ABB ACS880-604LC User manual

Type
User manual
—
ABB INDUSTRIAL DRIVES
ACS880-604LC 1-phase brake units as
modules
Hardware manual
ACS880-604LC 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
Table of contents
1 Introduction to the manual
9Contents of this chapter ..........................................................................
9Safety instructions ................................................................................
9Target audience ...................................................................................
10Related manuals ..................................................................................
11Terms and abbreviations .........................................................................
2 Operation principle and hardware description
13Contents of this chapter ..........................................................................
13Product overview ..................................................................................
13Operation principle ................................................................................
15Single-line diagram of the drive system .......................................................
16Layout ..............................................................................................
18Overview of power and control connections ..................................................
19Type designation label ...........................................................................
3 Planning the installation
21Contents of this chapter ..........................................................................
21Limitation of liability ...............................................................................
21Generic guidelines ................................................................................
22Equipping the drive with a main contactor and manual control switch or switches .....
24Selecting the brake circuit components .......................................................
24Calculating the maximum braking power ..................................................
25Example 1 ...................................................................................
25Example 2 ...................................................................................
26Example 3 ...................................................................................
26Selecting and routing the brake resistor cables ..............................................
26Minimizing electromagnetic interference ...................................................
26Maximum cable length ........................................................................
27EMC compliance of the complete installation .............................................
27Placing the brake resistors ......................................................................
27Selecting the chopper enable input cable .....................................................
27Protecting the system against thermal overload .............................................
27Operation principle ............................................................................
28Protecting the resistor cable against short-circuits ...........................................
28Controlling the brake chopper from an external control location ...........................
4 Mechanical installation
29Contents of this chapter ..........................................................................
29Checking the installation site ....................................................................
29Required tools .....................................................................................
30Installing the brake chopper module ...........................................................
31Examples: Installing the brake chopper module and related components ...............
31Example: Installation into a Rittal TS 8 or VX25 enclosure .............................
31Layout drawing .............................................................................
Table of contents 5
32Installation stages ..........................................................................
33Overview of kits ............................................................................
34Stage 1: Installation of common parts ..................................................
35Stage 2: Installation of mounting plate ..................................................
36Stage 3: Installation of cooling components ...........................................
37Stage 4: Installation of brake module and attenuator ................................
38Examples: Installing the brake resistors and cooling fan ...................................
38Example 1: Installation into a Rittal TS 8 enclosure ......................................
39Example 2: Installation into a generic enclosure .........................................
5 Electrical installation
41Contents of this chapter ..........................................................................
41Safety and liability ................................................................................
42Electrical safety precautions ....................................................................
43Checking the insulation of the resistor circuit .................................................
43General notes .....................................................................................
43Printed circuit boards .........................................................................
43Optical components ...........................................................................
44Selecting the voltage .............................................................................
45Synchronizing multiple brake choppers .......................................................
46Connecting the DC and resistor cables ........................................................
46Connection diagram ..........................................................................
47Connection procedure ........................................................................
48Connecting the thermal switch ..................................................................
6 Installation checklist
49Contents of this chapter ..........................................................................
50Checklist ...........................................................................................
7 Start-up
51Contents of this chapter ..........................................................................
51Start-up procedure ................................................................................
8 Fault tracing
53Contents of this chapter ..........................................................................
53Fault indications ...................................................................................
9 Maintenance
55Contents of this chapter ..........................................................................
56Maintenance intervals ............................................................................
57Maintenance timers and counters ..............................................................
57Cooling system ....................................................................................
57Cabinet .............................................................................................
57Cleaning the interior of the cabinet .........................................................
57Power connections ...............................................................................
57Retightening the power connections .......................................................
10 Ordering information
59Contents of this chapter ..........................................................................
60Brake chopper modules ..........................................................................
6 Table of contents
60Brake chopper cooling ...........................................................................
60Cooling fans ....................................................................................
60Fan kit (with heat exchanger) ................................................................
61Coolant piping and fittings ...................................................................
62DC bus installation parts (for Rittal TS 8 enclosures) .......................................
62DC bus installation parts (for Rittal VX25 enclosures) ......................................
63Fuses and fuse bases ............................................................................
63Brake resistors ....................................................................................
63Brake resistor cooling fans ......................................................................
63Attenuator ..........................................................................................
11 Internal cooling circuit
65Contents of this chapter ..........................................................................
65Applicability ........................................................................................
65Internal cooling system ..........................................................................
67Connection to a cooling unit .....................................................................
67Connection to an ACS880-1007LC cooling unit ..........................................
67Connection to a custom cooling unit ........................................................
67General requirements .....................................................................
67Coolant temperature control .............................................................
68Filling up and bleeding the internal cooling circuit ...........................................
68Drive line-ups with an ACS880-1007LC cooling unit .....................................
68Drive line-ups with a custom cooling unit ..................................................
70Draining the internal cooling circuit .............................................................
70Maintenance intervals ............................................................................
70Technical data .....................................................................................
70Coolant specification ..........................................................................
70Coolant type ................................................................................
70Temperature limits .............................................................................
71Pressure limits .................................................................................
72Cooling circuit materials ......................................................................
12 Technical data
73Contents of this chapter ..........................................................................
73Ratings .............................................................................................
73Chopper only ...................................................................................
74Chopper with standard resistors ............................................................
75Definitions ......................................................................................
76DC fuses ...........................................................................................
76Dimensions, weights and free space requirements ..........................................
77Losses, cooling data and noise .................................................................
77Brake chopper module only ..................................................................
77Brake resistors .................................................................................
78Brake circuit cable sizes .........................................................................
78Brake resistor terminal data .....................................................................
78Degree of protection ..............................................................................
78Optical components ..............................................................................
79Ambient conditions ...............................................................................
80Auxiliary circuit current consumption ...........................................................
80Definitions ......................................................................................
Table of contents 7
80CE marking ........................................................................................
80Compliance with the European Low Voltage Directive ..................................
81Compliance with the European EMC Directive ...........................................
81More information on standards and markings ................................................
13 Dimension drawings
83Contents of this chapter ..........................................................................
84Brake chopper module NBRW-669 ............................................................
85Attenuator ..........................................................................................
86Brake resistor ......................................................................................
87Brake resistor cooling fan D3G200-BF07-H2, D3G200-BB36-82 .........................
14 Circuit diagram examples
89Contents of this chapter ..........................................................................
90Brake unit with one chopper module – Sheet 001a ..........................................
91Brake unit with one chopper module – Sheet 005a ..........................................
92Brake unit with one chopper module – Sheet 026a ..........................................
93Brake unit with one chopper module – Sheet 027a ..........................................
94Brake unit with four chopper modules – Sheet 001a ........................................
95Brake unit with four chopper modules – Sheet 001b ........................................
96Brake unit with four chopper modules – Sheet 005a ........................................
97Brake unit with four chopper modules – Sheet 005b ........................................
98Brake unit with four chopper modules – Sheet 026a ........................................
99Brake unit with four chopper modules – Sheet 026b ........................................
100Brake unit with four chopper modules – Sheet 027a ........................................
101Brake unit with four chopper modules – Sheet 027b ........................................
Further information
8 Table of contents
Introduction to the manual
Contents of this chapter
This chapter introduces this manual.
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 Safety instructions for ACS880
liquid-cooled multidrive cabinets and modules (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
The manual is intended for people who plan the installation of or start up the brake unit.
Read the manual before working on the unit. You are expected to know the fundamentals
of electricity, wiring, electrical components and electrical schematic symbols.
1
Introduction to the manual 9
Related manuals
CodeManual
General manuals
3AXD50000048633Safety instructions for ACS880 liquid-cooled multidrive cabinets and modules
3AXD50000048634Electrical planning instructions for ACS880 liquid-cooled multidrive cabinets and modules
3AUA0000107668Cabinet design and construction instructions for ACS880 air-cooled and liquid-cooled
multidrive modules
Supply module manuals
3AXD50000045157ACS880-304LC+A019 diode supply modules hardware manual
3AUA0000103295ACS880 diode supply control program firmware manual
Inverter module manuals and guides
3AXD50000045610ACS880-104LC inverter modules hardware manual
3AUA0000085967ACS880 primary control program firmware manual
3AUA0000098062ACS880 primary control program quick start-up guide
Brake module manuals
3AXD50000184378ACS880-604LC 1-phase brake chopper modules hardware manual
Option manuals
3AUA0000085685ACX-AP-x assistant control panels user’s manual
3AUA0000094606Drive composer start-up and maintenance PC tool user’s manual
3AXD50000129607ACS880-1007LC liquid cooling unit user's manual
3AUA0000127808Drive application programming (IEC 61131-3) manual
Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, 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.
You can find all documentation related to the multidrive modules on the Internet at
https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.
10 Introduction to the manual
Terms and abbreviations
DescriptionTerm
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 installation.Brake chopper module
Dissipates the drive surplus braking energy conducted by the brake chopper to heatBrake resistor
Brake chopper modules under control of one control board, and related accessoriesBrake unit
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 machinery.
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 introduces the operation principle and construction of the brake unit.
Product overview
The ACS880-604LC is a liquid-cooled resistor brake unit available in the ACS880 multidrive
modules product range. The design presented in this manual has an NBRW-669C
liquid-cooled brake chopper module with two brake resistors. The chopper module has a
liquid-cooled heat sink which transfers most of the generated heat into the coolant. The air
inside the cubicle is circulated by a fan, and forced 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 can be connected in parallel to achieve a higher braking
capacity. However, each chopper module must have its own resistors.
Operation principle
The brake chopper handles the energy generated by a decelerating motor. The chopper
connects the brake resistor to the DC link of the drive whenever the voltage exceeds an
2
Operation principle and hardware description 13
activation limit. Energy consumption by the resistor losses lowers the voltage until the resistor
can again be disconnected.
Typically, a 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
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 ocnsists of two inverter modules connected in parallel6
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
Operation principle and hardware description 15
Layout
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
Fastening points on back plate (two at the top, two at the bottom)1
Front cover fastening screws2
Front cover3
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) clamp6
Grounding clamp7
Clamp for drive cable8
Clamp for resistor cable9
Enable input terminal block, see section Overview of power and control connections (page 18).
X1
16 Operation principle and hardware description
Power 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
Overview of power and control connections
The diagram below shows the power and control connections of the brake chopper module.
t°
X3
1
2
NBRC
X1
V23V22
R+ R-UDC- UDC+
13
2
t°
+
–
X2
12
Additional informationDescriptionItem
See section Protecting the system against thermal
overload (page 27).
Chopper enable inputX1
Fault indication relay outputX3
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 principle and hardware description
Type designation label
Each brake chopper module is equipped with a type designation label. An example label is
shown below.
ABB
Type
Code
Un
Rmin
Duty cycle
Irms
Rn
709…976 (848 UL, CSA) VDC
1.35 Ohm
1 / 5 min
267 ADC
2.72 Ohm
MADE IN ESTONIA
NBRW-669C
6426
OO
49
Serno
*
8 1 8 3 9 0 1 2 3 4
*
ABB Oy
Hiomotie 13
00380 Helsinki
Finland
1
2
3
4 5
DescriptionNo.
Type designation1
Brake chopper module order code2
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
Operation principle and hardware description 19
20
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ABB ACS880-604LC User manual

Type
User manual

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