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ABB ACS880-604LC Manuals
Manuals and User Guides for ABB ACS880-604LC. We have
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ABB ACS880-604LC manuals available for free PDF download: Hardware Manual
ABB ACS880-604LC Hardware Manual (194 pages)
3-phase dynamic brake units as modules
Brand:
ABB
| Category:
DC Drives
| Size: 57 MB
Table of Contents
Table of Contents
5
Introduction to the Manual
13
Contents of this Chapter
13
Applicability
13
Safety Instructions
13
Target Audience
13
Categorization by Frame Size and Option Code
14
Use of Component Designations
14
Related Documents
14
Terms and Abbreviations
14
Operation Principle and Hardware Description
17
Contents of this Chapter
17
Product Overview
17
Operation Principle
17
When Is Resistor Braking Necessary
17
Overview Diagram of the Drive System
18
Cooling System
19
Brake Module Hardware
19
General
19
DC Connection and Capacitor Charging
19
Frame R8I Hardware
20
Module Layout
20
Coolant Connectors
20
Connectors X50
21
Fibre Optic Connectors
22
Leds
22
Overview Circuit Diagram of the Brake Unit
23
Brake Unit Control Devices
24
Overview of the Control Connections of the UCU Control Unit
24
Overview of the Control Connections of the BCU Control Unit
25
The Control Panel
25
Control by PC Tools
26
Fieldbus Control
26
DC Switch and Charging Switch
26
Type Designation Label
27
Type Designation Key
28
Moving and Unpacking the Module
29
Contents of this Chapter
29
Cabinet Construction
31
Contents of this Chapter
31
Limitation of Liability
31
North America
31
Liquid Pipe Connector Installation Instructions
31
Pipe Connector Types
32
Type a Pipe Connector
32
Type B Pipe Connector
34
Type C Pipe Connector
35
General
36
Installation of the Brake Control Unit
36
Cabinet Configuration Overview
37
Installation Examples
37
R8I Module in a 600 MM Wide Rittal VX25 Enclosure
38
Layout Without DC Switch-Disconnector
38
Layout with DC Switch-Disconnector
39
Pipe Routing Example
40
Installation Stages
41
Overview of Kits
42
Stage 1: Installation of Common Parts
43
Stage 2: Installation of Side Plates, Module Mounting Mechanics and Quick Connector
44
Stage 3: Installation of Output Terminals (for Cabling) and Cable Entries
45
Stage 4A: Installation of DC Busbars (Without DC Switch-Disconnector or Charging)
46
Stage 4B: Installation of DC Busbars (with DC Switch-Disconnector and Charging)
47
Stage 5: Installation of Incoming Resistor Connection Busbars
48
Stage 6: Installation of Cooling Components
49
Stage 7: Installation of Module
50
Stage 8: Installation of Swing-Out Frame and Shrouds
51
Generic Enclosures
52
Guidelines for Planning the Electrical Installation
53
Contents of this Chapter
53
Limitation of Liability
53
North America
53
Generic Guidelines
53
Selecting the Brake Resistor
54
Selecting and Routing the Brake Resistor Cables
54
Minimizing Electromagnetic Interference
54
Selecting the Installation Location for the Brake Resistors
55
Selecting the Resistor Thermal Switch Cable
55
Protecting the System against Thermal Overload
55
Protecting the System against Short-Circuits
55
Electrical Installation
57
Contents of this Chapter
57
Safety and Liability
57
Electrical Safety Precautions
57
General Notes
59
Printed Circuit Boards
59
Handling Fiber Optic Cables
59
Measuring the Insulation Resistance of the Brake Resistor Circuit
59
Connecting the Brake Resistor Cables and Thermal Switch
61
Connection Diagram
61
Connection Procedure of the Components Inside the Brake Chopper Module Cubicle
62
Connection Procedure of the Resistor Cables
62
Connection Procedure of the Thermal Switch Cable
63
Connecting the Control Cables
63
Installing Option Modules
65
Connecting a PC
67
Control Unit (UCU) 69
69
Contents of this Chapter
69
General
69
Layout
69
Default I/O Diagram of the Brake Control Unit
73
Additional Information on the Connections
75
Power Supply for the Control Unit (XPOW)
75
Digital Interlock (DIIL)
76
Safe Torque off (XSTO, XSTO OUT)
76
Microsdhc Memory Card Slot
76
Connector Data
77
Ground Isolation Diagram
79
Control Unit (BCU) 81
81
Contents of this Chapter
81
General
81
Layout
82
Default I/O Diagram of the Brake Control Unit
84
Additional Information on the Connections
85
Power Supply for the Control Unit (XPOW)
85
Digital Interlock (DIIL)
86
Safe Torque off (XSTO, XSTO OUT)
86
Microsdhc Memory Card Slot
86
Connector Data
87
BCU Ground Isolation Diagram
89
Installation Checklist
91
Contents of this Chapter
91
Checklist
91
Start-Up
95
Contents of this Chapter
95
Start-Up Procedure
96
Maintenance
99
Contents of this Chapter
99
Maintenance Intervals
100
Description of Symbols
100
Recommended Maintenance Intervals after Start-Up
100
Cooling System
101
Power Connections
101
Retightening the Power Connections
101
Cooling Fans
102
Replacing Cooling Fans
102
Fan Replacement
102
Brake Module
103
Replacing the Brake Module
103
Removing the Module
103
Installing the Module
106
Control Unit
107
UCU Control Unit
107
Replacing the Memory Unit of the UCU Control Unit
107
Replacing the UCU Control Unit Battery
108
BCU Control Unit
108
Replacing the Memory Unit of BCU Control Unit
108
Replacing the BCU Control Unit Battery
109
Capacitors
110
Reforming the Capacitors
110
LED Indications
111
Control Panel and Panel Platform/Holder Leds
111
R8I Module Leds
111
Functional Safety Components
111
Ordering Information
113
Contents of this Chapter
113
Kit Code Key
113
Brake Chopper Modules
115
Control Panel
116
Control Electronics
117
Control Unit (UCU)
117
Control Unit (BCU)
118
Fiber Optic Cables
119
Mechanical Installation Accessories
119
Side Plate Kit
119
Module Top/Bottom Guides
120
Swing-Out Frame
120
Shrouds
121
Lifting Device
122
DC-Side Components
122
Common DC Flat-PLS Assembly
122
DC Connection Flanges and Busbars
123
DC Fuses
125
DC Fuses (IEC)
125
DC Fuses (UL)
125
DC Switch-Disconnector Kits
125
DC Charging Kits (for Units with DC Switch-Disconnector)
126
Charging Resistors (for Units with DC Switch-Disconnector)
126
Components at the Brake Resistor Side
126
Quick Connector
126
Outgoing Brake Resistor Connection Busbars
127
Brake Resistor Fuses
127
Cable Entry Kit
128
Cooling System Parts
128
Coolant Distribution Manifold Kits
128
Piping
130
Heat Exchanger
130
Main Pipe Support Kit
131
Cooling Fan
131
Miscellaneous
131
I/O Module
131
Internal Cooling Circuit
133
Contents of this Chapter
133
Applicability
133
Internal Cooling System
133
Connection to a Cooling Unit
135
Connection to an ACS880-1007LC Cooling Unit
135
Connection to a Custom Cooling Unit
135
General Requirements
135
Coolant Temperature Control
135
Filling up and Bleeding the Internal Cooling Circuit
136
Drive Line-Ups with an ACS880-1007LC Cooling Unit
136
Drive Line-Ups with a Custom Cooling Unit
136
Draining the Internal Cooling Circuit
137
Maintenance Intervals
137
Technical Data
138
Coolant Specification
138
Coolant Type
138
Temperature Limits
138
Pressure Limits
140
Coolant Flow Rate Limits
140
Cooling Circuit Materials
140
Technical Data
141
Contents of this Chapter
141
Ratings
141
Definitions
142
Derating
143
Surrounding Air Temperature Derating
143
Coolant Temperature Derating
143
Antifreeze Content Derating
143
Altitude Derating
144
Modules Used, Noise, DC Capacitance
144
Fuses
144
Dimensions and Weights
144
Free Space Requirements
145
Installation Orientations
145
Losses, Cooling Circuit Data and Efficiency
145
Energy Efficiency Data (Ecodesign)
145
Typical Power Cable Sizes
146
Input Power (DC) Connection
147
Resistor Connection
147
Control Connections
147
Coolant Connections
147
Auxiliary Power Consumption
147
Control Equipment
147
Cooling Fans
148
Definitions
148
Protection Classes
148
Ambient Conditions
148
Materials
149
Color
149
Package
149
Disposal
150
Standards
150
Markings
150
Tightening Torques
151
Electrical Connections
151
Mechanical Connections
151
Insulation Supports
151
Cable Lugs
151
Disclaimers
151
Generic Disclaimer
151
Cyber Security Disclaimer
152
Dimension Drawings
153
Contents of this Chapter
153
Brake Chopper Module
154
Quick Connector
155
Control Electronics
156
UCU Control Unit
156
BCU Control Unit
157
DPMP-01 Control Panel Mounting Platform
158
DPMP-02 Control Panel Mounting Platform
159
DC Fuse Blocks (Bussmann)
160
Size 3
160
Size 23
160
Switchgear and Charging Components
161
DC Switch-Disconnector
161
Ot1200U11, Ot1600E11
161
Charging Switch
162
Os100Gj04Fp
162
Os160Gd04F
163
Switch Handles
163
Ohb65J6
163
Ohb150J12P
164
Auxiliary Contacts
164
Oa1G10
164
Oa3G01
164
Charging Resistor
165
BSFC-12C Charging Controller
166
CIO-01 I/O Module
167
Example Circuit Diagrams
169
Contents of this Chapter
169
Component Designations Used in the Diagrams
169
Frame 2×R8I - Main Circuit (Sheet 001A)
170
Frame 2×R8I - Main Circuit (Sheet 001B)
171
Frame 2×R8I - Charging Circuit (Sheet 002A)
172
Frame 2×R8I - Charging Circuit (Sheet 002B)
173
Frame 2×R8I - Module Control Circuit (Sheet 005A)
174
Frame 2×R8I - Auxiliary Voltage Supply (Sheet 020A)
175
Frame 2×R8I - Auxiliary Voltage Supply (Sheet 020B)
176
Frame 2×R8I - 230/115 V Distribution (Sheet 021A)
177
Frame 2×R8I - (230/115 V Distribution (Sheet 021B)
178
Frame 2×R8I - 24 V Distribution (Sheet 022A)
179
Frame 2×R8I - 24 V Distribution (Sheet 022B)
180
Frame 2×R8I - Fan Control (Sheet 026A)
181
Frame 2×R8I - Control Unit 1 / RO (Sheet 040A)
182
Frame 2×R8I - Control Unit 1 / DI (Sheet 040B)
183
Frame 2×R8I - Control Unit 1 / AI, AO, DIO (Sheet 040C)
184
Frame 2×R8I - Control Unit 1 (Sheet 040D)
185
Frame 2×R8I - Control Panel (Sheet 041A)
186
Frame 2×R8I - Control Unit 2 / RO (Sheet 042A)
187
Frame 2×R8I - Control Unit 2 / DI (Sheet 042B)
188
Frame 2×R8I - Control Unit 2 / AI, AO, DIO (Sheet 042C)
189
Frame 2×R8I - Control Unit 2 (Sheet 042D)
190
Frame 2×R8I - Option Modules (Sheet 043A)
191
Further Information
193
Advertisement
ABB ACS880-604LC Hardware Manual (102 pages)
1-phase brake units as modules
Brand:
ABB
| Category:
Control Unit
| Size: 6 MB
Table of Contents
Table of Contents
5
Introduction to the Manual
9
Contents of this Chapter
9
Safety Instructions
9
Target Audience
9
Related Documents
10
Terms and Abbreviations
10
Operation Principle and Hardware Description
11
Contents of this Chapter
11
Product Overview
11
Operation Principle
11
Chopper Voltage Selection
12
When to Use Resistor Braking
12
Single-Line Diagram of the Drive System
12
Layout
13
Overview of Power and Control Connections
14
Controlling the Brake Chopper from an External Control Location
14
Master-Follower Connection
15
Type Designation Label
15
Planning the Installation
17
Contents of this Chapter
17
Limitation of Liability
17
Generic Guidelines
17
Equipping the Drive with a Main Contactor and Manual Control Switch or Switches
18
Selecting the Brake Circuit Components
20
Minimum Resistance for Custom Resistors
20
Maximum Resistance for Custom Resistors
20
Resistor Heat Dissipation Capacity
20
Calculating the Maximum Braking Power
21
Example 1
21
Example 2
22
Example 3
22
Selecting and Routing Brake Chopper Cable
23
Selecting and Routing the Brake Resistor Cables
23
Selecting the Brake Resistor Cables
23
Minimizing Electromagnetic Interference
23
Selecting the Installation Location for the Brake Resistors
23
Selecting the Chopper Enable Input Cable
24
Protecting the System against Thermal Overload
24
Protecting the System against Short-Circuits
24
Mechanical Installation
25
Contents of this Chapter
25
Examining the Installation Site
25
Tools
25
Installing the Brake Chopper Module
26
Examples: Installing the Brake Chopper Module and Related Components
27
Example: Installation into a Rittal VX25 Enclosure
27
Layout Drawing
27
Pipe Routing Example
28
Installation Stages
29
Overview of Kits
30
Stage 1: Installation of Common Parts
31
Stage 2: Installation of Mounting Plate
32
Stage 3: Installation of Cooling Components
33
Stage 4: Installation of Brake Module and Attenuator
34
Examples: Installing the Brake Resistors and Cooling Fan
35
Example 1: Installation into a Rittal VX25 Enclosure
35
Example 2: Installation into a Generic Enclosure
37
Electrical Installation
39
Contents of this Chapter
39
Safety and Liability
39
Electrical Safety Precautions
39
Measuring the Insulation of the Resistor Circuit
41
General Notes
42
Printed Circuit Boards
42
Handling Fiber Optic Cables
42
Selecting the Voltage
42
Connecting the DC and Resistor Cables
44
Connection Diagram
44
Connection Procedure
45
Connecting the Brake Resistor Thermal Switch
46
Installation Checklist
47
Contents of this Chapter
47
Checklist
48
Start-Up
49
Contents of this Chapter
49
Start-Up Procedure
49
Fault Tracing
51
Contents of this Chapter
51
Fault Indications
51
Fan Supervision
52
NRED Voltage Reducer Selection for NBRA-669
52
Maintenance
53
Contents of this Chapter
53
Maintenance Intervals
54
Description of Symbols
54
Recommended Maintenance Intervals after Start-Up
54
Cooling System
55
Cabinet
55
Cleaning the Interior of the Cabinet
55
Power Connections
55
Retightening the Power Connections
55
Cooling Fans
56
Replacing the Chopper Cooling Fan
56
Replacing the Resistor Cooling Fan
56
Ordering Information
59
Contents of this Chapter
59
Brake Chopper Modules
60
Brake Chopper Cooling
60
Cooling Fans
60
Fan Kit (with Heat Exchanger)
60
Coolant Distribution Manifold Kits
61
Main Pipe Support Kit
62
Coolant Piping and Fittings
62
DC Bus Installation Parts (for Rittal VX25 Enclosures)
63
Fuses and Fuse Bases
63
Brake Resistors
64
Brake Resistor Cooling Fan
64
Attenuator
64
Pressure Relief Kit
64
Internal Cooling Circuit
65
Contents of this Chapter
65
Applicability
65
Internal Cooling System
65
Connection to a Cooling Unit
67
Connection to an ACS880-1007LC Cooling Unit
67
Connection to a Custom Cooling Unit
67
General Requirements
67
Coolant Temperature Control
67
Filling up and Bleeding the Internal Cooling Circuit
68
Drive Line-Ups with an ACS880-1007LC Cooling Unit
68
Drive Line-Ups with a Custom Cooling Unit
68
Draining the Internal Cooling Circuit
69
Maintenance Intervals
69
Technical Data for the Internal Cooling Circuit
70
Coolant Specification
70
Coolant Type
70
Temperature Limits
70
Pressure Limits
71
Coolant Flow Rate Limits
71
Cooling Circuit Materials
71
Technical Data
73
Contents of this Chapter
73
Ratings
73
Chopper Only
73
Chopper with Standard Resistors
74
Definitions
75
DC Fuses
76
Dimensions, Weights and Free Space Requirements
76
Losses, Cooling Data and Noise
76
Brake Chopper Only
76
Brake Chopper with Factory-Installed Brake Resistors (Option +D151)
76
Brake Circuit Cable Sizes
78
Maximum Cable Length of the Resistor Cable
78
Maximum Inductance for the Brake Chopper Circuit
78
Brake Chopper Terminal Data
79
Brake Resistor Terminal Data
79
Protection Classes
79
Ambient Conditions
79
Materials
80
Disposal
80
Packaging of Brake Unit
81
Packaging of Options
81
Manuals
81
Auxiliary Circuit Current Consumption
82
UL Marking
82
More Information on Standards and Markings
82
Dimension Drawings
83
Contents of this Chapter
83
Brake Chopper Module NBRW-669
84
Attenuator
85
Brake Resistor
86
Brake Resistor Cooling Fan
87
14. Example Circuit Diagrams
89
Contents of this Chapter
89
Brake Unit with One Chopper Module - Sheet 001A
90
Brake Unit with One Chopper Module - Sheet 005A
91
Brake Unit with One Chopper Module - Sheet 026A
92
Brake Unit with Four Chopper Modules - Sheet 001A
93
Brake Unit with Four Chopper Modules - Sheet 001B
94
Brake Unit with Four Chopper Modules - Sheet 005A
95
Brake Unit with Four Chopper Modules - Sheet 005B
96
Brake Unit with Four Chopper Modules - Sheet 026A
97
Brake Unit with Four Chopper Modules - Sheet 027A
98
Brake Unit with Four Chopper Modules - Sheet 027B
99
Further Information
101
ABB ACS880-604LC Hardware Manual (104 pages)
1-phase brake units as modules
Brand:
ABB
| Category:
Industrial Equipment
| Size: 5 MB
Table of Contents
Table of Contents
5
1 Introduction to the Manual
9
Contents of this Chapter
9
Safety Instructions
9
Target Audience
9
Related Manuals
10
Terms and Abbreviations
11
2 Operation Principle and Hardware Description
13
Contents of this Chapter
13
Product Overview
13
Operation Principle
13
Single-Line Diagram of the Drive System
15
Layout
16
Overview of Power and Control Connections
18
Type Designation Label
19
3 Planning the Installation
21
Contents of this Chapter
21
Limitation of Liability
21
Generic Guidelines
21
Equipping the Drive with a Main Contactor and Manual Control Switch or Switches
22
Selecting the Brake Circuit Components
24
Calculating the Maximum Braking Power
24
Example 1
25
Example 2
25
Example 3
26
Selecting and Routing the Brake Resistor Cables
26
Minimizing Electromagnetic Interference
26
Maximum Cable Length
26
EMC Compliance of the Complete Installation
27
Placing the Brake Resistors
27
Selecting the Chopper Enable Input Cable
27
Protecting the System against Thermal Overload
27
Operation Principle
27
Protecting the Resistor Cable against Short-Circuits
28
Controlling the Brake Chopper from an External Control Location
28
4 Mechanical Installation
29
Contents of this Chapter
29
Checking the Installation Site
29
Required Tools
29
Installing the Brake Chopper Module
30
Examples: Installing the Brake Chopper Module and Related Components
31
Example: Installation into a Rittal TS 8 or VX25 Enclosure
31
Layout Drawing
31
Installation Stages
32
Overview of Kits
33
Stage 1: Installation of Common Parts
34
Stage 2: Installation of Mounting Plate
35
Stage 3: Installation of Cooling Components
36
Stage 4: Installation of Brake Module and Attenuator
37
Examples: Installing the Brake Resistors and Cooling Fan
38
Example 1: Installation into a Rittal TS 8 Enclosure
38
Example 2: Installation into a Generic Enclosure
39
5 Electrical Installation
41
Contents of this Chapter
41
Safety and Liability
41
Electrical Safety Precautions
42
Checking the Insulation of the Resistor Circuit
43
General Notes
43
Printed Circuit Boards
43
Optical Components
43
Selecting the Voltage
44
Synchronizing Multiple Brake Choppers
45
Connecting the DC and Resistor Cables
46
Connection Diagram
46
Connection Procedure
47
Connecting the Thermal Switch
48
6 Installation Checklist
49
Contents of this Chapter
49
Checklist
50
7 Start-Up
51
Contents of this Chapter
51
Start-Up Procedure
51
8 Fault Tracing
53
Contents of this Chapter
53
Fault Indications
53
9 Maintenance
55
Contents of this Chapter
55
Maintenance Intervals
56
Maintenance Timers and Counters
57
Cooling System
57
Cabinet
57
Cleaning the Interior of the Cabinet
57
Power Connections
57
Retightening the Power Connections
57
10 Ordering Information
59
Contents of this Chapter
59
Brake Chopper Modules
60
Brake Chopper Cooling
60
Cooling Fans
60
Fan Kit (with Heat Exchanger)
60
Coolant Piping and Fittings
61
DC Bus Installation Parts (for Rittal TS 8 Enclosures)
62
DC Bus Installation Parts (for Rittal VX25 Enclosures)
62
Fuses and Fuse Bases
63
Brake Resistors
63
Brake Resistor Cooling Fans
63
Attenuator
63
11 Internal Cooling Circuit
65
Contents of this Chapter
65
Applicability
65
Internal Cooling System
65
Connection to a Cooling Unit
67
Connection to an ACS880-1007LC Cooling Unit
67
Connection to a Custom Cooling Unit
67
General Requirements
67
Coolant Temperature Control
67
Filling up and Bleeding the Internal Cooling Circuit
68
Drive Line-Ups with an ACS880-1007LC Cooling Unit
68
Drive Line-Ups with a Custom Cooling Unit
68
Draining the Internal Cooling Circuit
70
Maintenance Intervals
70
Technical Data
70
Coolant Specification
70
Coolant Type
70
Temperature Limits
70
Pressure Limits
71
Cooling Circuit Materials
72
12 Technical Data
73
Contents of this Chapter
73
Ratings
73
Chopper Only
73
Chopper with Standard Resistors
74
Definitions
75
DC Fuses
76
Dimensions, Weights and Free Space Requirements
76
Losses, Cooling Data and Noise
77
Brake Chopper Module Only
77
Brake Resistors
77
Brake Circuit Cable Sizes
78
Brake Resistor Terminal Data
78
Degree of Protection
78
Optical Components
78
Ambient Conditions
79
Auxiliary Circuit Current Consumption
80
Definitions
80
CE Marking
80
Compliance with the European Low Voltage Directive
80
Compliance with the European EMC Directive
81
More Information on Standards and Markings
81
13 Dimension Drawings
83
Contents of this Chapter
83
Brake Chopper Module NBRW-669
84
Attenuator
85
Brake Resistor
86
Brake Resistor Cooling Fan D3G200-BF07-H2, D3G200-BB36-82
87
14 Circuit Diagram Examples
89
Contents of this Chapter
89
Brake Unit with One Chopper Module - Sheet 001A
90
Brake Unit with One Chopper Module - Sheet 005A
91
Brake Unit with One Chopper Module - Sheet 026A
92
Brake Unit with One Chopper Module - Sheet 027A
93
Brake Unit with Four Chopper Modules - Sheet 001A
94
Brake Unit with Four Chopper Modules - Sheet 001B
95
Brake Unit with Four Chopper Modules - Sheet 005A
96
Brake Unit with Four Chopper Modules - Sheet 005B
97
Brake Unit with Four Chopper Modules - Sheet 026A
98
Brake Unit with Four Chopper Modules - Sheet 026B
99
Brake Unit with Four Chopper Modules - Sheet 027A
100
Brake Unit with Four Chopper Modules - Sheet 027B
101
Further Information
103
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