Page is loading ...
—
ABB INDUSTRIAL DRIVES
ACS880-607LC 1-phase brake units
Hardware manual
Table of contents
1 Introduction to the manual
9Contents of this chapter ..........................................................................
9Applicability ........................................................................................
9Safety instructions ................................................................................
9Target audience ...................................................................................
10Related documents ...............................................................................
10Use of component designations ................................................................
10Terms and abbreviations .........................................................................
2 Operation principle and hardware description
13Contents of this chapter ..........................................................................
13Product overview ..................................................................................
13Operation principle ................................................................................
14Single-line diagram of the drive system .......................................................
15Layout ..............................................................................................
15Brake chopper cubicle ........................................................................
16Brake resistor cabinet ........................................................................
17Brake chopper module .......................................................................
19Overview of power and control connections ..................................................
20Controlling the brake chopper from an external control location .......................
20Master-follower connection ..................................................................
20Type designation labels ..........................................................................
20Brake unit type designation label ...........................................................
21Brake chopper module type designation label ............................................
21Brake unit type designation key ................................................................
21Basic code ......................................................................................
3 Mechanical installation
23Contents of this chapter ..........................................................................
23Brake unit ..........................................................................................
23Brake resistor cabinet ............................................................................
23User-defined brake resistors ....................................................................
4 Planning the electrical installation
25Contents of this chapter ..........................................................................
25Limitation of liability ...............................................................................
25Generic guidelines ................................................................................
25Selecting the user-defined brake resistors ....................................................
26Selecting and routing the brake resistor cables ...........................................
26Typical resistor cable sizes ...............................................................
26Minimizing electromagnetic interference ...............................................
26Maximum cable length ....................................................................
26Placing the brake resistors ...................................................................
27Selecting the resistor thermal switch circuit cable ........................................
Table of contents 5
27Protecting the system against thermal overload .............................................
27Operation principle ............................................................................
27Protecting the system against short-circuits ..................................................
5 Electrical installation
29Contents of this chapter ..........................................................................
29Electrical safety precautions ....................................................................
31Checking the insulation of brake resistor and resistor cable ...............................
32Connecting the brake resistor cables and thermal switch ..................................
32Connection diagram ..........................................................................
32Connection procedure ........................................................................
6 Installation checklist of the drive
35Contents of this chapter ..........................................................................
35Checklist ...........................................................................................
7 Start-up
37Contents of this chapter ..........................................................................
37Start-up procedure ................................................................................
8 Fault tracing
39Contents of this chapter ..........................................................................
39Fault indications ...................................................................................
40Fan supervision ...................................................................................
40Selecting the voltage .............................................................................
9 Maintenance
43Contents of this chapter ..........................................................................
43Maintenance intervals ............................................................................
44Cooling system ....................................................................................
44Retightening the power connections ...........................................................
45Replacing cooling fans ...........................................................................
45Brake chopper cubicle ........................................................................
46Brake resistor cabinet (option +D151) .....................................................
10 Internal cooling circuit
47Contents of this chapter ..........................................................................
47Applicability ........................................................................................
47Internal cooling system ..........................................................................
49Connection to a cooling unit .....................................................................
49Connection to an ACS880-1007LC cooling unit ..........................................
49Connection to a custom cooling unit ........................................................
49General requirements .....................................................................
49Coolant temperature control .............................................................
50Filling up and bleeding the internal cooling circuit ...........................................
50Drive line-ups with an ACS880-1007LC cooling unit .....................................
50Drive line-ups with a custom cooling unit ..................................................
52Draining the internal cooling circuit .............................................................
52Maintenance intervals ............................................................................
6 Table of contents
52Technical data .....................................................................................
52Coolant specification ..........................................................................
52Coolant type ................................................................................
52Temperature limits .............................................................................
54Pressure limits .................................................................................
54Coolant flow rate limits .......................................................................
54Cooling circuit materials ......................................................................
11 Technical data
57Contents of this chapter ..........................................................................
57Ratings .............................................................................................
57Brake chopper only ...........................................................................
58Brake chopper with factory-installed brake resistors (option +D151) ..................
59Definitions ......................................................................................
60DC fuses ...........................................................................................
60Dimensions, weights and free space requirements ..........................................
60Brake chopper only ...........................................................................
60Brake chopper with factory-installed brake resistors (option +D151) ..................
61Losses, cooling data and noise .................................................................
61Brake chopper only ...........................................................................
61Brake chopper with factory-installed brake resistors (option +D151) ..................
62
Terminal and lead-through data for the resistor cable for brake units with user-defined
brake resistors .....................................................................................
62Resistor cable sizes ..............................................................................
62Maximum cable length ........................................................................
63Protection classes ................................................................................
63Brake chopper cubicle ........................................................................
63Ambient conditions ...............................................................................
65Materials ...........................................................................................
65Standards and markings .........................................................................
65Disclaimers ........................................................................................
65Generic disclaimer ............................................................................
66Cybersecurity disclaimer .....................................................................
12 Example circuit diagrams
67Contents of this chapter ..........................................................................
68Brake unit with one brake chopper module ...................................................
69Brake chopper control ............................................................................
70External fan voltage supply ......................................................................
71Fan control for brake chopper cubicle .........................................................
72Fan control for resistor cabinet .................................................................
Further information
Table of contents 7
8
Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
The manual is applicable to ACS880-607LC 1-phase brake units that form a part of a
liquid-cooled ACS880 multidrive system.
Safety instructions
Follow all safety instructions delivered with 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 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
This manual is intended for people who plan the installation, install, start up and service the
drive, or create instructions for the end user of the drive concerning the installation and
maintenance of the drive.
Read the manual before working on the drive. You are expected to know the fundamentals
of electricity, wiring, electrical components and electrical schematic symbols.
1
Introduction to the manual 9
The manual is written for readers worldwide. Both SI and imperial units are shown.
Related documents
CodeManual
General manuals
3AXD50000048633
ACS880 liquid-cooled multidrive cabinets and modules safety instructions
3AXD50000048634
ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions
3AXD50000048635
ACS880 liquid-cooled multidrive cabinets mechanical installation instructions
3AXD50000126880
CIO-01 I/O module for distributed I/O bus control user's manual
Supply unit manuals
3AXD50000174782
ACS880-207LC IGBT supply units hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
Inverter unit manuals
3AXD50000196111
ACS880-107LC inverter units hardware manual
3AUA0000085967
ACS880 primary control program firmware manual
3AUA0000098062
ACS880 primary control program quick start-up guide
Manuals for application programs (Crane, Winder, etc.)
Brake unit and DC/DC converter unit manuals
3AXD50000481491
ACS880-607LC 1-phase brake units hardware manual
3AXD50000020967
ACS880 (3-phase) brake control program firmware manual
3AXD50000431342
ACS880-1607LC DC/DC converter units hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Option manuals
3AXD50000129607
ACS880-1007LC liquid cooling unit user's manual
3AUA0000085685
ACS-AP-x assistant control panels user’s manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
Manuals for I/O extension modules, fieldbus adapters, safety options etc.
You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals
not available in the document library, contact your local ABB representative.
Use of component designations
Some device names in the manual include the item designation in brackets, for example
[Q20], to make it possible to identify the components in the circuit diagrams of the drive.
Terms and abbreviations
DescriptionTerm/
Abbreviation
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 deceleration
(braking) of a high inertia motor.
Brake chopper
Brake chopper enclosed in a metal frame or housing. Intended for cabinet installa-
tion.
Brake chopper module
10 Introduction to the manual
DescriptionTerm/
Abbreviation
Dissipates the drive surplus braking energy conducted by the brake chopper to
heat
Brake resistor
Brake chopper modules under control of one control board, and related accessoriesBrake unit
I/O module for controlling cabinet fansCIO
One section of a cabinet-installed drive. A cubicle is typically behind a door of its
own.
Cubicle
DC circuit between rectifier and inverterDC link
Frequency converter for controlling AC motorsDrive
Electromagnetic compatibilityEMC
Insulated gate bipolar transistorIGBT
DC circuit between rectifier and inverterIntermediate circuit
Converts direct current and voltage to alternating current and voltage.Inverter
Drive for controlling several motors which are typically coupled to the same ma-
chinery. Includes one supply unit, and one or several inverter units.
Multidrive
Brake chopper control boardNBRC
Series of optional, liquid-cooled brake chopper modulesNBRW
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,
eg, variable, constant, or signal.
Parameter
Converts alternating current and voltage to direct current and voltageRectifier
Series of brake resistorsSAFUR
Introduction to the manual 11
12
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
available as an option (+D151).
Operation principle
The brake chopper handles the energy generated by a decelerating motor. The extra energy
increases the DC link voltage. The brake chopper connects the brake resistors to the DC
link of the drive when the voltage exceeds an activation limit. The energy consumption by
the resistor losses lowers the voltage until the resistor can be disconnected.
Typically, a drive system is equipped with a brake chopper 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.
2
Operation principle and hardware description 13
Single-line diagram of the drive system
The diagram below shows a typical common DC link drive system.
1
2
3
4
6
5
6
8
9
10
11
7
MM
AC supply1
Input (AC) fuses2
Supply unit3
DC link4
Inverter DC fuses5
Inverter units. In this example, one of the units consists of two inverter modules connected in parallel.6
Brake chopper DC fuses7
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 chopper9
Brake resistors10
Motors11
14 Operation principle and hardware description
Layout
￭ Brake chopper cubicle
The figure below shows the components of the brake chopper cubicle.
1
2
3
4
5
Attenuator [R121.x]4DC fuses [F121.xx]1
Brake chopper module [T121]5CIO-01 I/O module [A115.x]2
Cooling fan [G115.xx] and heat exchanger3
Operation principle and hardware description 15
￭ Brake resistor cabinet
The figure below shows the components of the brake resistor cabinet.
1
1
2
3
Door position indication switch [S121.7]3Brake resistors [R121.xx]1
Brake resistor cooling fans2
16 Operation principle and hardware description
￭ Brake chopper module
The components of the brake chopper module are shown below.
6
7
UDC+ R+
UDC- R-
X1
4
5
8
9
1
1
2
2
3
2
2
Clamp for drive cable8
Fastening points on back plate (two at the top,
two at the bottom)
1
Clamp for resistor cable9Front cover fastening screws2
Enable input terminal blockX1Front cover3
Power connection terminals
UDC-
Chopper control board (NBRC) with control ter-
minals
4
UDC+Voltage selection jumper5
R+PE (protective earth) clamp6
R-Grounding clamp7
Operation principle and hardware description 17
Coolant connections behind main mounting plate (side view).
18 Operation principle and hardware description
Overview of power and control connections
The diagram below shows the power and control connections of the brake unit.
X3
1
2
X1
V23V22
R+ R-UDC- UDC+
1 3
2
t
°
+
-
X2
1
2
3
4 5
6
7
21
Brake chopper cubicle1
Brake chopper module [T121]2
Brake chopper control board (NBRC)3
Brake resistor cabinet4
Brake resistors [R121.xx]5
Brake resistor monitoring circuit with a thermal switch and a door position indication switch [S121.7]6
Control voltage7
Chopper enable inputX1
Fault indication relay output. Connected in brake resistor monitoring circuit (monitored by the chopper
enable input X2). See Example circuit diagrams.
X3
Fiber optic cable connection (not connected as standard)V22
Fiber optic cable connection (not connected as standard)V23
Operation principle and hardware description 19
￭ 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.
￭ Master-follower connection
When several brake choppers are in use, the first chopper in the chain acts as the master
for the other choppers. The voltage selection jumper of the master (1) is set to the appropriate
voltage at the factory, while the followers (2) are set to FIBER.
V22V22
V23
V23
(Voltage)
V23
V22
FIBER
21 2
FIBER
Type designation labels
￭ Brake unit type designation label
Each brake unit is equipped with a type designation label. An example label is shown below.
1
2
3
4
5
Type designation1
Frame size2
Serial number3
• 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.
Ratings4
Valid markings5
20 Operation principle and hardware description
/
