ABB ACS880-604LC-3900-7 Manuals

Manuals and User Guides for ABB ACS880-604LC-3900-7. We have 1 ABB ACS880-604LC-3900-7 manual available for free PDF download: Hardware Manual

ABB ACS880-604LC-3900-7 Hardware Manual (194 pages)

3-phase dynamic brake units as modules

Brand: ABB | Category: DC Drives | Size: 57 MB

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

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ABB ACS880-604LC-3900-7 Hardware Manual (194 pages)

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