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Summary of Contents for ABB ACS880-607
- Page 1 — ABB INDUSTRIAL DRIVES ACS880-607 1-phase brake units Hardware manual...
- Page 3 ACS880-607 1-phase brake units Hardware manual Table of contents 3. Mechanical installation 5. Electrical installation 7. Start-up 3AUA0000102559 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............... . . Applicability. - Page 6 6 Table of contents Selecting the installation location for the brake resistors......Selecting the resistor thermal switch circuit cable........Protecting the system against thermal overload.
- Page 7 Table of contents 7 Terminal and lead-through data for the resistor cable for brake units with user-defined brake resistors..............Resistor cable sizes.
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Page 9: Introduction To The Manual
Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to ACS880-607 1-phase brake units that form a part of an 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 ACS880-607 is an air-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 with the door open and the shrouds removed. DC fuses Brake chopper module Attenuator Brake chopper cooling fan... -
Page 14: Brake Resistor Cubicle
14 Operation principle and hardware description Brake resistor cubicle ￭ The figure below shows the components of the brake resistor cubicle with the door open and the shrouds removed. Brake resistor Brake resistor cooling fan... -
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+ t ° Brake chopper cubicle Brake chopper module Brake chopper control board (NBRC) Brake resistor cubicle Brake resistors X1, X2... -
Page 17: Master-Follower Connection
Operation principle and hardware description 17 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 18: Brake Chopper Module Type Designation Label
18 Operation principle and hardware description 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 19: Mechanical Installation
Mechanical installation 19 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 multidrive cabinets mechanical installation instructions (3AUA0000101764 [English]). -
Page 21: Planning The Electrical 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 22: Brake Units With User-Defined Brake Resistors
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 23: Selecting The Installation Location For The Brake Resistors
Planning the electrical installation 23 • Shield the brake resistor cable. Use shielded cable or a metallic enclosure. If you use unshielded single-core cables, route them inside a cabinet that efficiently suppresses the radiated emissions. • Install the cables away from other cable routes. •... -
Page 24: Protecting The System Against Short-Circuits
24 Planning the electrical installation Protecting the system against short-circuits The brake unit is equipped with fuses as standard. The fuses protect the brake chopper, the brake resistor and the brake circuit cables in a short-circuit situation. -
Page 25: Electrical Installation
Electrical installation 25 Electrical installation Contents of this chapter This chapter describes the electrical installation of the brake unit. Obey the instructions with: • 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 26 26 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. •...
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Page 27: Measuring The Insulation Resistance Of The Brake Resistor Circuit
Electrical installation 27 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 28: Selecting The Voltage
28 Electrical installation 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. NBRA-658 and NBRA-659 brake choppers have an NBRC-51 brake chopper control unit, and can be used with 400 or 500 V drive nominal supply. -
Page 29: Connecting The Brake Resistor Cables And Thermal Switch
Electrical installation 29 Note: If you have parallel choppers which are synchronized through the fiber optic link (master-follower connection): • select the voltage in the master chopper only • set the voltage jumper to FIBER in the follower choppers. WARNING! An incorrect jumper setting or missing jumper can cause brake chopper malfunctioning or damage to the chopper or resistor. - Page 30 30 Electrical installation Connect the power cables of parallel brake resistors as shown below. Note: The cable between the chopper and the first resistor must be able to carry the entire braking power. Provide adequate support for the cables below the chopper and resistor units.
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Page 31: Use Of Fasteners In Cable Lug Connections
Electrical installation 31 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 33: Installation Checklist
Installation checklist 33 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 34 34 Installation checklist Make sure that … The cooling air can flow freely in and out of the drive. 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.
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Page 35: 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 36 36 Start-up Tasks Start-up the inverter units. See the procedure in the inverter unit hardware manual. Deactivate the overvoltage controllers of all inverter units (parameter 30.30 Overvoltage control in the primary control program). Operational tests Make sure that the stop mode of the motor to be decelerated is ramp stop (parameter 21.03 Stop mode in the primary control program) and set the deceleration time according to the drive control mode in parameter group 23, 26 or 28.
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Page 37: 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 38: Nred Voltage Reducer Selection For Nbra-669
38 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 39: 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 40: Cleaning The Interior Of The Cabinet
• The maintenance and component replacement intervals are based on the assumption that the equipment operates within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long-term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components. -
Page 41: Technical Data
Technical data 41 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. -
Page 42: Ratings
Duty cycle Duty cycle (1 min / 5 (10 s / 60 s) brmax cont min) ACS880-607-… Module type = 400 V (Range 380…415 V) 0320-3 NBRA-659 1.20 0640-3 2×NBRA-659 0.60... -
Page 43: Brake Chopper With Factory-Installed Brake Resistors (Option +D151)
Technical data 43 Brake chopper with factory-installed brake resistors (option +D151) ￭ ACS880- Module Resistors Duty cycle Duty cycle brmax brcont 607-… type (1 min / 5 (10 s / 60 s) min) Type = 400 V (Range 380…415 V) 0320-3 NBRA-659 2 ×... -
Page 44: Definitions
44 Technical data Definitions ￭ Example: ACS880-607-0640-3 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 45: Dc Fuses
Technical data 45 DC fuses ACS880-607-… Fuse type = 400 V (Range 380…415 V) 0320-3 170M5146 1250 0640-3 170M5146 1250 0960-3 170M5146 1250 1280-3 170M5146 1250 1600-3 170M5146 1250 1920-3 170M5146 1250 = 500 V (Range 380…500 V) 0400-5 170M5146... -
Page 46: Brake Chopper With Factory-Installed Brake Resistors (Option +D151)
46 Technical data ACS880-607-… Height Width Depth Weight 2000-5 2130 83.86 2000 78.74 23.62 1210 2400-5 2130 83.86 2400 94.49 23.62 1452 = 690 V 0400-7 2130 83.86 15.75 23.62 0800-7 2130 83.86 31.50 23.62 1200-7 2130 83.86 1200 47.24 23.62... -
Page 47: Losses, Cooling Data And Noise
> 400 mm (15.75 in.) 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) ACS880-607 Module type Air flow Noise Air flow Noise... -
Page 48: Typical Power Cable Sizes
48 Technical data 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. A correction factor K = 0.70 is used. Time const. -
Page 49: User-Defined Brake Resistors
Technical data 49 Terminal and lead-through data for the resistor cable for brake units with user-defined brake resistors ACS880-607-… R+, R-, grounding terminals Number of Hole diameter Screw Tightening torque holes N·m = 400 V (Range 380…415 V) 0320-3 0640-3 2×M10... -
Page 50: Maximum Cable Length
50 Technical data ACS880-607-… Resistor cable (Cu)* Multicore 1280-3 4×(3×95+50) 1600-3 5×(3×95+50) 1920-3 6×(3×95+50) = 500 V (Range 380…500 V) 0400-5 3×95+50 0800-5 2×(3×95+50) 1200-5 3×(3×95+50) 1600-5 4×(3×95+50) 2000-5 5×(3×95+50) 2400-5 6×(3×95+50) = 690 V (Range 525…690 V) 0400-7 3×95+50 0800-7 2×(3×95+50) -
Page 51: Protection Classes
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 … +40 °C -40 … +70 °C -40 …... -
Page 52: Colors
52 Technical data 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 (3S1 with IP20). - Page 53 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 54 54 Example circuit diagrams...
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Page 55: 11. Example Circuit Diagrams
Example circuit diagrams 55 11. 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 56: Brake Unit With One Brake Chopper Module
56 Example circuit diagrams Brake unit with one brake chopper module... -
Page 57: Brake Unit With Two Brake Chopper Modules - Master
Example circuit diagrams 57 Brake unit with two brake chopper modules – Master... -
Page 58: Brake Unit With Two Brake Chopper Modules - Follower
58 Example circuit diagrams Brake unit with two brake chopper modules – Follower... -
Page 59: 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 60 3AUA0000102559C © Copyright 2025 ABB. All rights reserved. Specifications subject to change without notice.
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