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ABB industrial drives Hardware manual ACS880-604 1-phase brake chopper units as modules...
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3AUA0000104271 ACS880 primary control program firmware manual 3AUA0000085967 ACS880 primary control program quick start-up guide 3AUA0000098062 Brake module manuals ACS880-604 1-phase brake chopper units as modules 3AUA0000106244 hardware manual Option manuals and guides ACS-AP-x Assistant control panels user's manual 3AUA0000085685 Drive composer start-up and maintenance PC tool user’s...
Introduction to the manual 9 Introduction to the manual Contents of this chapter This chapter introduces this manual. Safety instructions Obey all safety instructions delivered with the drive. Read the complete safety instructions before you install, start up, or use the drive. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).
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...
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Introduction to the manual 11 Term/Abbreviation Explanation Brake unit Brake chopper and resistors Cubicle One section of a cabinet-installed drive. A cubicle is typically behind a door of its own. DC link DC circuit between rectifier and inverter Drive Frequency converter for controlling AC motors Electromagnetic compatibility IGBT Insulated gate bipolar transistor;...
Contents of this chapter This chapter describes the operation principle and construction of the brake chopper. Product overview ACS880-604 is an air-cooled brake chopper unit. It includes an NBRA brake chopper module or two parallel-connected NBRA brake chopper modules. Operation principle The brake chopper handles the energy generated by a decelerating motor.
14 Operation principle and hardware description Single-line diagram of the drive system The diagram below shows a typical common DC link drive system. AC supply Input (AC) fuses Supply unit. In this example, the supply unit consists of one supply module. DC link Inverter DC fuses Inverter units.
Operation principle and hardware description 15 Layout drawing The components of the brake chopper module are shown below. Four fastening points at the back of the unit Four front panel fastening screws Front panel Chopper control board (NBRC) with control terminals (see page 16) Voltage selection jumper (see page 34) PE (protective earth) clamp Grounding clamp...
16 Operation principle and hardware description Overview of power and control connections The diagram below shows the power and control connections of the brake chopper module. NBRA NBRC t° UDC- UDC+ t° Item Description Additional information Chopper enable input Protecting the system against thermal overload (page 31) Fault indication relay output...
Operation principle and hardware description 17 Type designation label Each brake chopper module is equipped with a type designation label. An example label is shown below. Description Type designation Brake chopper module order code Serial number • The first digit of the serial number refers to the manufacturing plant. •...
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18 Operation principle and hardware description...
Mechanical installation 19 Mechanical installation Contents of this chapter This chapter contains installation instructions and examples. Checking the installation site The brake chopper module must be installed in an upright position. The degree of protection of the module is IP00. Take this into account when selecting the installation site. Installation in a cabinet is highly recommended.
20 Mechanical installation Installing the brake chopper module 1. Mark the locations of the four mounting holes onto the installation surface. For the module dimensions, see chapter Dimension drawings. 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.
Brake chopper cubicle, side view Brake chopper cubicle, front view Brake chopper module, front view DC fuses Brake chopper module Power connection terminals Cooling fan mounting plate* Cooling fan * Not available from ABB For more information on the dimensions, see chapter Dimension drawings.
Attenuator (optional) Brake chopper module Cooling fan Cooling fan mounting plate* Plastic bars on both sides to block airflow** * Not available from ABB. For an illustration, see 3AXD50000007886. ** Not available from ABB. For an illustration, see 3AXD50000008190 and 3AXD50000008209.
Brake resistor cubicle, front view Brake resistor cubicle, side view Mounting rails* Thermal circuit breakers Brake resistors Power connection terminals Cooling fan mounting plate* Cooling fan * Not available from ABB For more information on the dimensions, see chapter Dimension drawings.
Air flow out. Use open roof. Brake resistors Cooling fan mounting plate* Cooling fan Plastic bars on both sides to block airflow** * Not available from ABB. For an illustration, see 3AXD50000008316. ** Not available from ABB. For an illustration, see 3AXD50000008190 and 3AXD50000008209.
ABB does not assume any liability 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.
26 Planning the electrical installation Equipping the drive with a main contactor and manual control switch(es) It is highly recommended to equip the drive with a main contactor and wire it to fault indication relay output X3 on the chopper control board. This configuration also requires a manual start/stop switch(es) for system start-up.
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Planning the electrical installation 27 For connection examples, see the diagrams below. Example 1 NBRC Example 2 NBRC...
28 Planning the electrical installation Selecting the brake circuit components 1. Calculate the maximum power generated by the motor during braking (P 2. Select a suitable brake chopper and brake resistor combination for the application from the rating table on page 57. This condition must be met: >...
Planning the electrical installation 29 Calculating the maximum braking power The P value for each standard brake chopper and brake resistor combination is given brmax in the rating table on page 57. The rated value is specified for a reference braking cycle (10 s of braking, 50 s of rest).
The maximum cable length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user- defined brake resistors and cabling. The EMC compliance of the complete installation...
Planning the electrical installation 31 Placing the brake resistors Install the resistors in a place where they will cool. Arrange the cooling of the resistor in a way that: • no danger of overheating is caused to the resistor or nearby materials •...
32 Planning the electrical installation 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.
Electrical installation 33 Electrical installation Contents of this chapter This chapter contains instructions on wiring the brake chopper unit. Safety Obey the safety instructions for the drive. See Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]. WARNING! If you ignore these instructions, physical injury or death, or damage to the equipment can occur.
34 Electrical installation Checking the insulation of the resistor circuit Do not make any voltage tolerance or insulation resistance tests on the brake chopper modules. Every brake chopper module has been tested for insulation between the main circuit and the chassis at the factory. Check the insulation of the brake resistor assembly as follows: 1.
Electrical installation 35 WARNING! An incorrect jumper setting or missing jumper may cause brake chopper malfunctioning or damage to the chopper or resistor. Synchronizing multiple brake choppers When several brake choppers are in use, the first chopper in the chain acts as the master for the other choppers.
36 Electrical installation Connecting the DC and resistor cables WARNING! Never connect the output terminals of the brake chopper together. It short-circuits the chopper and will damage it. Connection diagram DC link and brake unit in separate cabinets DC link and brake unit in the same cabinet * The brake unit can be grounded to the frame through the mounting screws if the galvanic connection to PE (protective earth) is good enough.
Electrical installation 37 Connection procedure 1. If the DC link and the brake unit are located in separate cabinets, ground the DC cable 360 degrees at the cabinet lead-throughs. 2. At the brake chopper end, connect the twisted shields (protective earth conductor) of the DC and resistor cables and the third conductors to the grounding terminals.
38 Electrical installation Connecting the thermal switch Connect the thermal switches of the resistors in series to chopper enable input X1 as shown in the power and control connections diagram on page 16.
Installation checklist 39 Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the brake chopper. Checklist Check the mechanical and electrical installation of the brake chopper before start-up. Go through the checklist together with another person. WARNING! Only qualified electricians are allowed to carry out the work described below.
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40 Installation checklist Check that … The setting of the voltage selection jumper is correct. See section Selecting the voltage on page 34. The DC cable has been connected to the appropriate terminals, and the terminals have been tightened. (Pull the conductors to check.) Appropriate DC fuses have been installed.
Start-up 41 Start-up Contents of this chapter This chapter contains the start-up procedure of a brake unit. WARNING! Only qualified electricians are allowed to perform the work described in this chapter. Obey all safety instructions in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English].
42 Start-up Action Additional information Check that the drive is ready for the brake chopper start-up: See the supply and inverter module hardware manuals and • The supply and inverter units have been installed according other appropriate manuals on the to the instructions given in their hardware manuals.
Fault tracing and maintenance 43 Fault tracing and maintenance Contents of this chapter This chapter describes the fault tracing possibilities and maintenance of a brake unit. Maintenance If installed into an appropriate environment, the brake chopper module does not require maintenance, except for regular cleaning.
Short circuit in power cables or Check power cables and resistor. resistor. Chopper control board failure. Contact local ABB representative. Chopper damaged; it is not able to disconnect resistor from intermediate circuit. Chopper does not function. Chopper voltage setting too high.
Fault tracing and maintenance 45 NRED voltage reducer selection for NBRA-669 The NRED voltage reducer can be used to protect the NBRC-61 chopper control board from overvoltage peaks. Jumper X6 on the chopper control board defines if the NRED voltage reducer is used. By default, the NRED voltage reducer is used and the jumper is set to OFF (recommended).
50 Ordering information Fuses ACS880-604- Module type Ordering code Fuse type Ratings = 400 V (Range 380…415 V) 0210-3 NBRA-658 10028183 170M5142 400 A, 1250 V 0320-3 NBRA-659 10028191 170M5146 630 A, 1250 V 0640-3 2×NBRA-659 10028191 170M5146 630 A, 1250 V 0960-3 3×NBRA-659...
Ordering information 53 Brake resistor cooling fans One cooling fan is sufficient for two of the above resistors when the resistors are installed side by side. ACS880-604- Module type Ordering code Additional information = 400 V (Range 380…415 V) 0210-3...
54 Ordering information Attenuator Attenuator (optional) for suppressing voltage spikes at the chopper input. Must be fitted if it is possible to disconnect all inverter units from the DC link with the supply unit on. ACS880-604- Module type Ordering code Type = 400 V (Range 380…415 V)
Technical data 55 Technical data Contents of this chapter This chapter contains the technical specifications of the brake chopper module, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Standard brake resistor and cooling fan specifications are also included where applicable.
58 Technical data Definitions Brake unit Example: ACS880-604-0640-3 Maximum braking power per brake unit allowed brmax momentarily Nominal resistance of the brake resistors connected to one brake chopper unit Total recommended brake resistor resistance of the listed resistor assembly Peak brake current (DC) per chopper Continuous braking power per brake unit.
Technical data 61 Losses, cooling data and noise The heat loss of a brake chopper is one percent of the braking power. Only chopper ACS880-604- Module type Air flow Noise /min dB(A) = 400 V (Range 380…415 V) 0210-3 NBRA-658...
66 Technical data CE marking A CE mark is attached to the brake chopper module to verify that the unit follows the provisions of the European Low Voltage and EMC Directives. Compliance with the European Low Voltage Directive The compliance with the European Low Voltage Directive has been verified according to standards EN 61800-5-1 and EN 60204-1.
Dimension drawings 67 Dimension drawings Contents of this chapter 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.
Example circuit diagrams 71 Example circuit diagrams Contents of this chapter This chapter contains example circuit diagrams of a brake unit. The installation consists of two parallel units both including a brake chopper and two brake resistors. One chopper – the first in the chain – acts as the master for the other. The switching of the follower chopper is controlled by the master via a fiber optic link.
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
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Contact us www.abb.com/drives www.abb.com/drivespartners 3AUA0000106244 Rev B (EN) 2013-12-05...