ABB SACE 08 RE 44 Hardware Manual
ABB SACE 08 RE 44 Hardware Manual

ABB SACE 08 RE 44 Hardware Manual

Brake resistors

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SACE, SAFUR and JBR brake resistors
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Summary of Contents for ABB SACE 08 RE 44

  • Page 1 — ABB OPTIONS SACE, SAFUR and JBR brake resistors Hardware manual...
  • Page 3 SACE, SAFUR and JBR brake resistors Hardware manual Table of contents 3AXD50001283780 Rev A Original instructions EFFECTIVE: 2025-04-17...
  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter............... . . Safety messages.
  • Page 6 6 Table of contents JBR resistors..................Degree of protection, thermal constant and insulation resistance of the resistor.
  • Page 7: Safety Instructions

    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.
  • Page 8: Electrical Safety Precautions

    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.
  • Page 9: Operation Principle

    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.
  • Page 11: Planning The Braking System

    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: •...
  • Page 12: Selection Example

    • 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.
  • Page 13: Selecting A Custom Brake Resistor

    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 >...
  • Page 14: Maximum Cable Length

    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...
  • Page 15: Mechanical Installation

    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 •...
  • Page 16: Sace Type

    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...
  • Page 17: Safur Type

    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...
  • Page 18 300 [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.
  • Page 19: Jbr Type

    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]...
  • Page 20 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]...
  • Page 21: Electrical Installation

    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.
  • Page 22: Protecting The System In Brake Circuit Fault Situations

    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.
  • Page 23: Protecting The Brake Resistor Cable Against Short-Circuits

    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...
  • Page 24: Connection Procedure

    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.
  • Page 25: Start-Up

    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.
  • Page 27: Dimension Drawings

    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].
  • Page 28: Sace Resistors

    28 Dimension drawings SACE resistors Type L1 mm[in] L2 mm[in] H mm[in] Weight kg[lbs] SACE 08 RE 44 367.5 [14.47] 290 [11.42] 135 [5.32] 5.25 [11.6] SACE 15 RE 13 367.5 [14.47] 290 [11.42] 135 [5.32] 6.35 [14.0] SACE 15 RE 22 367.5 [14.47]...
  • Page 29 Dimension drawings 29 Type mm[in] mm[in] mm[in] mm[in] mm[in] mm[in] mm[in] mm[in] mm[in] mm[in] SACE 08 89.8 124.5 21 [0.83] 29 [1.14] 13 [0.51] 7 [0.28] 41 [1.61] RE 44 [10.31] [10.24] [13.78] [3.52] [4.90] SACE 15 89.8 124.5 21 [0.83] 29 [1.14] 13 [0.51] 7 [0.28]...
  • Page 30: Safur Resistors

    30 Dimension drawings SAFUR resistors Type L1 mm[in] L2 mm[in] H mm[in] Weight kg[lbs] SAFUR 80 F500 306.5 [12.07] 376.7 [14.83] 600 [23.62] 16.33 [35.99] SAFUR 90 F575 SAFUR 125 F500 305.5 [12.03] 366.4 [14.42] 1320 [51.97] 39.21 [86.44] SAFUR 200 F500...
  • Page 31 Dimension drawings 31 Type L1 mm[in] L2 mm[in] H mm[in] weight kg [lbs] SAFUR 80F500 306.5 [12.07] 376.7 [14.83] 600 [23.62] 16.33 [35.99] SAFUR 90F575 SAFUR 80F500 305.5 [12.03] 366.4 [14.42] 1320 [51.97] 39.21 [86.44] SAFUR 90F575...
  • Page 32: Jbr Resistors

    32 Dimension drawings JBR resistors Type L1 mm[in] L2 mm[in] H mm[in] Weight kg[lbs] CAR 155 DT 414 295 [11.61] 124 [4.88] 77 [3.03] 0.93 [2.05] 120R CAR 200 DT 415 80R 340 [13.39] 124 [4.88] 77 [3.03] 1.06 [2.34] CBR-V 210 DT 415 355 [13.98] 124 [4.88]...
  • Page 33 Dimension drawings 33 Type L1 mm[in] L2 mm[in] H mm[in] weight kg [lbs] CAR 155 DT 414 295 [11.61] 124 [4.88] 77 [3.03] 0.93 [2.05] 120R CAR 200 DT 415 340 [13.39] 366.4 [14.42] 1320 [51.97] 1.06 [2.34] CBR-V 210 DT 415 355 [13.98] 366.4 [14.42] 123 [4.84]...
  • Page 35: Technical Data

    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)
  • Page 36: Jbr Resistors

    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...
  • Page 37: Declarations Of Conformity

    Declarations of conformity 37 Declarations of conformity Link to EU Declaration of conformity (3AXD10002156065)
  • Page 39: Circuit Diagrams

    Circuit diagrams 39 Circuit diagrams SACE resistors -S1 Θ...
  • Page 40: Safur Resistors

    40 Circuit diagrams SAFUR resistors -R21 -R24 -R22 -R25 -Rn-1 -S1 Θ -R23 -R26 JBR resistors -S1 Θ...
  • Page 41: 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 42 3AXD50001283780A © Copyright 2025 ABB. All rights reserved. Specifications subject to change without notice.

This manual is also suitable for:

Sace 15 re 13Sace 15 re 22Safur 80f500Safur 90f575Safur 125f500Safur 200f575 ... Show all

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