ABB ACS880-607LC Hardware Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Industrial Equipment
  5. ACS880-607LC
  6. Hardware manual
ABB ACS880-607LC Hardware Manual

ABB ACS880-607LC Hardware Manual

1-phase brake units
Hide thumbs Also See for ACS880-607LC:
Table of Contents

Advertisement

Quick Links

Download this manual
—
ABB INDUSTRIAL DRIVES
ACS880-607LC 1-phase brake units
Hardware manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ACS880-607LC and is the answer not in the manual?

Questions and answers

Related Manuals for ABB ACS880-607LC

Summary of Contents for ABB ACS880-607LC

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-607LC 1-phase brake units Hardware manual...
  • Page 3 ACS880-607LC 1-phase brake units Hardware manual Table of contents 3. Mechanical installation 5. Electrical installation 7. Start-up 3AXD50000481491 Rev B Original instructions EFFECTIVE: 2025-04-08...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter............... . . Applicability.
  • Page 6 6 Table of contents Protecting the system against thermal overload......... . Operation principle.
  • Page 7 Table of contents 7 Drive line-ups with a custom cooling unit..........Draining the internal cooling circuit.

  • Page 9: 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 Obey all safety instructions of the drive.

  • Page 10: Related Documents

    10 Introduction to the manual Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. Manuals for ACS880 multidrives cabinets Use of component designations Some device names in the manual include the component designation in brackets (for example, [Q20]).

  • Page 11: Operation Principle And Hardware Description

    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).

  • Page 12: When To Use Resistor Braking

    12 Operation principle and hardware description When to use resistor braking Resistor braking is necessary for high capacity braking of the motor and machinery if a regenerative drive cannot be used. 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...

  • Page 13: Layout

    Operation principle and hardware description 13 Layout Brake chopper cubicle ￭ The figure below shows the components of the brake chopper cubicle. DC fuses [F121.xx] Attenuator [R121.x] CIO-01 I/O module [A115.x] Brake chopper module [T121] Cooling fan [G115.xx] and heat exchanger...

  • Page 14: Brake Resistor Cabinet

    14 Operation principle and hardware description Brake resistor cabinet ￭ The figure below shows the components of the brake resistor cabinet. Brake resistors [R121.xx] Door position indication switch [S121.7] Brake resistor cooling fans...

  • Page 15: Brake Chopper Module

    Operation principle and hardware description 15 Brake chopper module ￭ The components of the brake chopper module are shown below. UDC+ R+ UDC- Fastening points on back plate (two at the Clamp for drive cable top, two at the bottom) Front cover fastening screws Clamp for resistor cable Front cover...

  • Page 16: Overview Of Power And Control Connections

    16 Operation principle and hardware description Overview of power and control connections The diagram below shows the power and control connections of the brake unit. t ° UDC- UDC+ Brake chopper cubicle Brake chopper module [T121] Brake chopper control board (NBRC) Brake resistor cabinet Brake resistors [R121.xx] Brake resistor monitoring circuit with a thermal switch and a door position indication switch...

  • Page 17: Controlling The Brake Chopper From An External Control Location

    Operation principle and hardware description 17 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.

  • Page 18: Type Designation Labels

    18 Operation principle and hardware description Type designation labels Brake unit type designation label ￭ Each brake unit is equipped with a type designation label. An example label is shown below. Type designation Frame size Serial number • The first digit of the serial number refers to the manufacturing plant. •...

  • Page 19: Brake Chopper Module Type Designation Label

    Operation principle and hardware description 19 Brake chopper module type designation label ￭ Each brake chopper module is equipped with a type designation label. An example label is shown below. Type designation Brake chopper module order code Serial number • The first digit of the serial number refers to the manufacturing plant. •...

  • Page 21: Mechanical Installation

    Mechanical installation 21 Mechanical installation Contents of this chapter This chapter describes the mechanical installation of the brake units. Brake unit The ACS880 multidrive - the brake unit as one part of the complete drive - is transported in sections. Refer to ACS880 liquid-cooled multidrive cabinets mechanical installation instructions (3AXD50000048635 [English]).

  • Page 23: Planning The Electrical Installation

    Brake units with user-defined brake resistors Selecting the brake resistor ￭ WARNING! ABB is not responsible for user resistor selection or protection of the resistor. Select the resistor according to the resistor specification given in the technical data. In addition, consider the following:...

  • Page 24: Selecting And Routing The Brake Resistor Cables

    ￭ Selecting the brake resistor cables • Select cables that are compliant with the ABB brake resistor cable specification. Refer to technical data. • Make sure that the resistor cable is not longer than 50 m (164 ft). Longer cables increase the inductance in the circuit and may cause drive or chopper fault trips, or other malfunctions.

  • Page 25: Selecting The Resistor Thermal Switch Circuit Cable

    Roxtec cable entry (option +H394) The cabinet can be equipped with a multi-cable transit frame for Roxtec cable entry (option +H394). ABB provides only the frames, not the seals or the installation tools. For sealing components and installation instructions, refer to www.roxtec.com.
  • Page 26 The table below lists the Roxtec cable entry frames for different cabinet sizes. Designed for Cable frame Roxtec frame Description Cabinets with bottom cable entry 3AUA5000479445 ABB designed flange and Roxtec frame ACS880LC W300 S 8X1 AISI316 (kit) welded together. 3AUA5000221237 ABB designed flange and Roxtec frame...

  • Page 27: Electrical Installation

    Electrical installation 27 Electrical installation Contents of this chapter This chapter describes the electrical installation of the brake unit. • user-defined brake resistors • brake resistors that are separate from the basic line-up. A brake unit with factory-installed brake resistors in the basic line-up is an operational unit after the shipping splits are joined.
  • Page 28 28 Electrical installation • Select the correct personal protective equipment (PPE). • Stop the drive and motor(s). Clearly identify the work location and equipment. Disconnect all possible voltage sources. Make sure that connection is not possible. Lock out and tag out. •...
  • Page 29 Electrical installation 29 WARNING! The busbars inside the cabinet of liquid-cooled drives are partially coated. Measurements made through the coating are potentially unreliable, so only measure at uncoated portions. Note that the coating does not constitute a safe or touch-proof insulation. Install temporary grounding as required by the local regulations.

  • Page 30: Measuring The Insulation Resistance Of The Brake Resistor Circuit

    30 Electrical installation Measuring the insulation resistance of the brake resistor circuit WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do electrical installation, commissioning or maintenance work.

  • Page 31: Selecting The Voltage

    Electrical installation 31 Selecting the voltage The voltage is preset, according to the drive supply voltage, at the factory for each brake chopper. On the field, you need to adjust the voltage setting only if a brake chopper is changed. NBRW-669 brake chopper has an NBRC-61 brake chopper control unit, and can be used only with 690 V drive nominal supply.

  • Page 32: Connecting The Brake Resistor Cables And Thermal Switch

    32 Electrical installation Connecting the brake resistor cables and thermal switch Connection diagram ￭ 11 12 X121.1 11 12 X121.7 Brake chopper cubicle (all connections done at the factory) Brake chopper module Brake resistor cabinet Connection procedure ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 33 Electrical installation 33 Stop the drive and do the steps in section Electrical safety precautions (page 27) before you start the work. Open the door of the brake chopper cubicle and remove the shrouding. Connect the resistor cables: • Connect the power cable between the brake chopper and the brake resistor. Note the connection of the third conductor and the cable shield.

  • Page 34: Use Of Fasteners In Cable Lug Connections

    34 Electrical installation Use of fasteners in cable lug connections Use the bolts, nuts and washers delivered with the drive. Install all the fasteners in the correct order. See the figure below. Tighten the cable lug to the torque specified for the connection.

  • Page 35: Installation Checklist

    Installation checklist 35 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do electrical installation, commissioning or maintenance work.
  • Page 36 36 Installation checklist Make sure that … If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground-to-phase varistor) Refer to the electrical installation instructions in the supply unit manual.

  • Page 37: Start-Up

    This chapter contains the start-up procedure of the brake unit. ABB recommends that you connect a commissioning PC tool (DriveComposer) to the inverter unit that will be used to test the braking. By using the tool, you can set up the parameters and monitor the drive during the test.
  • Page 38 38 Start-up Tasks Make sure that the coolant can flow freely in all cubicles. Make sure that drive system cools down. Refer to ACS880-1007LC liquid cooling unit user’s manual (3AXD50000129607 [English]). Install all shrouds (if removed) and close the cabinet doors. Powering up the drive DC bus and starting up the inverters Make sure that all cabinet doors are closed.

  • Page 39: Fault Tracing

    Check that enable input is on. overriding control system. chopper control board. Short circuit in resistor or power Check power cables and resistor. cables. Chopper control board failure. Contact local ABB representative. Chopper damaged; it is not able to disconnect resistor from inter- mediate circuit.

  • Page 40: Fan Supervision

    40 Fault tracing Fault indication/Fault Cause Remedy Chopper does not function. Chopper voltage setting too high. Check voltage setting. Inverter overvoltage control is on. Check parameters of all invert- ers. Check that enable input is on. Chopper starts to function at too Chopper voltage setting too low.

  • Page 41: Maintenance

    Contents of this chapter This chapter describes the maintenance of a brake unit. Maintenance intervals The tables show the maintenance tasks that can be done by the end user. For the ABB Service offering, contact your local ABB Service representative (new.abb.com/contact-centers).

  • Page 42: Recommended Maintenance Intervals After Start-Up

    Reset the running time signal after fan replacement. Refer also to CIO-01 I/O module and distributed I/O bus user's manual (3AXD50000126880 [English]). Replacement fans are available from ABB. Do not use other than ABB-specified spare parts. Brake chopper cubicle ￭ WARNING!
  • Page 43 Maintenance 43 Stop the drive and do the steps in section Electrical safety precautions (page 27) before you start the work. Remove any shrouding in front of the cooling fan. Disconnect the fan wiring. Undo the fastening screws. Pull the fan housing outwards. Install a new fan in reverse order.

  • Page 44: Brake Resistor Cabinet (Option +D151)

    44 Maintenance Brake resistor cabinet (option +D151) ￭ WARNING! Wear protective gloves and long sleeves. Some parts have sharp edges. Stop the drive and do the steps in section Electrical safety precautions (page 27) before you start the work. Remove any shrouding in front of the cooling fans. Disconnect the fan wiring.

  • Page 45: Internal Cooling Circuit

    Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain valve. The stop valves can be closed to isolate all modules in the cubicle from the main cooling circuit. In cabinet line-ups built by ABB, valves are color-coded: • Blue – Open during operation •...
  • Page 46 46 Internal cooling circuit Supply modules. The drawing shows the configuration of a diode supply unit with two modules, ie. there is a common air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each module has a dedicated air-to-liquid exchanger as shown for item 2. Inverter modules To/From cooling unit Air-to-liquid heat exchanger...

  • Page 47: Connection To A Cooling Unit

    Internal cooling circuit 47 Connection to a cooling unit Connection to an ACS880-1007LC cooling unit ￭ Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]). Connection to a custom cooling unit ￭ General requirements Equip the system with an expansion tank to damp pressure rise due to volume changes when the temperature varies.

  • Page 48: Filling Up And Bleeding The Internal Cooling Circuit

    48 Internal cooling circuit Filling up and bleeding the internal cooling circuit Both the drive and coolant must be at room temperature before filling up the cooling circuit. WARNING! Make sure that the maximum permissible operating pressure is not exceeded. When necessary, regulate the pressure to appropriate level by draining excess coolant out of the system.

  • Page 49: Draining The Internal Cooling Circuit

    Internal cooling circuit 49 Open the inlet and outlet valves in all cubicles. Let any air remaining in the system out through the bleed valve at the cooling unit. Close the bleed valve at the cooling unit. 10. Continue to fill in coolant until a base pressure of approximately 250 kPa is achieved.

  • Page 50: Technical Data For The Internal Cooling Circuit

    Coolant type Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% mixture, available from Clariant distributors and ABB Service representatives. Do not dilute the coolant. It is ready to use. Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).

  • Page 51: Pressure Limits

    Internal cooling circuit 51 Min. T (°C) coolant (°C) RH = 95% RH = 80% RH = 65% RH = 50% RH = 40% -0.1 -3.0 14.2 11.5 19.2 16.5 13.2 24.1 21.4 17.9 13.8 10.5 29.1 26.2 22.7 18.4 15.0 34.1 31.1...
  • Page 52 52 Internal cooling circuit • plastic materials such as PA, PEX and PTFE Note: PVC hoses are not suitable for use with antifreeze. • rubber gasketing NBR (nitrile rubber). WARNING! If you connect external piping to the internal cooling circuit, use only materials that are specified above.

  • Page 53: Technical Data

    Technical data 53 Technical data Contents of this chapter This chapter contains the technical specifications of the brake unit, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Ratings Brake chopper only ￭...

  • Page 54: Brake Chopper With Factory-Installed Brake Resistors (Option +D151)

    54 Technical data Brake chopper with factory-installed brake resistors (option +D151) ￭ Duty cycle Duty cycle (1/5 min) (10/60 s) ACS880- Module brmax brcont Resistor type 607LC-… type 0400-7 NBRW- 2 × AFUR 1.35 10800 669C 200F500/MK160 0800-7 2 × 2 ×...

  • Page 55: Definitions

    Technical data 55 Definitions ￭ Example: ACS880-607LC-0800-7 Brake unit Energy pulse that all the resistors of the unit put – together will withstand (400 s duty cycle). This en- ergy will heat the resistor elements from 40°C to the maximum allowable temperature.

  • Page 56: Dc Fuses

    56 Technical data DC fuses ACS880-607LC-… Fuse type = 690 V (Range 525…690 V) 0400-7 170M5146 1250 0800-7 170M5146 1250 1200-7 170M5146 1250 1600-7 170M5146 1250 2000-7 170M5146 1250 2400-7 170M5146 1250 Dimensions, weights and free space requirements Brake chopper only ￭...

  • Page 57: Losses, Cooling Data And Noise

    Losses, cooling data and noise Brake chopper only ￭ Power loss Coolant Noise Pres- Volume Flow rate sure Into Into ACS880-607LC-… Module type loss coolant dB(A) US gal l/min gal/min (PSI) = 690 V (Range 525…690 V) 0400-7 NBRW-669 0.68 0.42...

  • Page 58: Typical Power Cable Sizes

    58 Technical data Air flow Noise ACS880- Module Resistor type 607LC-… type /min dB(A) 6 × NBRW- 6 × (2 × SAFUR 2400-7 11700 6890 200F500/MK160) Typical power cable sizes The tables below give the current carrying capacity ( I ) and typical size for copper Lmax and aluminum cables with PVC or XLPE insulation.

  • Page 59: User-Defined Brake Resistors

    3 × 240 + 72 Cu 3478 3229 3 × 300 + 88 Cu Terminal and lead-through data for the resistor cable for brake units with user-defined brake resistors ACS880-607LC-… R+, R-, grounding terminals Number of Hole diameter Screw Tightening torque holes N·m...

  • Page 60: Maximum Cable Length

    Installation site altitude 0…2000 m (0…6562 ft) above sea level. For alti- tudes over 2000 m, con- tact ABB. Output derated above 1000 m (3281 ft). Air temperature 0 … +45 °C -40 … +70 °C -40 …...

  • Page 61: Colors

    Technical data 61 Operation Storage Transportation installed for stationary in the protective pack- in the protective pack- Contamination IEC/EN 60721-3-3:2002 IEC 60721-3-1:1997 IEC 60721-3-2:1997 Chemical gases: Class Chemical gases: Class Chemical gases: Class Solid particles: Class 3S2. Solid particles: Class 1S3 Solid particles: Class 2S2 No conductive dust al- (packing must support...
  • Page 62 ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of...

  • Page 63: 12. Example Circuit Diagrams

    Example circuit diagrams 63 12. Example circuit diagrams Contents of this chapter This chapter contains example circuit diagrams of 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.

  • Page 64: Brake Unit With One Brake Chopper Module

    Circuit diagram EFS2 Item Des. Cust. Doc. No. Prep. Title Cust. Ref. No. App. SAP Doc. No. +60.1 JOLU_DBU ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 001a ABB Ref. No. Rev. Sheet DBULC 2xBRC+BRR Resp. Dept. No. of Sheets...

  • Page 65: Brake Chopper Control

    Circuit diagram EFS2 Cust. Doc. No. Prep. Title Item Des. Cust. Ref. No. App. SAP Doc. No. +60.1 JOLU_DBU ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 005a ABB Ref. No. Rev. Sheet DBULC 2xBRC+BRR Resp. Dept. No. of Sheets...

  • Page 66: External Fan Voltage Supply

    Circuit diagram EFS2 Cust. Doc. No. Prep. Title Item Des. Cust. Ref. No. App. SAP Doc. No. +60.1 JOLU_DBU ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 020a ABB Ref. No. Rev. Sheet DBULC 2xBRC+BRR Resp. Dept. No. of Sheets...

  • Page 67: Fan Control For Brake Chopper Cubicle

    Circuit diagram EFS2 Cust. Doc. No. Prep. Title Item Des. Cust. Ref. No. App. SAP Doc. No. +60.1 JOLU_DBU ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 026a ABB Ref. No. Rev. Sheet DBULC 2xBRC+BRR Resp. Dept. No. of Sheets...

  • Page 68: Fan Control For Resistor Cabinet

    Circuit diagram EFS2 Cust. Doc. No. Prep. Title Item Des. Cust. Ref. No. App. SAP Doc. No. +60.2 JOLU_DBU ACS880-607LC-0400-7 3AFE Customer Project EPLAN Doc. No. 690V 027a ABB Ref. No. Rev. Sheet DBULC 2xBRC+BRR Resp. Dept. No. of Sheets...

  • Page 69: Further Information

    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 new.abb.com/contact-centers.
  • Page 70 3AXD50000481491B © Copyright 2025 ABB. All rights reserved. Specifications subject to change without notice.

Table of Contents