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Related Manuals for ABB ACS880-604
Summary of Contents for ABB ACS880-604
- Page 1 — ABB INDUSTRIAL DRIVES ACS880-604 1-phase brake units as modules Hardware manual...
- Page 3 ACS880-604 1-phase brake units as modules Hardware manual Table of contents 4. Mechanical installation 5. Electrical installation 7. Start-up 3AUA0000106244 Rev C Original instructions EFFECTIVE: 2025-04-08...
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Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter............... . . Safety instructions. - Page 6 6 Table of contents Tools....................Installing the brake chopper module.
- Page 7 Table of contents 7 Brake chopper modules................Brake chopper cooling fan.
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Page 9: Introduction To The Manual
Introduction to the manual 9 Introduction to the manual Contents of this chapter This chapter introduces this manual. Safety instructions Obey all safety instructions of the drive. • Read the complete safety instructions before you install, commission, use or service the drive. The complete safety instructions are given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). -
Page 10: Related Documents
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. ACS880 multidrive modules link list You can find all documentation related to the multidrive modules on the Internet at https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content. -
Page 11: Operation Principle And Hardware Description
This chapter introduces the operation principle and construction of the brake unit. Product overview The ACS880-604 is an air-cooled resistor brake unit available in the ACS880 multidrive modules product range. The design presented in this manual has a NBRA-658C, NBRA-659C or NBRA-669C brake chopper module with two brake resistors. The chopper module cubicle has an inlet and an outlet for cooling air, and a fan blows the air through the module. -
Page 12: Chopper Voltage Selection
12 Operation principle and hardware description Chopper voltage selection The brake chopper starts operating when the drive DC link voltage exceeds the "on" limit (Ubr_on). The brake chopper stops operating when voltage goes below the "off" limit (Ubr_off). Voltage limits depend on the position of voltage selection jumper. Refer to Selecting the voltage (page 36). -
Page 13: Layout
Operation principle and hardware description 13 Layout 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 Enable input terminal block... -
Page 14: Overview Of Power And Control Connections
14 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. NBRC t° UDC- UDC+ t° – X1, X2 Chopper enable inputs Fault indication relay output. Fiber optic cable connection: Chopper control signal to another chopper (Transmitter) Fiber optic cable connection: Chopper control signal from another chopper (Receiver) Controlling the brake chopper from an external control location... -
Page 15: Master-Follower Connection
Operation principle and hardware description 15 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. -
Page 17: Planning The Installation
Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. 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. -
Page 18: Equipping The Drive With A Main Contactor And Manual Control Switch Or Switches
18 Planning the installation Equipping the drive with a main contactor and manual control switch or switches 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. - Page 19 Planning the installation 19 Example 1 NBRC Example 2 NBRC...
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Page 20: Selecting The Brake Circuit Components
Calculate the term on the left. The result is the maximum resistance limit. Resistor heat dissipation capacity ￭ Make sure that the resistor heat dissipation capacity ER is high enough for the braking cycle that you have. Refer to step 3 above for the ABB default resistor and the default braking cycle. -
Page 21: Calculating The Maximum Braking Power
Planning the installation 21 Resistor power consumption when connected to the drive DC link Maximum power generated by the motor during braking Voltage over the resistor during braking: 1.35 · 1.20 · 415 V DC when supply voltage is 380…415 V AC 1.35 ·... -
Page 22: Example 2
22 Planning the installation Example 2 The duration of a braking cycle is three minutes. The braking time is 40 seconds. brmax 600 s T = Duration of braking cycle Result: The maximum allowed braking power for the cycle is 62% of the rated value given for the reference cycle. -
Page 23: Selecting And Routing Brake Chopper Cable
Planning the installation 23 Selecting and routing brake chopper cable • Select a cable that is compliant with the ABB brake chopper cable specification. Refer to technical data. • Make sure that you install the brake chopper module inside the same cabinet line-up with the drive, and route the cabling inside the cabinet. -
Page 24: Selecting The Chopper Enable Input Cable
24 Planning the installation WARNING! The materials near the brake resistor must be non-flammable. The surface temperature of the resistor is high. Airflow from the resistor can have a high temperature. If the exhaust vents connect to a ventilation system, make sure that the material withstands high temperatures. -
Page 25: Mechanical Installation
Mechanical installation 25 Mechanical installation Contents of this chapter This chapter contains installation instructions and examples. Examining the installation site The brake chopper module must be installed in upright position. The degree of protection of the module is IP00. Take this into account when selecting the installation site. -
Page 26: Installing The Brake Chopper Module
26 Mechanical installation Installing the brake chopper module Mark the locations of the four holes onto the installation surface. For the module dimensions, see Dimension drawings (page 69). Drill the mounting holes. Make sure that dust and burr from drilling does not enter the module or other equipment at the installation site. -
Page 27: Examples: Installing The Brake Chopper Module And Related Components
Air flow out. Use a roof with an air outlet. DC fuses Attenuator Brake chopper module Cooling fan Cooling fan mounting plate Plastic bars on both sides to block air flow 1) Illustration available at ABB engineering support site. Contact ABB for access. -
Page 28: Example 2: Installation Into A Generic Enclosure
28 Mechanical installation Example 2: Installation into a generic enclosure ￭ Note: To ensure proper cooling, the brake chopper module and the cooling fan must be positioned exactly as illustrated in relation to each other. The components in the generic enclosure should be installed in similar locations as in example Attach the brake chopper module to the installation surface of the enclosure. -
Page 29: Examples: Installing The Brake Resistors And Cooling Fan
Cooling fan mounting plate Cooling fans Steel air guides on both sides of the mounting plate 1) Illustration available at ABB engineering support site (3AXD50000472338). Contact ABB for access. 2) Illustration available at ABB engineering support site (3AXD50000472628). Contact ABB for access. - Page 30 Cooling fan mounting plate Cooling fans Steel air guides on both sides of the mounting plate 1) Illustration available at ABB engineering support site (3AXD50000472338). Contact ABB for access. 2) Illustration available at ABB engineering support site (3AXD50000472628). Contact ABB for access.
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Page 31: Example 2: Installation Into A Generic Enclosure
Mechanical installation 31 Example 2: Installation into a generic enclosure ￭ Note: To ensure proper cooling, the brake resistor and the cooling fan must be positioned in relation to each other. Make sure that the cooling air flows through the resistors and cools them down. -
Page 33: Electrical Installation
Safety and liability The installation must always be designed and made according to applicable local laws and regulations. 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 system may experience problems that the warranty does not cover. - Page 34 34 Electrical installation • Make sure that you have a work order. • Do an on-site risk assessment or job hazard analysis. • Make sure that you have the correct tools available. • Make sure that the workers are qualified. •...
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Page 35: Measuring The Insulation Of The Resistor Circuit
Electrical installation 35 Install temporary grounding as required by the local regulations. Ask for a permit to work from the person that is responsible for the electrical installation work. Measuring the insulation of the resistor circuit WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. -
Page 36: General Notes
36 Electrical installation General notes Printed circuit boards ￭ WARNING! Use an antistatic wrist strap when you handle printed circuit boards. Do not touch the boards unnecessarily. The boards are sensitive to electrostatic discharge. Handling fiber optic cables ￭ WARNING! Obey these instructions. - Page 37 Electrical installation 37 • Drive supply voltage 380…415 V • Brake chopper control unit NBRC-51 • Ubr_on 674 V, Ubr_off 660 V • Drive supply voltage 440…500 V • Brake chopper control unit NBRC-51 • Ubr_on 811 V, Ubr_off 795 V •...
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Page 38: Connecting The Dc And Resistor Cables
38 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 ￭ Brake chopper module and resistors in separate Brake chopper module and resistor in the same cubicles cubicle UDC+ UDC -... -
Page 39: Connection Procedure
Electrical installation 39 Connection procedure ￭ If the drive DC link and the brake unit are located in separate cabinets, ground the DC cable 360 degrees at the cabinet entries. 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. -
Page 40: Connecting The Brake Resistor Thermal Switch
40 Electrical installation Chopper Resistor Resistor R– R– R– Connecting the brake resistor thermal switch Connect the thermal switches of the resistors in series and to chopper enable input X1 as shown in section Overview of power and control connections (page 14). -
Page 41: Installation Checklist
Installation checklist 41 Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the brake chopper. -
Page 42: Checklist
42 Installation checklist Checklist Check the mechanical and electrical installation of the brake chopper before start-up. Go over the checklist together with another person. 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 installation, commissioning, or maintenance work. -
Page 43: 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 44 44 Start-up Tasks Make sure that all cabinet doors are closed. Close the disconnector of the supply transformer. Start the supply unit. See the procedure in the supply unit hardware manual. When started, the supply unit charges the capacitors of all inverters and brake units connected to the DC bus.
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Page 45: 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 46: Nred Voltage Reducer Selection For Nbra-669
46 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 47: Maintenance
Maintenance 47 Maintenance Contents of this chapter This chapter describes the maintenance of a brake unit. -
Page 48: Maintenance Intervals
48 Maintenance 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). Description of symbols ￭ Action Description Inspection (visual inspection and maintenance action if needed) -
Page 49: Cabinet
Maintenance 49 Cabinet Cleaning the interior of the cabinet ￭ 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 50: Cooling Fans
The life span of the cooling fan depends on the running time of the fan, ambient temperature and dust concentration. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the resistor cooling fan ￭... -
Page 51: Ordering Information
Ordering information 51 Ordering information Contents of this chapter This chapter lists the components and accessories available for the brake unit. -
Page 52: Brake Chopper Modules
52 Ordering information Brake chopper modules ACS880-604-… Ordering code Module type = 400 V (Range 380…415 V) 0210-3 59006428 NBRA-658C 0320-3 0640-3 0960-3 59006436 NBRA-659C 1280-3 1600-3 1920-3 = 500 V (Range 380…500 V) 0260-5 59006428 NBRA-658C 0400-5 0800-5 1200-5... -
Page 53: Fuses And Fuse Bases
Ordering information 53 Fuses and fuse bases Each brake chopper module is connected to the DC bus of the drive system through fuses. The table also shows a suitable fuse base. A fuse with the same ratings from another manufacturer can be used if it meets the ratings, and its melting curve does not exceed that of the fuse listed here. -
Page 54: Brake Resistors
54 Ordering information Brake resistors Each brake chopper module has two resistors of its own. ACS880-604-… Ordering code Type Data = 400 V (Range 380…415 V) SAFUR 0210-3 3AXD50000420384 575 V, 210 kW, R = 3.4 ohm 210F575/K160 0320-3 0640-3... -
Page 55: Attenuator
Ordering information 55 Attenuator The attenuator suppresses voltage spikes at the chopper input. The attenuator is otherwise optional, but must be fitted if all inverter units have a DC switch. Brake unit Ordering code Data All types 1 per chopper module 64019236 NRCB-010006... -
Page 57: Technical Data
Technical data 57 Technical data Contents of this chapter This chapter contains the technical specifications of the brake units, 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. - Page 58 58 Technical data Duty cycle Duty cycle (1 min / 5 (10 s / 60 s) ACS880- brmax cont min) Module type 604-… = 500 V (Range 380…500 V) 0260-5 NBRA-658C 2.15 0400-5 NBRA-659C 1.43 0800-5 2 × NBRA- 0.72 1142 659C 1200-5...
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Page 59: Chopper With Standard Resistors
Technical data 59 Chopper with standard resistors ￭ ACS880- Module Resistor type Duty cycle Duty cycle brmax brcont 604-… type (1 min / 5 (10 s / 60 s) min) = 400 V (Range 380…415 V) 0210-3 NBRA- 2 × SAFUR 2×21 658C 210F575/K160... -
Page 60: Definitions
60 Technical data Definitions ￭ Example: ACS880-604-0640-3 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 61: Dc Fuses
150 mm (5.91 in.) free space is required below and above the brake chopper module. Losses, cooling data and noise The heat loss of brake chopper is one percent of the braking power. With specified resistors (op- Brake chopper module only tion +D151) ACS880-604 Module type Air flow Air flow Noise Noise... - Page 62 3 × NBRA-669C 1980 1166 7500 4410 4 × NBRA- 1600-7 2640 1554 10000 5890 669C 2000-7 5 × NBRA-669C 3300 1943 12500 7360 2400-7 6 × NBRA-669C 3960 2331 15000 8830 1) Measured in a typical ABB (ACS880-607) cabinet installation.
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Page 63: Brake Circuit Cable Sizes
This table gives the typical size for copper cables with PVC (70 °C) or XLPE (90 °C) insulation. With the ABB SAFUR resistors, use only resistor cables that have min. 90 °C cable conductor temperature rating. Make sure that the cable voltage rating is higher than the brake chopper operating voltage. -
Page 64: Maximum Cable Length Of The Resistor Cable
64 Technical data Maximum cable length of the resistor cable ￭ The maximum cable length of the resistor cable or cables is 50 m (164 ft). Note: In order for the installation to comply with the EMC Directive, unshielded single-core cable can only be used if it is routed inside a cabinet that efficiently suppresses radiated emissions. -
Page 65: Brake Chopper Terminal Data
Technical data 65 Brake chopper terminal data UDC+, UDC-, R+, R- Grounding clamps Module type Tightening torque Tightening torque Hole diameter Max. wire size Screw N·m lbf·ft N·m lbf·ft NBRA-658C NBRA-659C NBRA-669C Brake resistor terminal data R+, R- and grounding terminals Resistor type Tightening torque Hole diameter... -
Page 66: Materials
66 Technical data Operation installed for Storage in protective Transportation in pro- stationary use package tective package Air temperature 0 … +45 °C -40 … +70 °C -40 … +70 °C (+32 … +113 °F), no con- (-40 … +158 °F) (-40 …... -
Page 67: Packaging Of Brake Unit
Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located. -
Page 68: Auxiliary Circuit Current Consumption
68 Technical data Auxiliary circuit current consumption start Cooling fan type V AC Brake resistor cooling fan 50/60 2.25 Brake resistor cooling fan 50/60 Brake chopper cooling fan 50/60 0.65 Brake chopper cooling fan 0.85 Nominal voltage Frequency Nominal current consumption Starting current consumption start UL marking... -
Page 69: Dimension Drawings
Dimension drawings 69 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. -
Page 70: Brake Chopper Modules Nbra-658, Nbra-659, Nbra-669
70 Dimension drawings Brake chopper modules NBRA-658, NBRA-659, NBRA-669... -
Page 71: Brake Chopper Cooling Fan 230 V 50/60 Hz
Dimension drawings 71 Brake chopper cooling fan 230 V 50/60 Hz... -
Page 72: Attenuator
72 Dimension drawings Attenuator... -
Page 73: Brake Resistor
Dimension drawings 73 Brake resistor R+ R- Ø... -
Page 74: Brake Resistor Cooling Fan
R+ R- Ø 74 Dimension drawings Brake resistor cooling fan D4E225-CC01-39 Brake resistor cooling fan... -
Page 75: 13. Example Circuit Diagrams
Example circuit diagrams 75 13. Example circuit diagrams Contents of this chapter This chapter contains example circuit diagrams of a brake unit. The purpose of these diagrams is to help in: • understanding the internal connections and operation of a brake unit, and •... -
Page 76: Brake Unit With Two Chopper Modules - Sheet 001A
76 Example circuit diagrams Brake unit with two chopper modules - Sheet 001a... -
Page 77: Brake Unit With Two Chopper Modules - Sheet 005A
Example circuit diagrams 77 Brake unit with two chopper modules - Sheet 005a... -
Page 78: Brake Unit With Two Chopper Modules - Sheet 026A
78 Example circuit diagrams Brake unit with two chopper modules - Sheet 026a... -
Page 79: Brake Unit With Two Chopper Modules - Sheet 026B
Example circuit diagrams 79 Brake unit with two chopper modules - Sheet 026b... - Page 80 80 Example circuit diagrams...
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Page 81: 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 82 3AUA0000106244C © Copyright 2025 ABB. All rights reserved. Specifications subject to change without notice.
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