Safety instructions 7 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the brake choppers and brake resistors. If you ignore the safety instructions, injury, death or damage can occur. Safety messages These safety messages help to prevent personal injury and damage to the equipment.
8 Safety instructions Electrical safety precautions These electrical safety precautions are for all persons who do work on the drive, motor cable or motor. WARNING Obey these instructions. 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 or maintenance work.
Operation principle 9 Operation principle The brake chopper handles the extra energy generated by motor during a quick deceleration. The extra energy increases the drive DC link voltage. The chopper connects the brake resistor to the DC link whenever the voltage is higher than the operation limit of the chopper.
The energy generated by the motor during one resistor heat dissipation period (400 s) must be equal to or smaller than the heat dissipation capacity ( E of the resistor assembly. If it is not, you cannot use the default ABB resistor assembly. These alternatives are possible: •...
• The sum energy generated by the motor during the resistor heat dissipation period is: 2.2 × 4500 kJ = 9900 kJ. This value is lower than the ABB default resistor assembly E value. Thus, the ABB default brake resistor can be used.
Planning the braking system 13 Selecting a custom brake resistor If you use a resistor other than the default brake resistor, make sure that the resistance of the custom brake resistor is greater or equal than the resistance of the brake default resistor in the rating table: R >...
The maximum length of the brake resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation ABB has not verified that the EMC requirements are fulfilled with external user-defined brake resistors and cabling. The EMC compliance of the complete installation must...
Mechanical installation 15 Mechanical installation Placing the brake resistors Install the brake resistors outside the drive in a place where they will cool. Arrange the cooling of the brake resistor in a way that: • no danger of overheating is caused to the brake resistor or nearby materials •...
16 Mechanical installation SACE type Free space ■ Type X mm[in] Y mm[in] Z mm[in] SACE 08 RE 44 SACE 15 RE 13 150 [5.9] 150 [5.9] 300 [11.8] SACE 15 RE 22...
Mechanical installation 17 SAFUR type Free space ■ Type X mm[in] Y mm[in] Z mm[in] SAFUR 80F500 40 [1.57] 40 [1.57] 300 [11.8] SAFUR 90F575...
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300 [11.8] SAFUR 200F575 NOTICE SAFUR braking resistors are specifically designed for integration within ABB ACS880-BRR cabinets and are not intended for standalone use. Active cooling is necessary to make sure that their operation and thermal management is correct. Within the ACS880-BRR solution, cooling is supplied by a W2E250-HL06-21 fan, which delivers an airflow of 1275 m /h at 90 Pa.
Mechanical installation 19 JBR type Free space ■ Type X mm[in] Y mm[in] Z mm[in] CAR 155 DT 414 120R 200 [7.8] 200 [7.8] 200 [7.8] CAR 200 DT 415 80R 200 [7.8] 200 [7.8] 200 [7.8]...
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20 Mechanical installation Type X mm[in] Y mm[in] Z mm[in] CBR-V 210 DT 415 40R 200 [7.8] 200 [7.8] 200 [7.8]...
Electrical installation 21 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.
The drive has a brake thermal model which protects the brake resistor against overload. ABB recommends to enable the thermal model at start up. ABB recommends to equip the drive with a main contactor for safety reasons even when you have enabled the resistor thermal model. Wire the contactor so that it opens in case the resistor overheats.
Electrical installation 23 ABB recommends that you also wire the thermal switch to a digital input of the drive, and configure the input to cause a fault trip at resistor overtemperature indication. Θ +24V Drive input power connection with a main contactor...
24 Electrical installation Connection procedure Connect the resistor cables to the R+ and R- terminals of the drive. If a shielded three-conductor cable is used, cut the third conductor and ground the twisted shield of the cable (protective earth conductorof the resistor assembly) at both ends. Wire the thermal switch to a digital input on the drive control unit.
Start-up 25 Start-up WARNING Make sure that there is sufficient ventilation. New brake resistors can have a protective grease coating. When the resistor warms up for the first time, the grease burns off and can cause some smoke. For brake resistor related parameter settings, refer to the drive hardware and firmware manuals.
Dimension drawings 27 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of SACE, SAFUR and JBR brake resistors. Note: The dimensions are given in millimeters and [inches].
Technical data SACE resistors Type Terminal peak Rcont connection (kW) (kW) (ohm) (kJ) SACE 08 RE 44 max. 6 mm SACE 15 RE 22 cable length max. 10 m SACE 15 RE 13 SAFUR resistors Type peak Rcont (kW) (kW)
36 Technical data JBR resistors Resistor Pulse load (W) Temperature 40 °C, cycle 120 s Manufacturer type duty duty duty duty Rcont type (°C) (ohm) 10 s 40 s JBR-01 CAR 155 DT 414 R120 3750 1170 JBR-03 CAR 200 D T 415 7420 1910 1230...
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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