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 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633...
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.
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.
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 42).
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...
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...
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.
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.
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.
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Planning the installation 19 Example 1 NBRC Example 2 NBRC...
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.
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 · 1.25 · 690 V DC when supply voltage is 525…690 V AC Resistor resistance value (ohm) WARNING! Never use a brake resistor with a resistance value below the minimum allowed...
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.
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.
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.
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.
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 83). Drill the mounting holes. Make sure that dust and burr from drilling does not enter the module or other equipment at the installation site.
Mechanical installation 27 Examples: Installing the brake chopper module and related components Example: Installation into a Rittal VX25 enclosure ■ Layout drawing Brake chopper cubicle, side view Brake chopper cubicle, front view Brake chopper cubicle, right-top view DC fuses DC busbars Cooling fan and heat exchanger Attenuator Brake chopper module...
28 Mechanical installation Pipe routing example Coolant in Inlet manifold with stop and drain valves Heat exchanger and fan Brake module Attenuator Outlet manifold with stop and drain valves Coolant out...
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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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.
Mechanical installation 37 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.
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.
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40 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. •...
Electrical installation 41 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.
42 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.
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Electrical installation 43 • Drive supply voltage 525…690 V • Brake chopper control unit NBRC-61 • Ubr_on 1120 V, Ubr_off 1096 V 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 •...
44 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 -...
Electrical installation 45 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.
46 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).
Installation checklist 47 Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the brake chopper.
48 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.
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.
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50 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 WARNING! Before the power switch-on, make sure that there are inverters connected to the intermediate...
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.
52 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.
54 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)
Maintenance 55 Cooling system For instructions on coolant replacement and checking the cooling system, see chapter Internal cooling circuit (page 65). 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.
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 chopper cooling fan ■...
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Maintenance 57 Disconnect the fan wiring. Undo the two fastening screws (a). Pull the fan housing outwards. Install a new fan in reverse order.
60 Ordering information Brake chopper modules ACS880-604LC-… Ordering code Module type = 690 V (Range 525…690 V) 0400-7 0800-7 1200-7 64260049 NBRW-669C 1600-7 2000-7 2400-7 Brake chopper cooling Cooling fans ■ The cooling fan forces the air inside the cubicle through an air-to-liquid heat exchanger.
Nipples for connecting the valves to manifolds Connectors for PA piping Plugs for unused piping connectors Chokes for flow limitation – not used with the ACS880-604LC. You must order the following parts separately as they are not included in the manifold kits: •...
62 Ordering information Main pipe support kit ■ Used with … Ordering code Kit code Illustration Rittal VX25 en- L-468-X-450- 3AXD50001155179 closure Instruction code: 3AXD50001155353 Coolant piping and fittings ■ The chopper module and the heat exchanger are connected in series so that the flow direction is up, ie.
Ordering information 63 DC bus installation parts (for Rittal VX25 enclosures) The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat-PLS DC bus and ensure its correct placement and alignment inside the cabinet line-up.
64 Ordering information Brake resistors Each brake chopper module has two resistors of its own. ACS880-604LC-… Ordering code Type Ratings = 690 V (Range 525…690 V) 0400-7 0800-7 1200-7 SAFUR 3AXD50000323197 200 kW, R = 2.7 ohm 200F500/MK160 1600-7 2000-7...
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 •...
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66 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...
Internal cooling circuit 67 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.
68 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.
Internal cooling circuit 69 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.
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).
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72 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.
Technical data 73 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.
Technical data 75 Definitions ■ Example: ACS880-604LC-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.
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.
Altitude above sea level 0 … 2000 m (0 … 6561.7 ft) no derat- ing. For altitudes over 2000 m (6561.7 ft), contact ABB. Air temperature 0 … +55 °C -40 … +70 °C -40 … +70 °C (+32 … +131 °F), no con- (-40 …...
80 Technical data Operation installed for Storage in protective Transportation in pro- stationary use package tective package Contamination IEC/EN 60721-3-3:2002: IEC 60721-3-1:1997 IEC 60721-3-2:1997 Classification of environ- mental conditions - Part 3-3: Classification of groups of environmental parameters and their severities - Stationary use of weather protected locations...
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.
82 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 Brake chopper cooling fan 50/60 Nominal voltage Frequency Nominal current consumption Starting current consumption start UL marking...
Dimension drawings 83 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.
Example circuit diagrams 89 14. 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 •...
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.
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