the power supply to the drive This is the only way to guarantee safe operation in case of a chopper failure since the chopper is unable to...

Page 23: ...L3 1 2 3 4 5 6 1 2 13 14 1 2 3 4 0 1 K S1 3 NBRC K1 S1 1 2 3 4 K X X 1 X 0 0 1 K 13 14 1 2 1 2 3 NBRC K1 Example 2 X3 X3 OFF L1 L2 L3 1 2 3 4 5 6 L1 L2 L3 1 2 3 4 5 6 3 4 ON Example 1 Planning the installation 23 ...

Page 24: ... resistor assembly must be equipped with a thermal switch all SAFUR resistors include a thermal switch Make sure that the switch is properly isolated over 2 5 kV and shrouded against contact A custom resistor can be selected within the limits imposed by the brake chopper That is the resistance value of the custom resistor is at least equal to the resistance value of the resistor given in the ratin...

Page 25: ...cle kW Pbrmax 2 The braking power must not exceed the rated maximum value Pbrmax Pbr Pbrmax d Example 1 The duration of braking cycle is 30 minutes The braking time is 15 minutes Result If the braking time exceeds ten minutes the braking is considered continuous The allowed continuous braking power is 10 percent of the maximum braking power Pbrmax Example 2 The duration of a braking cycle is three...

Page 26: ...ges in the resistor cables Shield the braking power line completely either by using shielded cable or a metallic enclosure Unshielded single core cable can only be used if it is routed inside a cabinet that efficiently suppresses radiated emissions Install the cables away from other cable routes Avoid long parallel runs with other cables The minimum parallel cabling separation distance should be 0...

Page 27: ...resistor thermal switch to chopper enable input X1 meets the following requirements shielded cable rated operating voltage between a core and ground 750 U0 insulation test voltage 2 5 kV Protecting the system against thermal overload The drive control program includes a resistor and resistor cable thermal protection function which can be tuned by the user The brake chopper protects itself and the ...

Page 28: ...cuit situation 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 For instructions see section Synchronizing multiple brake choppers page 45 28 Planning the installation ...

Page 29: ...inet design and construction instructions for ACS880 multidrive modules 3AUA0000107668 English In addition observe these restrictions The brake unit can be grounded to the frame through the mounting screws if the galvanic connection to PE protective earth is good enough To prevent the module from overheating do not install it directly above the brake resistors The maximum lengths of the chopper an...

Page 30: ...page 83 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 3 Put screws into the holes Tighten the screws far enough to make sure that they can carry the weight of the module 4 Lift the module onto the mounting screws 5 Tighten the screws 30 Mechanical installation ...

Page 31: ...TS 8 or VX25 enclosure Layout drawing C B a d e c A b a c d e Description Brake chopper cubicle side view A Brake chopper cubicle front view B Brake chopper cubicle front side view C DC fuses a DC busbars b Cooling fan and heat exchanger c Attenuator d Brake chopper module e Mechanical installation 31 10 ...

Page 32: ...50000333387 A 468 X 001 VX 3AUA0000115891 DC bus VX25 3AXD50000137251 Mounting plate 2 3AXD50000050763 3AXD50000137435 Cooling fan 230 V AC 3 3AXD50000050767 3AXD50000137435 Cooling fan 115 V AC 3AXD50000137190 L 468 X 404 3AXD50000137435 Fan kit with heat exchanger See chapter Ordering in formation page 59 3AXD50000137251 Coolant piping and fittings See chapter Ordering in formation page 59 3AXD5...

Page 33: ...Overview of kits Mechanical installation 33 10 ...

Page 34: ...Stage 1 Installation of common parts 34 Mechanical installation ...

Page 35: ...Stage 2 Installation of mounting plate Mechanical installation 35 10 ...

Page 36: ...Stage 3 Installation of cooling components 36 Mechanical installation ...

Page 37: ...Stage 4 Installation of brake module and attenuator Mechanical installation 37 10 ...

Page 38: ...ake resistor cubicle side view C Air flow in Use a door with an inlet a Air flow into components b Air flow out Use a ventilated roof c Brake resistors d Cooling fan mounting plate e Cooling fan f Plastic bars on both sides to block airflow g Not available from ABB For an illustration see 3AXD50000008316 Not available from ABB For an illustration see 3AXD50000008190 and 3AXD50000008209 38 Mechanic...

Page 39: ...he enclosure using four M6 screws per rail 2 Attach each brake resistor c to the rails using four M6 screws 3 Install the cooling fan f using a separate mounting plate e B A a b c d e f Description Brake resistor cubicle front view A Brake resistor cubicle side view B Mounting rails a Thermal circuit breakers b Brake resistors c Power connection terminals d Cooling fan mounting plate e Cooling fan...

Page 40: ...40 ...

Page 41: ...ly qualified electricians are allowed to do the work described in this chapter Read the complete safety instructions before you install commission use or service the drive The complete safety instructions are given in Safety instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048633 English Note The installation must always be designed and made according to applicable lo...

Page 42: ...ent open the motor protective circuit breaker s of the cooling pumps If you have a permanent magnet motor connected to the drive disconnect the motor from the drive with a safety switch or by other means Make sure that re connection is not possible Disconnect any external power sources from the control circuits After you disconnect the drive always wait 5 minutes to let the intermediate circuit ca...

Page 43: ...rs of the resistor cable together Measure the insulation resistance between the combined conductors and the PE conductor by using a measuring voltage of 1 kV DC The insulation resistance must be higher than 1 Mohm ohm R R General notes Printed circuit boards WARNING Use a grounding wrist band when you handle printed circuit boards Do not touch the boards unnecessarily The boards contain components...

Page 44: ...propriate voltage as shown below FIBER 230 V 400 V 500 V Drive supply voltage 380 415 V FIBER 230 V 400 V 500 V Drive supply voltage 440 500 V FIBER 230 V 400 V 500 V Drive supply voltage 525 690 V Note In follower choppers you must set the voltage to FIBER as shown in section Synchronizing multiple brake choppers below WARNING An incorrect jumper setting or missing jumper may cause brake chopper ...

Page 45: ... the chain acts as the master for the other choppers To synchronize the choppers 1 Set the voltage selection jumper of the master to the appropriate voltage 2 Set the voltage selection jumpers of the followers to FIBER V22 V22 V23 V23 Voltage V23 V22 FIBER 2 1 2 FIBER Electrical installation 45 11 ...

Page 46: ...hopper module and resistor in the same cubicle Brake chopper module and resistors in separate cubicles UDC UDC R R R R DC link NBRW 669 Resistor assembly UDC UDC R R R R DC link NBRW 669 Resistor assembly The chopper and resistor housings can be grounded to the frame through the mounting screws if the galvanic connection to PE protective earth is good enough 46 Electrical installation ...

Page 47: ...e UDC and UDC terminals of the brake chopper as shown below 4 Connect the conductors to the R and R terminals of the brake chopper as shown below 35 N m 6 N m UDC UDC R R 3 3 4 4 2 2 2 2 26 lbf ft 4 4 lbf ft 5 Connect the brake resistors in parallel as shown below See the Connection diagram page 46 for the cable shield grounding Note The cable between the chopper and the first resistor must be abl...

Page 48: ...istor Resistor Connecting the thermal switch Connect the thermal switches of the resistors in series to chopper enable input X1 as shown in section Overview of power and control connections page 18 48 Electrical installation ...

Page 49: ...Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the brake chopper 6 Installation checklist 49 ...

Page 50: ...s must be unpainted The supply voltage matches the nominal input voltage of the brake chopper module Check the type designation label The setting of the voltage selection jumper is correct See section Selecting the voltage page 44 The DC cable has been connected to the appropriate terminals and the terminals have been tightened Pull on the conductors to check Appropriate DC fuses have been install...

Page 51: ...New brake resistors may be coated with storage grease As the brake chopper operates for the first time the grease burns off and may produce some smoke Make sure there is proper ventilation Start up procedure Additional information Action Preliminary actions WARNING Make sure that the disconnector of the supply transformer is locked to open position ie no voltage is or can be connected to the drive...

Page 52: ...the supply transformer Switch on power to the drive and start the supply unit Operational checks Make sure that it is safe to start the drive Start the drive and increase the rotation speed of the high inertia motor that will generate power to the drive intermediate circuit when it is decel erated Use a low speed at first For the inverter parameter settings see the appropriate firmware manual Deac...

Page 53: ... switch of the fault indication relay output is released The relay output indicates the following faults brake resistor or resistor cable short circuit brake chopper IGBT short circuit chopper control board failure chopper enable input signal switched off Note The chopper is not able to switch off a short circuit current If the fault indication relay output X3 is wired to the main contactor circui...

Page 54: ...circuit Check voltage setting Chopper voltage setting too high Inverter overvoltage control is on Chopper does not function Check parameters of all inverters Check that enable input is on Check voltage setting Chopper voltage setting too low Chopper starts to function at too low a DC voltage Check voltage setting Chopper voltage setting too high Inverter trips on fault 3210 DC link overvoltage Che...

Page 55: ... cabinet construction examples presented in this manual WARNING Only qualified electricians are allowed to do the work described in this chapter Read the complete safety instructions before you install commission use or service the converter The complete safety instructions are given in Safety instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048633 English 9 Maintenan...

Page 56: ...Tightening if needed I I I I I I I I I I I I I Checking ambient conditions dustiness corro sion temperature I I I I I I I I I I I I I Checking coolant pipe connections Symbols Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other work P Replacement R Maintenance and component replacement intervals are based on the ...

Page 57: ...ARNING Use a vacuum cleaner with an antistatic hose and nozzle and wear a grounding wristband Otherwise an electrostatic charge might build up and damage the circuit boards 1 Stop the drive and do the steps in section Electrical safety precautions page 42 before you start the work 2 Open the cabinet door 3 Clean the interior of the cabinet Use a vacuum cleaner and a soft brush 4 Clean the air inle...

Page 58: ...58 ...

Page 59: ...Ordering information Contents of this chapter This chapter lists the components and accessories available for the brake unit 10 Ordering information 59 ...

Page 60: ... an air to liquid heat exchanger Data Ordering code Qty Fan supply R3G225 RE07 20 3AXD50000050763 1 per chopper module 230 V 50 60 Hz R3G225 RE19 22 3AXD50000050767 1 per chopper module 115 V 50 60 Hz Fan kit with heat exchanger This kit includes the heat exchanger and the parts of the fan heat exchanger housing Illustration Kit code Ordering code Qty Instruction code 3AXD50000137190 L 468 X 404 3...

Page 61: ...nectors Each end is converted to 3 8 threading using a connector and a reducing nipple The remaining stretch of piping from the heat exchanger to the hot main line is 8 6 mm Note Any stop and bleed valves fitted in the cubicle must be sourced separately Illustration Data Ordering code Qty Connector for 8 6 mm pipe thread 3 8 68617359 2 Connector for 6 4 mm pipe thread 1 4 57323710 2 Reducing nippl...

Page 62: ...it for all frame sizes 3AXD50000044095 L 6 8 205 Kit A 468 Kit L 6 8 20 Kit L 6 8 A 468 X 001 3AUA0000115906 1 kit per cu bicle 400 600 800mm TS 8 enclosure Instruction code 3AUA0000115891 DC bus installation parts for Rittal VX25 enclosures The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat PLS DC bus and ensure its correct placement and alignment inside th...

Page 63: ... Type Ordering code Qty ACS880 604LC UN 690 V Range 525 690 V 200 kW R 2 7 ohm SAFUR200F500 68759340 2 0400 7 4 0800 7 6 1200 7 8 1600 7 10 2000 7 12 2400 7 Brake resistor cooling fans The two resistors connected to one brake chopper module share a single cooling fan Data Ordering code Qty Fan supply D3G200 BF07 H2 3AXD50000100170 1 per chopper module 1 per 2 resistors 230 V 50 60 Hz D3G200 BB36 8...

Page 64: ...64 ...

Page 65: ...is applicable to cabinet built ACS880 liquid cooled drives Except where otherwise indicated the information is also applicable to drives built out of ACS880 liquid cooled multidrive modules Internal cooling system Note This section describes cabinet built liquid cooled ACS880 drives The information in this section can be used as guidelines for building a drive system out of ACS880 liquid cooled mo...

Page 66: ...m cooling unit 3 Air to liquid heat exchanger A L Heat sink HS Inlet valve a Inlet side drain valve b Outlet valve c Outlet side drain valve d The coolant used with ACS880 liquid cooled drive systems is Antifrogen L 25 or 50 water mixture See Coolant specification page 70 66 Internal cooling circuit ...

Page 67: ...the limits specified in Technical data page 70 Install a pressure regulator to make sure that the maximum permissible operating pressure is not exceeded Install a bleed valve at the highest point of the cooling circuit and a drain valve at the lowest point The materials that can be used are listed in Cooling circuit materials page 72 Coolant temperature control The temperature of the coolant in th...

Page 68: ...tion for the valve is usually near or at the cooling unit Observe the instructions given by the manufacturer of the cooling unit Pay special attention to filling up and bleeding the pumps properly as they may be damaged if operated when dry Draining coolant into the sewer system is not allowed 1 Open the bleed valve at the cooling unit 2 Open the inlet valve and the outlet side drain valve of one ...

Page 69: ... stop the pump or block the coolant flow with a valve 15 Re check the pressure and add coolant if necessary 16 Repeat steps 13 to 15 a few times until all air is let out of the cooling circuit Listen for a humming sound and or feel the piping for vibration to find out if there is still air left in the circuit Internal cooling circuit 69 ...

Page 70: ...it with coolant specified under Coolant specification page 70 drain the cooling circuit again Maintenance intervals As a general rule the quality of the coolant should be checked at intervals of two years This can be done by distributors of Antifrogen L see www clariant com if a 250 milliliter sample is provided Technical data Coolant specification Coolant type Antifrogen L by Clariant Internation...

Page 71: ...4 24 1 25 15 0 18 4 22 7 26 2 29 1 30 19 4 23 0 27 4 31 1 34 1 35 23 8 27 6 32 2 35 9 39 0 40 28 2 32 1 36 8 40 8 44 0 45 32 8 36 7 41 6 45 6 49 0 50 37 1 42 2 46 3 50 4 53 9 55 Not allowed as standard but the coolant temperature must be 0 C 32 F or above At an air temperature of 45 C and relative humidity of 65 the coolant temperature may not be below 36 8 C Example Maximum temperature rise Depen...

Page 72: ...ING If connecting external piping to the internal cooling circuit use only materials that are specified above Copper brass or bronze must not be used under any circumstances Even minor dissolution of copper can cause copper precipitation on aluminum and subsequent galvanic corrosion The liquid cooling system must not contain any zinc eg galvanized pipes If the plant incorporates normal iron pipes ...

Page 73: ...ble Ratings Chopper only Duty cycle 10 60 s Duty cycle 1 5 min Pcont Irms Imax Rn Pbrmax Module type ACS880 604LC Irms Pbr Irms Pbr A kW A kW kW A A ohm kW 361 404 267 298 119 107 414 2 72 404 NBRW 669C 0400 7 722 808 534 596 238 214 828 2 72 807 2 NBRW 669C 0800 7 1083 1212 801 894 357 321 1242 2 72 1211 3 NBRW 669C 1200 7 1444 1616 1068 1192 476 428 1656 2 72 1615 4 NBRW 669C 1600 7 1805 2020 13...

Page 74: ...NBRW 669C 0400 7 21600 514 575 298 333 108 194 1670 1 35 807 2 2 SAFUR200F500 2 NBRW 669C 0800 7 32400 771 862 447 500 162 291 2505 1 35 1211 3 2 SAFUR200F500 3 NBRW 669C 1200 7 43200 1028 1150 596 667 216 388 3340 1 35 1615 4 2 SAFUR200F500 4 NBRW 669C 1600 7 54000 1285 1437 745 833 270 485 4175 1 35 2019 5 2 SAFUR200F500 5 NBRW 669C 2000 7 64800 1542 1724 894 1000 324 582 5010 1 35 2422 6 2 SAFU...

Page 75: ... minimum allowed resistance for the resistor assembly R Total brake resistor resistance of the whole brake unit Rtot NBRW 669 SAFUR200F500 SAFUR200F500 Imax Irms Rtot NBRW 669 SAFUR200F500 SAFUR200F500 Pbrmax Pbr R R Pcont Duty cycle 10 s 60 s Total rms current during a period of 10 seconds with braking power Pbr Irms Maximum braking power allowed for 10 seconds every 60 seconds 10 s 50 s Pbr 0 Pb...

Page 76: ...le NBRW 669C 71 32 13 58 345 11 81 300 51 97 1320 Brake resistor SAFUR200F500 3 9 1 8 3 90 99 8 86 225 8 86 225 Brake chopper cubicle cooling fan R3G225 RE07 20 R3G225 RE19 22 22 9 10 4 15 63 397 13 43 341 12 87 327 Brake resistor cooling fan D3G200 BF07 H2 D3G200 BB36 82 See also chapter Dimension drawings page 83 150 mm 5 91 in free space is required below and above the brake chopper module 76 T...

Page 77: ... 120 17 4 4 0 42 4 1 6 4 0 11 4 0 4 0 8 7 2 4 NBRW 669C 1600 7 TBA 120 17 4 5 0 42 5 1 6 5 0 11 5 0 4 1 0 9 0 5 NBRW 669C 2000 7 TBA 120 17 4 6 0 42 6 1 6 6 0 11 6 0 4 1 2 10 8 6 NBRW 669C 2400 7 Brake resistors Noise Air flow Resistor type Module type ACS880 604LC dB A ft3 min m3 h UN 690 V Range 525 690 V TBA 1080 1840 2 SAFUR200F500 NBRA 669C 0400 7 TBA 2550 4340 2 2 SAFUR200F500 2 NBRA 669C 08...

Page 78: ...h the EMC Directive unshielded single core cable can only be used if it is routed inside a cabinet that efficiently suppresses radiated emissions Brake resistor terminal data R R and grounding terminals Resistor type Tightening torque Screw Hole diameter mm lbf ft N m 5 2 7 M6 7 SAFUR200F500 Degree of protection The degree of protection of the brake chopper module and the SAFUR resistors is IP00 U...

Page 79: ...ed for stationary use 0 2000 m 0 6561 7 ft no derat ing Altitude above sea level For altitudes over 2000 m 6561 7 ft contact ABB 40 70 C 40 70 C 0 55 C 32 131 F no con densation allowed Air temperature 40 158 F 40 158 F Maximum 95 no con densation allowed Maximum 95 no con densation allowed Maximum 95 no con densation allowed Relative humidity No condensation allowed Maximum allowed relative humid...

Page 80: ...27 Tests Test Ea and guidance Shock Auxiliary circuit current consumption Istart IN f UN Cooling fan type A A Hz V AC 4 5 2 25 50 60 230 D3G200 BF07 H2 8 2 4 1 50 60 115 D3G200 BB36 82 2 8 1 4 50 60 230 R3G225 RE07 20 4 8 2 4 50 60 115 R3G225 RE19 22 Definitions Nominal voltage UN Frequency f Nominal current consumption IN Starting current consumption Istart CE marking A CE mark is attached to the...

Page 81: ... liquid cooled multidrive cabinets and modules 3AXD50000048634 English Cabinet design and construction instructions for ACS880 multidrive modules 3AUA0000107668 English Technical guide 3 EMC Compliant Installation and Configuration for a Power Drive System 3AFE61348280 English More information on standards and markings See Electrical planning instructions for ACS880 liquid cooled multidrive cabine...

Page 82: ...82 ...

Page 83: ...ter 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 13 Dimension drawings 83 ...

Page 84: ...Brake chopper module NBRW 669 84 Dimension drawings ...

Page 85: ...Attenuator Dimension drawings 85 ...

Page 86: ...Brake resistor 234 300 1320 Ø 7 345 R R 1270 86 Dimension drawings ...

Page 87: ...Brake resistor cooling fan D3G200 BF07 H2 D3G200 BB36 82 Brake resistor cooling fan D4E225 CC01 39 300 Ø 7 345 R R 105 105 Dimension drawings 87 ...

Page 88: ...88 ...

Page 89: ...o help in understanding the internal connections and operation of a brake unit and learning how to wire a brake unit In an installation with parallel connected brake chopper modules one chopper acts as the master for the others The switching of the follower chopper s is controlled by the master via a fiber optic link 14 Circuit diagram examples 89 ...

Page 90: ...Y 6 3 RF 1R 3 1 RF 1R 5HI 1R 5HVS HSW WHP HV 6KHHW 7LWOH 3UHS SS 3URMHFW XVW RF 1R XVW 5HI 1R XVWRPHU 0LND VLNDLQHQ 6 2OHJ 9DQLQ LUFXLW GLDJUDP 6 5 5 5 5 5 5 UDNH 5HVLVWRUV LQN 7 D 9 7 51 1 5 5 5 8 8 3 5 77 18 725 66 0 15 3 D 7 D 7 0 90 Circuit diagram examples ...

Page 91: ...R 3 1 RF 1R 5HI 1R 5HVS HSW WHP HV 6KHHW 7LWOH 3UHS SS 3URMHFW XVW RF 1R XVW 5HI 1R XVWRPHU 0LND VLNDLQHQ 6 2OHJ 9DQLQ LUFXLW GLDJUDP 6 9 9 9 LEHU DXOW 2 9ROWDJH UHGXFHU 6XSSO 8QLW LJLWDO 2 9 VXSSO 7 D 75 9 6ODYH FRQWURO 5 9 7 FRQWURO D 5 2 D 5 Circuit diagram examples 91 ...

Page 92: ... 6 9 D RQW D 5HY 6 3 RF 1R 3 1 RF 1R 5HI 1R 5HVS HSW WHP HV 6KHHW 7LWOH 3UHS SS 3URMHFW XVW RF 1R XVW 5HI 1R XVWRPHU 0LND VLNDLQHQ 6 2OHJ 9DQLQ LUFXLW GLDJUDP 6 0 a 7DFKR 1 3 0 5 9 21 1 21 3 1 21 9 VXSSO 68 52 3 4 1 D D 92 Circuit diagram examples ...

Page 93: ...a 6 9 D RQW 5HY 6 3 RF 1R 3 1 RF 1R 5HI 1R 5HVS HSW WHP HV 6KHHW 7LWOH 3UHS SS 3URMHFW XVW RF 1R XVW 5HI 1R XVWRPHU 0LND VLNDLQHQ 6 2OHJ 9DQLQ LUFXLW GLDJUDP 6 0 a 5 7DFKR 1 3 0 5 9 1 3 1 3 1 1 20 5 56 56 68 52 3 4 D D Circuit diagram examples 93 ...

Page 94: ...Tuomi Circuit diagram EFS2 RD75439 2373 R121 21 R R 4 3 R121 22 R R 4 3 R121 11 R R 4 3 R121 12 R R 4 3 DC Link T121 1 005a 1B 690V EXTERNAL NBRW 669C R R UDC UDC PE 60 1 1 2 F121 11 1 2 F121 12 R121 1 ATTENUATOR ASSEMBLY NRCB 010006 1 2 F121 21 1 2 F121 22 60 2 R121 2 ATTENUATOR ASSEMBLY NRCB 010006 T121 2 005a 4B 690V EXTERNAL NBRW 669C UDC UDC PE R R 60 7 60 6 DCP 2 DCM 2 005a 4C T121 2 X1 1 00...

Page 95: ...04LC Joni Tuomi Circuit diagram EFS2 RD75439 2373 R121 41 R R 4 3 R121 42 R R 4 3 R121 31 R R 4 3 R121 32 R R 4 3 T121 3 005b 1B 690V EXTERNAL NBRW 669C UDC UDC PE R R 60 3 1 2 F121 31 1 2 F121 32 R121 3 ATTENUATOR ASSEMBLY NRCB 010006 60 9 1 2 F121 41 1 2 F121 42 60 4 R121 4 ATTENUATOR ASSEMBLY NRCB 010006 T121 4 005b 4B 690V EXTERNAL NBRW 669C UDC UDC PE R R 60 8 001a 6A F121 21 1 001a 6A F121 2...

Page 96: ...2 500V 230V 400V Fiber X4 1 1 1 1 2 2 Fault K1 OFF X6 1 2 Voltage reducer Supply Unit Digital I O 230VAC supply T121 1 001a 2B A1 A2 K121 1 14 13 3F TR V22 Slave control RE V23 EXT control 1 X1 2 4 X121 1 1 1 2 F121 1 214 X25 1 204 60 1 13 14 3C K121 1 T121 2 001a 5B TR V22 Slave control RE V23 EXT control 1 X1 2 A1 A2 K121 2 14 13 6F 4 X121 2 1 1 2 F121 2 204 214 X25 2 60 2 13 14 6C K121 2 X25 20...

Page 97: ...2 2 Fault K1 OFF X6 1 2 Voltage reducer 2 2 500V 230V 400V Fiber X4 1 1 1 1 2 2 Fault K1 OFF X6 1 2 Voltage reducer T121 3 001b 2B A1 A2 K121 3 14 13 3F TR V22 Slave control RE V23 EXT control 1 X1 2 4 X121 3 1 1 2 F121 3 214 X25 3 204 60 3 13 14 3C K121 3 T121 4 001b 5B TR V22 Slave control RE V23 EXT control 1 X1 2 A1 A2 K121 4 14 13 6F 4 X121 4 1 1 2 F121 4 204 214 X25 4 60 4 13 14 6C K121 4 00...

Page 98: ...stomer Mika Asikainen 15 1 2018 1 2 3 4 5 6 7 8 A B C D E F 04 05 2017 ACS880 604LC Joni Tuomi Circuit diagram EFS2 RD75439 2373 M 1 WH Tacho 4 BL GND 1 YE PWM 2 RD 10V 3 L BK CON10 N BL CON11 PE GNYE CON12 G115 11 230VAC supply DSU RO3 60 1 1 X115 11 1 2 PE 13 12 14 11 X115 11 FE 1 2 3 4 F115 10 6A 22 21 24 Q26 1 2F115 L 2F115 N 027a 1A X115 71 1 027a 1A X115 71 2 026b 1A F115 20 1 026b 1A F115 2...

Page 99: ...NYE CON12 G115 31 M 1 WH Tacho 4 BL GND 1 YE PWM 2 RD 10V 3 L BK CON10 N BL CON11 PE GNYE CON12 G115 21 M 1 WH Tacho 4 BL GND 1 YE PWM 2 RD 10V 3 L BK CON10 N BL CON11 PE GNYE CON12 G115 41 DSU RO3 DSU RO3 DSU RO3 60 2 1 2 3 4 F115 30 6A 1 13 12 14 11 X115 31 1 2 PE X115 31 FE 60 3 1 2 3 4 F115 20 6A 1 13 12 14 11 X115 21 1 2 PE X115 21 FE 60 2 1 2 3 4 F115 40 6A 1 13 12 14 11 X115 41 1 2 PE X115 ...

Page 100: ... No Cust Ref No Customer Mika Asikainen 15 1 2018 1 2 3 4 5 6 7 8 A B C D E F 04 05 2017 ACS880 604LC Joni Tuomi Circuit diagram EFS2 RD75439 2373 DSU RO3 M 1 GR Tacho 9 BL GND 12 YE PWM 8 RD 10V 13 L BK 5 N BL 3 PE GNYE 1 G115 71 14 11 A1 A2 PE GNYE 2 NC WH 6 COM WH 7 BR RSB 10 WH RSA 11 X115 71 1 2 13 12 14 11 X115 71 FE 60 6 22 21 24 Q26 2 1 PE 026a 3B F115 10 2 026a 3B F115 10 4 100 Circuit di...

Page 101: ... 14 11 A1 A2 PE GNYE 2 NC WH 6 COM WH 7 BR RSB 10 WH RSA 11 M 1 GR Tacho 9 BL GND 12 YE PWM 8 RD 10V 13 L BK 5 N BL 3 PE GNYE 1 G115 91 14 11 A1 A2 PE GNYE 2 NC WH 6 COM WH 7 BR RSB 10 WH RSA 11 M 1 GR Tacho 9 BL GND 12 YE PWM 8 RD 10V 13 L BK 5 N BL 3 PE GNYE 1 G115 1011 14 11 A1 A2 PE GNYE 2 NC WH 6 COM WH 7 BR RSB 10 WH RSA 11 60 7 13 12 14 11 X115 91 1 2 X115 91 FE 60 8 13 12 14 11 X115 81 1 2...

Page 102: ......

Page 103: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

Page 104: ...www abb com drives 3AXD50000184378A Copyright 2018 ABB All rights reserved Specifications subject to change without notice 3AXD50000184378 Rev A EN EFFECTIVE 2018 12 31 ...

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