abbindustrialdrives acs880-607lc1-phasebrakeunits … · 2019-06-28 ·...

—ABB INDUSTRIAL DRIVES

ACS880-607LC 1-phase brake unitsHardware manual

ACS880-607LC 1-phase brake unitsHardware manual

Table of contents

3. Mechanical installation

5. Electrical installation

7. Start-up

© 2019 ABB Oy. All Rights Reserved. 3AXD50000481491 Rev AEN

EFFECTIVE: 2019-06-28

Table of contents

1 Introduction to the manual

9Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Applicability ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Safety instructions .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Target audience .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Related documents .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Use of component designations .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Terms and abbreviations .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Operation principle and hardware description

13Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Product overview ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Operation principle .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Single-line diagram of the drive system ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Layout .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Brake chopper cubicle .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Brake resistor cabinet ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Brake chopper module .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19Overview of power and control connections .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Controlling the brake chopper from an external control location .... . . . . . . . . . . . . . . . . . . .20Master-follower connection .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Type designation labels .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Brake unit type designation label ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Brake chopper module type designation label ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Brake unit type designation key .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Basic code ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Mechanical installation

23Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Brake unit .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Brake resistor cabinet ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23User-defined brake resistors .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Planning the electrical installation

25Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Limitation of liability ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Generic guidelines .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Selecting the user-defined brake resistors .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Selecting and routing the brake resistor cables .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Typical resistor cable sizes .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Minimizing electromagnetic interference .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Maximum cable length .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Placing the brake resistors .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Selecting the resistor thermal switch circuit cable .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contents 5

27Protecting the system against thermal overload .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Operation principle .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Protecting the system against short-circuits ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Electrical installation

29Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Electrical safety precautions .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Checking the insulation of brake resistor and resistor cable .... . . . . . . . . . . . . . . . . . . . . . . . . . . .32Connecting the brake resistor cables and thermal switch .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Connection diagram ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Connection procedure .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Installation checklist of the drive

35Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Checklist .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Start-up

37Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Start-up procedure .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Fault tracing

39Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Fault indications .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Fan supervision .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Selecting the voltage .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Maintenance

43Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Maintenance intervals .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Cooling system ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Retightening the power connections .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Replacing cooling fans .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Brake chopper cubicle .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Brake resistor cabinet (option +D151) .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Internal cooling circuit

47Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Applicability ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Internal cooling system ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Connection to a cooling unit .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Connection to an ACS880-1007LC cooling unit .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Connection to a custom cooling unit .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49General requirements .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Coolant temperature control .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Filling up and bleeding the internal cooling circuit .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Drive line-ups with an ACS880-1007LC cooling unit .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Drive line-ups with a custom cooling unit .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Draining the internal cooling circuit .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Maintenance intervals .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Table of contents

52Technical data .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Coolant specification .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Coolant type .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Temperature limits .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Pressure limits .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Coolant flow rate limits .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Cooling circuit materials .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Technical data

57Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Ratings .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Brake chopper only .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58Brake chopper with factory-installed brake resistors (option +D151) .... . . . . . . . . . . . . . .59Definitions .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60DC fuses .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Dimensions, weights and free space requirements .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Brake chopper only .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Brake chopper with factory-installed brake resistors (option +D151) .... . . . . . . . . . . . . . .61Losses, cooling data and noise .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Brake chopper only .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Brake chopper with factory-installed brake resistors (option +D151) .... . . . . . . . . . . . . . .

62Terminal and lead-through data for the resistor cable for brake units with user-definedbrake resistors .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62Resistor cable sizes .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62Maximum cable length .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Protection classes .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Brake chopper cubicle .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Ambient conditions .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Materials .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Standards and markings .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Disclaimers .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Generic disclaimer .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Cybersecurity disclaimer .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Example circuit diagrams

67Contents of this chapter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Brake unit with one brake chopper module .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69Brake chopper control .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70External fan voltage supply .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71Fan control for brake chopper cubicle .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72Fan control for resistor cabinet ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Further information

Table of contents 7

Introduction to the manual

Contents of this chapterThis chapter gives basic information on the manual.

ApplicabilityThe manual is applicable to ACS880-607LC 1-phase brake units that form a part of aliquid-cooled ACS880 multidrive system.

Safety instructionsFollow all safety instructions delivered with 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 multidrivecabinets and modules safety instructions (3AXD50000048633 [English]).

• Read the software-function-specific warnings and notes before changing the defaultsettings of a function. For each function, the warnings and notes are given in the sectiondescribing the related user-adjustable parameters.

• Read the task-specific safety instructions before starting the task. See the sectiondescribing the task.

Target audienceThis manual is intended for people who plan the installation, install, start up and service thedrive, or create instructions for the end user of the drive concerning the installation andmaintenance of the drive.

Read the manual before working on the drive. You are expected to know the fundamentalsof electricity, wiring, electrical components and electrical schematic symbols.

1Introduction to the manual 9

The manual is written for readers worldwide. Both SI and imperial units are shown.

Related documentsCodeManual

General manuals

3AXD50000048633ACS880 liquid-cooled multidrive cabinets and modules safety instructions

3AXD50000048634ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions

3AXD50000048635ACS880 liquid-cooled multidrive cabinets mechanical installation instructions

3AXD50000126880CIO-01 I/O module for distributed I/O bus control user's manual

Supply unit manuals

3AXD50000174782ACS880-207LC IGBT supply units hardware manual

3AUA0000131562ACS880 IGBT supply control program firmware manual

Inverter unit manuals

3AXD50000196111ACS880-107LC inverter units hardware manual

3AUA0000085967ACS880 primary control program firmware manual

3AUA0000098062ACS880 primary control program quick start-up guide

Manuals for application programs (Crane, Winder, etc.)

Brake unit and DC/DC converter unit manuals

3AXD50000481491ACS880-607LC 1-phase brake units hardware manual

3AXD50000020967ACS880 (3-phase) brake control program firmware manual

3AXD50000431342ACS880-1607LC DC/DC converter units hardware manual

3AXD50000024671ACS880 DC/DC converter control program firmware manual

Option manuals

3AXD50000129607ACS880-1007LC liquid cooling unit user's manual

3AUA0000085685ACS-AP-x assistant control panels user’s manual

3AUA0000094606Drive composer start-up and maintenance PC tool user’s manual

Manuals for I/O extension modules, fieldbus adapters, safety options etc.

You can find manuals on the Internet. See www.abb.com/drives/documents. For manualsnot available in the document library, contact your local ABB representative.

Use of component designationsSome device names in the manual include the item designation in brackets, for example[Q20], to make it possible to identify the components in the circuit diagrams of the drive.

Terms and abbreviationsDescriptionTerm/

Abbreviation

Conducts the surplus energy from the intermediate circuit of the drive to the brakeresistor when necessary. The chopper operates when the DC link voltage exceedsa certain maximum limit. The voltage rise is typically caused by deceleration(braking) of a high inertia motor.

Brake chopper

Brake chopper enclosed in a metal frame or housing. Intended for cabinet installa-tion.

Brake chopper module

10 Introduction to the manual

www.abb.com/drives/documents

DescriptionTerm/Abbreviation

Dissipates the drive surplus braking energy conducted by the brake chopper toheat

Brake resistor

Brake chopper modules under control of one control board, and related accessoriesBrake unitI/O module for controlling cabinet fansCIOOne section of a cabinet-installed drive. A cubicle is typically behind a door of itsown.

Cubicle

DC circuit between rectifier and inverterDC linkFrequency converter for controlling AC motorsDriveElectromagnetic compatibilityEMCInsulated gate bipolar transistorIGBTDC circuit between rectifier and inverterIntermediate circuitConverts direct current and voltage to alternating current and voltage.InverterDrive for controlling several motors which are typically coupled to the same ma-chinery. Includes one supply unit, and one or several inverter units.

Multidrive

Brake chopper control boardNBRCSeries of optional, liquid-cooled brake chopper modulesNBRWIn the drive control program, user-adjustable operation instruction to the drive, orsignal measured or calculated by the drive.In some (for example fieldbus) contexts, a value that can be accessed as an object,eg, variable, constant, or signal.

Parameter

Converts alternating current and voltage to direct current and voltageRectifierSeries of brake resistorsSAFUR

Introduction to the manual 11

Operation principle and hardwaredescription

Contents of this chapterThis chapter describes the operation principle and construction of the brake unit.

Product overviewACS880-607LC is a liquid-cooled cabinet-installed brake unit, which forms a part of anACS880 multidrive system. As standard, it includes brake chopper(s). Brake resistors areavailable as an option (+D151).

Operation principleThe brake chopper handles the energy generated by a decelerating motor. The extra energyincreases the DC link voltage. The brake chopper connects the brake resistors to the DClink of the drive when the voltage exceeds an activation limit. The energy consumption bythe resistor losses lowers the voltage until the resistor can be disconnected.

Typically, a drive system is equipped with a brake chopper if• high capacity braking is needed and the drive cannot be equipped with a regenerative

supply unit• a backup for the regenerative supply unit is needed.

2Operation principle and hardware description 13

Single-line diagram of the drive systemThe diagram below shows a typical common DC link drive system.

1

2

3

4

6

5

6

8

9

10

11

7

MM

AC supply1

Input (AC) fuses2

Supply unit3

DC link4

Inverter DC fuses5

Inverter units. In this example, one of the units consists of two inverter modules connected in parallel.6

Brake chopper DC fuses7

Attenuator. Suppresses voltage spikes at chopper input. Must be installed if it is possible to disconnectall inverter units from the DC link with the supply unit on, otherwise optional.

8

Brake chopper9

Brake resistors10

Motors11


Layout￭ Brake chopper cubicleThe figure below shows the components of the brake chopper cubicle.

1

2

3

4

5

Attenuator [R121.x]4DC fuses [F121.xx]1

Brake chopper module [T121]5CIO-01 I/O module [A115.x]2

Cooling fan [G115.xx] and heat exchanger3

Operation principle and hardware description 15

￭ Brake resistor cabinetThe figure below shows the components of the brake resistor cabinet.

1 1

23

Door position indication switch [S121.7]3Brake resistors [R121.xx]1

Brake resistor cooling fans2


￭ Brake chopper moduleThe components of the brake chopper module are shown below.

6 7

UDC+ R+

UDC- R-X1

4

5

8 9

11

22

3

2

2

Clamp for drive cable8Fastening points on back plate (two at the top,two at the bottom)1

Clamp for resistor cable9Front cover fastening screws2

Enable input terminal blockX1Front cover3

Power connection terminals

UDC-Chopper control board (NBRC) with control ter-minals4

UDC+Voltage selection jumper5

R+PE (protective earth) clamp6

R-Grounding clamp7


Coolant connections behind main mounting plate (side view).


Overview of power and control connectionsThe diagram below shows the power and control connections of the brake unit.

X3 12

X1

V23V22

R+ R-UDC- UDC+

1 3 2

t°

+

-

X2

1

2 3

4 5

6

7

21

Brake chopper cubicle1

Brake chopper module [T121]2

Brake chopper control board (NBRC)3

Brake resistor cabinet4

Brake resistors [R121.xx]5

Brake resistor monitoring circuit with a thermal switch and a door position indication switch [S121.7]6

Control voltage7

Chopper enable inputX1

Fault indication relay output. Connected in brake resistor monitoring circuit (monitored by the chopperenable input X2). See Example circuit diagrams.

X3

Fiber optic cable connection (not connected as standard)V22

Fiber optic cable connection (not connected as standard)V23


￭ Controlling the brake chopper from an external control locationThe brake chopper can be controlled from an external control location via a fiber optic link(terminals V22 and V23 on the chopper control board). Using the link, it is possible tosynchronize several brake choppers.

￭ Master-follower connectionWhen several brake choppers are in use, the first chopper in the chain acts as the masterfor the other choppers. The voltage selection jumper of the master (1) is set to the appropriatevoltage at the factory, while the followers (2) are set to FIBER.

V22V22 V23V23

(Voltage)

V23 V22

FIBE

R

21 2

FIBE

R

Type designation labels￭ Brake unit type designation labelEach brake unit is equipped with a type designation label. An example label is shown below.

1

2

3

4

5

Type designation1

Frame size2

Serial number3• The first digit of the serial number refers to the manufacturing plant.• The next four digits refer to the unit’s manufacturing year and week, respectively.• The remaining digits complete the serial number so that there are no two units or modules with thesame number.

Ratings4

Valid markings5


￭ Brake chopper module type designation labelEach brake chopper module is equipped with a type designation label. An example label isshown below.

ABB

Type

Code

Un

Rmin

Duty cycle

Irms

Rn

709…976 (848 UL, CSA) VDC

1.35 Ohm

1 / 5 min

267 ADC

2.72 Ohm

MADE IN ESTONIA

NBRW-669C

6426OO49

Serno *8183901234 *ABB OyHiomotie 1300380 HelsinkiFinland

1

2

3

4 5

Type designation1

Brake chopper module order code2

Serial number3• The first digit of the serial number refers to the manufacturing plant.• The next four digits refer to the unit's manufacturing year and week respectively.• The remaining digits complete the serial number so that there are no two units or modules with thesame number.

Ratings4

Valid markings5

Brake unit type designation keyThe type designation contains information on the specifications and configuration of thebrake unit. The first digits express the basic configuration. The optional selections are giventhereafter, separated by plus signs.

￭ Basic codeThis table describes the fields of the basic code.

DescriptionCode

Product series.ACS880

Construction. 607LC = cabinet-installed liquid-cooled brake unit.607LC

Size. See the ratings table.xxxx

709…976 V DC. This is indicated in the type designation label as typical input voltage levels 742/ 849 / 976 V DC.

7


Mechanical installation

Contents of this chapterThis chapter describes the mechanical installation of the brake units.

Brake unitThe ACS880 multidrive - the brake unit as one part of the complete drive - is transported insections. See ACS880 liquid-cooled multidrive cabinets mechanical installation instructions(3AXD50000048635 [English]).

Brake resistor cabinetInstallation guidelines:• Install the brake resistor cabinet separate from the basic drive line-up• Make sure that the installation site has proper ventilation. The ventilation must meet

the air flow amounts specified.• For the installation instructions, see ACS880 multidrive cabinets mechanical installation

instructions (3AUA0000101764 [English]).

User-defined brake resistorsObey the brake resistor manufacturer’s instructions.

3Mechanical installation 23

10

Planning the electrical installation

Contents of this chapterThis chapter contains instructions on selecting, placing and protecting the brake circuitcomponents and cables.

Limitation of liabilityThe installation must always be designed and made according to applicable local laws andregulations. ABB does not assume any liability whatsoever for any installation which breachesthe local laws and/or other regulations. Furthermore, if the recommendations given by ABBare not followed, the drive may experience problems that the warranty does not cover.

Generic guidelinesSeeElectrical planning instructions for ACS880 liquid-cooledmultidrive cabinets andmodules(3AXD50000048634 [English]) for the generic guidelines for planning the electrical installation(selecting cables, routing cables, etc.) of multidrive cabinets and modules.

Selecting the user-defined brake resistorsWARNING!ABB is not responsible for user resistor selection or protection of the resistor.

Select the resistor according to the resistor specification given in the technical data. Inaddition, consider the following:• Each chopper must feed a resistor or resistor assembly of its own.• The resistance (R) of the brake resistor assembly must be equal to or above the value

specified. Never use resistance values below the specified value.

4Planning the electrical installation 25

• The resistor must withstand the specified brake cycles.• The ventilation of the space/room in which the resistors are located must meet the air

flow amounts specified.• The resistor assembly must be equipped with a thermal switch.

￭ Selecting and routing the brake resistor cables

Typical resistor cable sizes

See the technical data.

Minimizing electromagnetic interference

Obey these rules in order to minimize the electromagnetic interference caused by rapidcurrent changes in the resistor cables:• Shield the braking power line completely, either by using shielded cable or a metallic

enclosure. Unshielded single-core cable can only be used if it is routed inside a cabinetthat efficiently suppresses radiated emissions.

• Install the cables away from other cable routes.• Avoid long parallel runs with other cables. The minimum parallel cabling separation

distance is 0.3 meters (1 ft).• Cross the other cables at right angles.• Keep the cable as short as possible in order to minimize the radiated emissions and

stress on chopper IGBTs. The longer the cable, the higher the radiated emissions,inductive load and voltage peaks over the IGBT semiconductors of the brake chopper.

Maximum cable length

See the technical data.

￭ Placing the brake resistorsInstall the resistors outside the drive in a place where they will cool.

Arrange the cooling of the resistor in a way that:• no danger of overheating is caused to the resistor or nearby materials• the temperature of the room the resistor is located in does not exceed the allowed

maximum.

Supply the resistor with cooling air or coolant according to the resistor manufacturer’sinstructions.

WARNING!The materials near the brake resistor must be non-flammable. The surfacetemperature of the resistor is high. Air flowing from the resistor is of hundreds ofdegrees Celsius. If the exhaust vents are connected to a ventilation system, makesure that the material withstands high temperatures. Protect the resistor againstcontact.

26 Planning the electrical installation

￭ Selecting the resistor thermal switch circuit cableMake sure that the cable in the resistor thermal switch circuit meets the followingrequirements:• shielded cable• operating voltage 450 V / 750 V (U0 / U)• insulation test voltage > 1.7 kV• jacket material for at least 90 °C (194 °F). Take into account further requirements due

to resistor construction and temperature.

Protecting the system against thermal overloadThe brake chopper protects itself and the resistor cables against thermal overload. Makesure that the resistor assembly is equipped with a thermal switch, which is wired to disablethe chopper in case of overtemperature.

￭ Operation principleIf the resistor overheats, the thermal switch opens and interrupts the chopper control unitinput signal and the chopper stops operating. In addition, the control unit relay output eitheropens the drive main contactor/breaker or gives a fault indication to the overriding controlsystem, which takes care of the protection.

Protecting the system against short-circuitsThe brake unit is equipped with fuses as standard.

The fuses protect the brake chopper, the brake resistors and the brake circuit cables in ashort-circuit situation.

Planning the electrical installation 27

Electrical installation

Contents of this chapterThis chapter describes the electrical installation of the brake unit.

Electrical safety precautionsThese electrical safety precautions are for all personnel who do work on the drive, motorcable or motor.

WARNING!Obey these instructions. If you ignore them, injury or death, or damage to theequipment can occur.

If you are not a qualified electrician, do not do installation or maintenance work.

Go through these steps before you begin any installation or maintenance work.

1. Keep the cabinet doors closed when the drive is powered. With the doors open, a riskof a potentially fatal electric shock, arc flash or high-energy arc blast exists.

2. Clearly identify the work location and equipment.3. Disconnect all possible voltage sources. Lock out and tag out.

• Open the main disconnecting device of the drive.• Open the charging switch if present.• Open the disconnector of the supply transformer. (The main disconnecting device

in the drive cabinet does not disconnect the voltage from the AC input power busbarsof the drive cabinet.)

• If the drive is equipped with a DC/DC converter unit (optional): Open the DCswitch/disconnector ([Q11], option +F286) of the DC/DC converter. Open thedisconnecting device of the energy storage connected to the DC/DC converter unit(outside the drive cabinet).

5Electrical installation 29

11

• Open the auxiliary voltage switch-disconnector (if present), and all other possibledisconnecting devices that isolate the drive from dangerous voltage sources.

• In the liquid cooling unit (if present), open the motor protective circuit breaker(s) ofthe cooling pumps.

• If you have a permanent magnet motor connected to the drive, disconnect the motorfrom the drive with a safety switch or by other means.

• Make sure that re-connection is not possible. Lock out and tag out.• Disconnect any dangerous external voltages from the control circuits.• After you disconnect power from the drive, always wait 5 minutes to let the

intermediate circuit capacitors discharge before you continue.

4. Protect any other energized parts in the work location against contact.5. Take special precautions when close to bare conductors.6. Measure that the installation is de-energized. If the measurement requires removal or

disassembly of shrouding or other cabinet structures, obey the local laws and regulationsapplicable to live working (including – but not limited to – electric shock and arcprotection).• Use a multimeter with an impedance greater than 1 Mohm.• Make sure that the voltage between the drive input power terminals (L1, L2, L3)

and the grounding (PE) busbar is close to 0 V.• Make sure that the voltage between the drive DC busbars (+ and -) and the

grounding (PE) busbar is close to 0 V.• If you have a permanent magnet motor connected to the drive, make sure that the

voltage between the drive output terminals (T1/U, T2/V, T3/W) and the grounding(PE) busbar is close to 0 V.

WARNING!The busbars inside the cabinet are partially coated. Measurements madethrough the coating are potentially unreliable, so only measure at uncoatedportions. Note that the coating does not constitute a safe or touch-proofinsulation.

7. Install temporary grounding as required by the local regulations.8. Ask the person in control of the electrical installation work for a permit to work.


Checking the insulation of brake resistor and resistor cableWARNING!Obey the safety instructions of the drive. If you ignore them, injury or death, ordamage to the equipment can occur.


1. Stop the drive and do the steps in section Electrical safety precautions (page 29) beforeyou start the work.

2. Check that the resistor cable is connected to the resistor and disconnected from thedrive output terminals.

3. At the drive end, connect the R+ and R- conductors of the resistor cable together.Measure the insulation resistance between the conductors and the PE conductor witha measuring voltage of 1000 V DC. The insulation resistance must be higher than1 Mohm.

R-

R+

ohmPE

1 kV DC,> 1 Mohm

Electrical installation 31

11

Connecting the brake resistor cables and thermal switch￭ Connection diagram

1

2

3

11 12

11 12

X121.1

X121.7R+ R-

R+ R-

Brake chopper cubicle (all connections done at the factory)1

Brake chopper module2

Brake resistor cabinet3

￭ Connection procedure

WARNING!Obey the safety instructions of the drive. If you ignore them, injury or death, ordamage to the equipment can occur.




2. Open the door of the brake chopper cubicle and remove the shrouding.3. Connect the resistor cables:

• Connect the power cable between the brake chopper and the brake resistor. Notethe connection of the third conductor and the cable shield. See the connectiondiagram.

• Connect the power cables of parallel brake resistors as shown below.

Note: The cable between the chopper and the first resistor must be able to carrythe entire braking power. Provide adequate support for the cables below the chopperand resistor units.

R+ R– R+ R– R+ R–

Chopper Resistor Resistor

• Connect the cable between the brake chopper cubicle and the resistor monitoringcircuit. See the connection diagram.

Factory installed brake resistors (option +D151):• Connect the cable between the brake resistor cabinet and a user-defined 230 V

AC power supply. See the circuit diagrams delivered with the unit.• Connect the cabling between the brake resistor fan control circuit and the brake

chopper cubicle. See the circuit diagrams delivered with the unit.User-defined brake resistors:• Connect the possible additional cabling between the brake chopper cubicle and the

brake resistor cabinet. See the circuit diagrams delivered with the unit.• Make the possible user-defined connections to the brake resistor cabinet.

Electrical installation 33

11

Installation checklist of the drive

Contents of this chapterThis chapter contains a checklist of the mechanical and electrical installation of the drive.

ChecklistExamine the mechanical and electrical installation of the drive before start-up. Go throughthe checklist together with another person.



WARNING!Stop the drive and do the steps in section Electrical safety precautions (page 29)before you start the work.

Make sure that …

The ambient operating conditions meet the drive ambient conditions specification, and enclosure rating(IP code or UL enclosure type).

The supply voltage matches the nominal input voltage of the drive. See the type designation label.

The drive cabinet has been attached to floor, and if necessary due to vibration etc, also by its top tothe wall or roof.

If the drive is connected to a network other than a symetrically grounded TN-S system: Check thecompatibility. See the electrical installation instructions in the supply unit manual.

There is an adequately sized protective earth (ground) conductor between the drive and the switchboard,the conductor has been connected to appropriate terminal, and the terminal has been tightened to theproper torque. Proper grounding has also been measured according to the regulations.

6Installation checklist of the drive 35

Make sure that …

The input power cable has been connected to the appropriate terminals, the phase order is right, andthe terminals have been tightened to the proper torque.

There is an adequately sized protective earth (ground) conductor between the motor and the drive,and the conductor has been connected to appropriate terminal, and the terminal has been tightenedto the proper torque. (Pull on the conductors to check.). Proper grounding has also been measuredaccording to the regulations.

The motor cable has been connected to the appropriate terminals, the phase order is right, and theterminals have been tightened to the proper torque.

The motor cable has been routed away from other cables.

No power factor compensation capacitors have been connected to the motor cable.

If an external brake resistor has been connected to the drive: There is an adequately sized protectiveearth (ground) conductor between the brake resistor and the drive, and the conductor has been con-nected to appropriate terminal, and the terminals have been tightened to the proper torque. (Pull onthe conductors to check.) Proper grounding has also been measured according to the regulations.

If an external brake resistor has been connected to the drive: The brake resistor has been connectedto the appropriate terminals, and the terminals have been tightened to the proper torque.

If an external brake resistor has been connected to the drive: The brake resistor cable has been routedaway from other cables.

The control cables have been connected to the appropriate terminals, and the terminals have beentightened to the proper torque.

The voltage setting of the auxiliary voltage transformers (if any) is correct. See the electrical installationinstructions.

If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive outputcontactor are either mechanically and/or electrically interlocked, ie, cannot be closed simultaneously.A thermal overload device must be used for protection when bypassing the drive. Refer to local codesand regulations.

There are no tools, foreign objects or dust from drilling inside the drive.

Cover(s) of the motor connection box are in place. Cabinet shrouds are in place and doors are closed.

The motor and the driven equipment are ready for start.

The coolant connections between cubicles (if any) and to the cooling circuit are tight.

If the drive is equipped with a cooling unit: Refer to the cooling unit documentation for specific tasks.

36 Installation checklist of the drive

Start-up

Contents of this chapterThis chapter contains the start-up procedure of the brake unit. The symbols in brackets, forexample [Q1], refer to the item designations used in the circuit diagrams.

If a task is valid only for a certain option device or feature, the option code is given in brackets,for example, (option +F286).

Start-up procedureTasks

Safety

WARNING!Obey the safety instructions of the drive. If you ignore them, injury or death, or damageto the equipment can occur.


Note: Some brake resistors are coated with oil film for protection. The protective oil will burn offwhen the brake resistor is used for the first time. Make sure that the airflow is sufficient.

Installation checklist

Make sure that the installation has been inspected. See the installation checklist.

Supply and inverter units start-up

Make sure that the supply unit of the drive system has been started up according to the instruc-tions in its hardware manual.

Make sure that the inverter units of the drive system have been started up according to the in-structions in their hardware manual.

7Start-up 37

12

Tasks

Make sure that the supply unit is stopped, and the drive system has been isolated from thesupply network.

Powering up the DC bus

Make sure that all cabinet doors are closed.

Close the disconnector of the supply transformer.

Close the drive auxiliary voltage switch [Q21] to power up the control units.

Start the supply unit. See the supply unit hardware manual. When started, the supply unit chargesthe capacitors of all inverters and brake units connected to the DC bus.

In all inverter units, disable the overvoltage control (30.30).

Connect a Drive composer PC tool to an inverter unit that is suitable for the brake choppertesting (ie. it runs a high inertia motor that generates power to the drive when decelerated).

Tune a suitable deceleration time setting (23.13) for the motor: make it short enough to causegeneration back to the drive and start the brake chopper. Do not make it too short not to exceedthe capacity of the brake chopper and resistor.

Operational tests

Test the operation of the braking. Start the test inverter and motor, accelerate and decelerate.During the deceleration, monitor the drive DC bus voltage (with the Drive composer PC tool)and the brake chopper. Make sure that the brake chopper starts when the DC link voltage exceedsthe brake operation limit.

38 Start-up

Fault tracing

Contents of this chapterThis chapter describes the fault tracing possibilities of the brake unit.

Fault indicationsA fault in the resistor braking circuit prevents fast motor deceleration, and may cause thedrive to trip on a fault.

If a fault is detected by the chopper control board, the brake chopper disconnects the brakeresistor from the intermediate circuit, and the chopper fault indication relay output isde-energized.

Depending on the application, the relay output either opens the drive main circuit breakeror gives a fault indication to the overriding control system. See the circuit diagrams deliveredwith the unit.

RemedyCauseFault indication/Fault

Check connections. Let equipmentcool.

Chopper or resistor overheated.Fault indication relay outputswitches off the main power or givesa fault indication to an overridingcontrol system. Check that enable input is on.No enable input received by chop-

per control board.

Check power cables and resistor.Short circuit in resistor or powercables.

Contact local ABB representative.Chopper control board failure.Chopper damaged; it is not able todisconnect resistor from intermedi-ate circuit.

8Fault tracing 39

RemedyCauseFault indication/Fault

Check voltage setting.Chopper voltage setting too high.Chopper does not function.Check parameters of all inverters.Inverter overvoltage control is on.Check that enable input is on.

Check voltage setting.Chopper voltage setting too low.Chopper starts to function at too lowa DC voltage.

Check voltage setting.Chopper voltage setting is too high.Inverter trips on fault 3210 DC linkovervoltage. Check parameters of all inverters.

Check duty cycle and resistor cool-ing.

The maximum brake cycle ex-ceeded or resistor cooling insuffi-cient.

Brake resistor or chopper overheats.

Ensure that voltage setting is correctand jumper is properly in place.

Chopper voltage setting incorrect orjumper missing.

Fan supervisionSee CIO-01 I/O module for distributed I/O bus control user's manual (3AXD50000126880[English]).

Selecting the voltageThe voltage is preset, according to the drive supply voltage, at the factory for each brakechopper. On the field, you need to adjust the voltage setting only if a brake chopper ischanged.



To adjust the setting:1. Stop the drive and do the steps in section Electrical safety precautions (page 29) before

you start the work.2. Remove the chopper front panel by undoing the four screws at the top and bottom of

the panel.3. Set the voltage selection jumper on the chopper control board to the appropriate voltage

as shown below.

40 Fault tracing

FIBE

R

230 V

400 V

>500 V

Drive supply voltage 380…415 V

FIBE

R

230 V

400 V

>500 VDrive supply voltage 440…500 V

FIBE

R

230 V

400 V

>500 V

Drive supply voltage 525…690 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• set the voltage jumper to FIBER in the follower choppers.

WARNING!An incorrect jumper setting or missing jumper may cause brake choppermalfunctioning or damage to the chopper or resistor.

Fault tracing 41

Maintenance

Contents of this chapterThis chapter describes the maintenance of a brake unit.

Maintenance intervalsThe table below shows the maintenance tasks which can be done by the end user. Thecomplete maintenance schedule is available on the Internet (www.abb.com/drivesservices).For more information, consult your local ABB Service representative(www.abb.com/searchchannels).

Years from start-upMaintenance task/object

…1211109876543210

Coolant

PPPPPPPPPPPPChecking coolant antifreeze concentration

PPPPPPChecking coolant quality

RRCoolant draining and replacement

Cooling fan

RCooling fans (chopper and resistor)

Inspections

IIIIIIIIIIIIIChecking tightness of cable and busbar termin-als. Tightening if needed.

IIIIIIIIIIIIIChecking ambient conditions (dustiness, corro-sion, temperature)

IIIIIIIIIIIIIChecking coolant pipe connections

Symbols

9Maintenance 43

www.abb.com/drivesservices

www.abb.com/searchchannels

Inspection (visual inspection and maintenance action if needed)I

Performance of on/off-site work (commissioning, tests, measurements or other work)P

ReplacementR

Maintenance and component replacement intervals are based on the assumption that theequipment is operated within the specified ratings and ambient conditions. ABB recommendsannual drive inspections to ensure the highest reliability and optimum performance.

Note:Long term operation near the specified maximum ratings or ambient conditions may requireshorter maintenance intervals for certain components. Consult your local ABB Servicerepresentative for additional maintenance recommendations.

Cooling systemFor instructions on coolant replacement and checking the cooling system, see chapterInternal cooling circuit.

Retightening the power connectionsWARNING!Read the safety instructions given in Safety instructions for ACS880liquid-cooled multidrive cabinets and modules (3AXD50000048633[English]). If you ignore them, injury or death, or damage to the equipmentcan occur.

1. Repeat the steps described in section Electrical safety precautions (page 29).2. Check the tightness of the cable connections. Use the tightening torques given in the

technical data.

44 Maintenance

Replacing cooling fansThe lifespan of the cooling fans of the drive depends on the running time, ambienttemperature and dust concentration. See the firmware manual for the actual signal whichindicates the running time of the cooling fan. Reset the running time signal after fanreplacement.

Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

￭ Brake chopper cubicle

WARNING!Wear protective gloves and long sleeves. Some parts have sharp edges.


2. Remove any shrouding in front of the cooling fan.3. Disconnect the fan wiring.4. Undo the fastening screws.5. Pull the fan housing outwards.6. Install a new fan in reverse order.

Maintenance 45

￭ Brake resistor cabinet (option +D151)

WARNING!Wear protective gloves and long sleeves. Some parts have sharp edges.


2. Remove any shrouding in front of the cooling fans.3. Disconnect the fan wiring.4. Undo the two fastening screws (a).5. Pull the fan housing outwards.6. Install a new fan in reverse order.

a

46 Maintenance

Internal cooling circuit

Contents of this chapterThe cooling system of a liquid-cooled drive consists of two circuits: the internal cooling circuitand the external cooling circuit. The internal cooling circuit covers the heat-generatingelectrical components of the drive and transfers the heat to the cooling unit. In the coolingunit, the heat is transferred to the external cooling circuit which is usually part of a largerexternal cooling system. This chapter deals with the internal cooling circuit.

ApplicabilityThe information in this chapter is applicable to cabinet-built ACS880 liquid-cooled drives.Except where otherwise indicated, the information is also applicable to drives built out ofACS880 liquid-cooled multidrive modules.

Internal cooling systemNote: This section describes cabinet-built, liquid-cooled ACS880 drives. The information inthis section can be used as guidelines for building a drive system out of ACS880 liquid-cooledmodules.

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 coolingcircuit.

The following diagram shows the coolant pipe connections in a drive system consisting ofa supply unit and an inverter unit.

10Internal cooling circuit 47

A/L

HS HS

a cdba db c

A/L A/L

A/L

HS

HS

A/L

1

2

3

2

Supply modules1

Inverter modules2

To/From cooling unit3

Air-to-liquid heat exchangerA/L

Heat sinkHS

Inlet valvea

Inlet-side drain valveb

Outlet valvec

Outlet-side drain valved

The coolant used with ACS880 liquid-cooled drive systems is Antifrogen® L 25% or 50%water mixture. See Coolant specification (page 52).


Connection to a cooling unit￭ Connection to an ACS880-1007LC cooling unitRefer 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 changeswhen the temperature varies. Equip the system with a pump that provides a nominal flowand pressure. Keep the pressure within the limits specified in Technical data (page 52).Install a pressure regulator to make sure that the maximum permissible operating pressureis not exceeded.

Install a bleed valve at the highest point of the cooling circuit, and a drain valve at the lowestpoint.

The materials that can be used are listed in Cooling circuit materials (page 54).

Coolant temperature control

The temperature of the coolant in the internal cooling circuit must be kept within the limitsspecified in Technical data (page 52). Note that the minimum temperature is dependent onambient temperature and relative humidity.

Internal cooling circuit 49

Filling up and bleeding the internal cooling circuitBoth 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 excesscoolant out of the system.

WARNING!Bleeding of the cooling circuit is very important and has to be done with great care.Air bubbles in the cooling circuit may reduce or completely block coolant flow andlead to overheating. Let the air out of the cooling system while filling in coolantand, eg. after any power module replacements.

￭ Drive line-ups with an ACS880-1007LC cooling unitFollow the filling up and bleeding instructions in ACS880-1007LC cooling unit user's manual(3AXD50000129607 [English]).

￭ Drive line-ups with a custom cooling unit

Note:• In filling up the system, the drain valves in the line-up are used only to vent the air from

the circuit so that it can be displaced by the coolant. The actual bleeding of the circuitmust be done via an external bleed valve installed at the highest point of the coolingcircuit. The most practical location for the valve is usually near or at the cooling unit.

• Observe the instructions given by the manufacturer of the cooling unit. Pay specialattention to filling up and bleeding the pumps properly as they may be damaged ifoperated when dry.

• Draining coolant into the sewer system is not allowed.

1. Open the bleed valve at the cooling unit.2. Open the inlet valve and the outlet-side drain valve of one cubicle. Keep the outlet valve

and the inlet-side drain valve closed.3. Attach a hose to the outlet-side drain valve and lead it into a suitable container.4. Fill the circuit with coolant. For coolant specification, seeCoolant specification (page 52).

Note: To minimize foaming, do not exceed the filling flow rate of 5 l/min(1.3 US gallon/min).

5. As the piping and modules in the cubicle fills up, coolant starts to flow from the hose.Let some coolant flow out, then close the drain valve.

6. Close the inlet valve.7. Repeat steps 2 to 6 for all cubicles in the line-up.8. 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.9. Close the bleed valve at the cooling unit.10. Continue to fill in coolant until a base pressure of 100…150 kPa is achieved.11. Open the bleed valve of the pump to let out any air.12. Re-check the pressure and add coolant if necessary.


13. Start the coolant pump. Let any air remaining in the system out through the bleed valveat the cooling unit.

14. After one to two minutes, stop the pump or block the coolant flow with a valve.15. Re-check the pressure and add coolant if necessary.16. Repeat steps 13 to 15 a few times until all air is let out of the cooling circuit. Listen for

a humming sound and/or feel the piping for vibration to find out if there is still air left inthe circuit.


Draining the internal cooling circuitThe modules in each cubicle can be drained through the drain valves without draining thewhole internal cooling circuit.

WARNING!Hot, pressurized coolant can be present in the cooling circuit. Do not work on thecooling circuit before the pressure is released by stopping the pumps and drainingcoolant.

1. Attach hoses to each drain valve in the cubicle to be drained. Lead the hoses into asuitable container. Make sure the ends of the hoses are not immersed in coolant at anypoint so that air can displace the coolant in the system.

2. Open the drain valves. Wait until all coolant has drained.

Note: Draining coolant into the sewer system is not allowed.

3. If required, dry the piping with compressed oil-free air of less than 6 bar.4. If the drive is to be stored in temperatures below 0 °C (32 °F),

• dry the cooling circuit with air,• fill the cooling circuit with coolant specified under Coolant specification (page 52).• drain the cooling circuit again.

Maintenance intervalsAs a general rule, the quality of the coolant should be checked at intervals of two years.This can be done by distributors of Antifrogen® L (see www.clariant.com) if a 250 millilitersample is provided.

Technical data￭ Coolant specification

Coolant type

Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% water mixture,available from Clariant distributors and ABB Service representatives.

Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).Antifrogen® L 50% mixture is usable in storage temperatures down to -40 °C (-40 °F).

Note that operation below 0 °C (32 °F) is not allowed regardless of the freezing point of thecoolant.

WARNING!The warranty does not cover damage occurring from use of improper coolant.

￭ Temperature limitsAmbient temperature: See the technical data of the drive/unit.

Freeze protection: The freezing point of the coolant is determined by the concentration ofheat transfer fluid in the mixture.


www.clariant.com

www.clariant.com

The higher the concentration of heat transfer fluid, the higher the viscosity of the coolant.This results in a higher pressure loss in the system. See Pressure limits (page 54).

The nominal current ratings of drive system modules apply to an Antifrogen® L / watersolution of 25/75% (volume). With the Antifrogen® L concentration between 25% and 50%,the drive output current must be derated by 1/3 percentage point per 1 p.p. increase inAntifrogen® L concentration. The drawing below shows the derating factor (k) in relation toAntifrogen® L concentration.

1.00

0.95

25%

k

0.9030% 35% 40% 45% 50% Antifrogen® L concentration

Incoming coolant temperature:• 0…40 °C (32…104 °F): no drive output current derating required• 40…45 °C (104…113 °F): drive output current must be derated by 2 percentage points

per 1 °C (1.8 °F) temperature increase, as shown by curve (a).• 45…50 °C (113…122 °F):

• If components with a maximum operating temperature of 55 °C (131 °F) are installedin the same space as the drive modules, drive output current must be derated by6 percentage points per 1 °C (1.8 °F) temperature increase, as shown by curve (c).

• If there are no components with a maximum operating temperature of 55 °C (131 °F)installed in the same space as the drive modules, drive output current must bederated by 2 percentage points per 1 °C (1.8 °F) temperature increase, as shownby curve (b).

The drawing below shows the derating factor (k) in relation to coolant temperature.


The drawing below shows the derating factor (k) in relation to coolant temperature.

Condensation is not allowed. The minimum coolant temperature to avoid condensation (at an atmospheric pressure of 1 bar) is shown below as a function of relative humidity (f) and ambient temperature (Tair).

Maximum temperature rise: Depends on heat losses and mass flow. Typically 5 °C (9 °F) with nominal losses and flow.

Pressure limitsBase pressure: 100 … 150 kPa (recommended); 200 kPa (maximum). “Base pressure” denotes the pressure of the system compared with the atmospheric pressure when the cooling circuit is filled with coolant.

Air counterpressure in the expansion tank: 40 kPa

Design pressure: 600 kPa

Nominal pressure difference (between main in/out lines): 120 kPa

Maximum pressure difference (between main in/out lines): 200 kPa

Tair(°C)

Min. Tcoolant (°C) = 95% = 80% = 65% = 50% = 40%

5 4.3 1.9 -0.9 -4.5 -7.410 9.2 6.7 3.7 -0.1 -3.015 14.2 11.5 8.4 4.6 1.520 19.2 16.5 13.2 9.4 6.025 24.1 21.4 17.9 13.8 10.530 29.1 26.2 22.7 18.4 15.035 34.1 31.1 27.4 23.0 19.440 39.0 35.9 32.2 27.6 23.845 44.0 40.8 36.8 32.1 28.250 49.0 45.6 41.6 36.7 32.855 53.9 50.4 46.3 42.2 37.1

= Not allowed as standard but the coolant temperature must be 4 °C (39 °F) or above. Consult an ABB representative if operation below coolant temperature 4 °C is required.

Example: At an air temperature of 45 °C and relative humidity of 65% the coolant temperature may not be below +36.8 °C

T

1.00

0.90

+40 °C+104 °F

k

0.80

0.70

0.60

+45 °C+113 °F

+50 °C+122 °F

(a)

(b)

(c)

ACS880LC_coolant temp derating curve.pdf

Condensation is not allowed. The minimum coolant temperature to avoid condensation (atan atmospheric pressure of 1 bar) is shown below as a function of relative humidity (RH)and ambient temperature (Tair).

Min. Tcoolant (°C)Tair(°C)

RH = 40%RH = 50%RH = 65%RH = 80%RH = 95%

-7.4-4.5-0.91.94.35


Min. Tcoolant (°C)Tair(°C)

RH = 40%RH = 50%RH = 65%RH = 80%RH = 95%

-3.0-0.13.76.79.210

1.54.68.411.514.215

6.09.413.216.519.220

10.513.817.921.424.125

15.018.422.726.229.130

19.423.027.431.134.135

23.827.632.235.939.040

28.232.136.840.844.045

32.836.741.645.649.050

37.142.246.350.453.955

= Not allowed as standard but the coolant temperature must be 0 °C (32 °F) or above.

At an air temperature of 45 °C and relative humidity of 65% the coolant temperature maynot be below +36.8 °CExample:

Maximum temperature rise: Depends on heat losses and mass flow. Typically 10 °C (18°F) with nominal losses and flow.

￭ Pressure limitsBase pressure: 100 … 150 kPa (recommended); 200 kPa (maximum). “Base pressure”denotes the pressure of the system compared with the atmospheric pressure when thecooling circuit is filled with coolant.

Air counterpressure in the expansion tank: 40 kPa

Design pressure (PS): 600 kPa

Nominal pressure difference (between main in/out lines): 120 kPa with 25/75% (volume)coolant solution, 150 kPa with 50/50% (volume) coolant solution. This has to be taken intoaccount when dimensioning the liquid cooling circuit.

Maximum pressure difference (between main in/out lines): 200 kPa

￭ Coolant flow rate limitsThe maximum coolant flow rate for all drive equipment is 1.3 × nominal. See the technicaldata chapter for nominal values.

￭ Cooling circuit materialsMaterials used in the internal cooling circuit are listed below. These are also the only materialsthat can be used in the external cooling circuit.• stainless steel AISI 316L (UNS 31603)• heavy gauge aluminum• 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 connecting external piping to the internal cooling circuit, use only materialsthat are specified above. Copper, brass or bronze must not be used underany circumstances. Even minor dissolution of copper can cause copperprecipitation on aluminum and subsequent galvanic corrosion. The liquidcooling system must not contain any zinc (eg. galvanized pipes).

If the plant incorporates normal iron pipes or cast iron accessories (eg. motor housings), acooling unit with a heat exchanger (such as the ACS880-1007LC) must be used to separatethe systems.


Technical data

Contents of this chapterThis chapter contains the technical specifications of the brake unit, for example, the ratings,sizes and technical requirements, provisions for fulfilling the requirements for CE and othermarkings.

Ratings￭ Brake chopper onlyThese brake units are not equipped with brake resistors or fans. The resistors must beselected according to the specifications and installed by the user.

Duty cycle(10/60 s)

Duty cycle(1/5 min)PcontIrmsImaxRnPbrmax

Module typeACS880-607LC-… IrmsPbrIrmsPbr

AkWAkWkWAAohmkW

3614042672981191074142.72404NBRW-669C0400-7

7228085345962382148282.728072 × NBRW-669C0800-7

1083121280189435732112422.7212113 × NBRW-669C1200-7

144416161068119247642816562.7216154 × NBRW-669C1600-7

180520201335149059553520702.7220195 × NBRW-669C2000-7

216624241602178871464224842.7224226 × NBRW-669C2400-7

11Technical data 57

￭ Brake chopper with factory-installed brake resistors (option +D151)

ER

Duty cycle(10/60 s)

Duty cycle(1/5 min)PbrcontIrmsImaxRminPbrmax

Resistor typeModuletype

ACS880-607LC-… IrmsPbrIrmsPbr

kJAkWAkWkWAAohmkW

1080025728714916754978351.354042 ×SAFUR200F500

NBRW-669C

0400-7

2160051457529833310819416701.358072 × (2 ×SAFUR200F500)

2 ×NBRW-669C

0800-7

3240077186244750016229125051.3512113 × (2 ×SAFUR200F500)

3 ×NBRW-669C

1200-7

432001028115059666721638833401.3516154 × (2 ×SAFUR200F500)

4 ×NBRW-669C

1600-7

540001285143774583327048541751.3520195 × (2 ×SAFUR200F500)

5 ×NBRW-669C

2000-7

6480015421724894100032458250101.3524226 × (2 ×SAFUR200F500)

6 ×NBRW-669C

2400-7

58 Technical data

￭ Definitions

Brake unitExample: ACS880-607LC-0800-7

Energy pulse that all the resistors of the unit put togetherwill withstand (400 s duty cycle). This energy will heatthe resistor elements from 40°C to the maximum allow-able temperature.

ER

Maximum peak current of the whole brake unitImaxMaximum continuous power ratingPbrcontMaximum short-term (1 min every 10 mins) brakingpower

Pbrmax

Resistance of specified resistors (per chopper module).This is also the minimum allowed resistance for theresistor assembly.

R

Total brake resistor resistance of the whole brake unitRtot

NBRW-669

SAFUR200F500

SAFUR200F500

ImaxIrms

Rtot

NBRW-669

SAFUR200F500

SAFUR200F500

+–

PbrmaxPbr

RR

Pcont

Duty cycle (10 s / 60 s)

Total rms current during a period of 10 seconds withbraking power Pbr

Irms

Maximum braking power, allowed for 10 seconds every60 seconds

10 s 50 s

Pbr

0

Pbr

Duty cycle (1 min / 5 min)

Total rms current during a period of 1 minute withbraking power Pbr

Irms

Maximum braking power, allowed for 1 minute every 5minutes

1 min 4 min

Pbr

0

Pbr

Brake current wave form

1 min or 10 s 4 min or 50 s

Imax

0

Irms

Technical data 59

DC fusesINA

UNV

QtyFuse typeACS880-607LC-…

UN = 690 V (Range 525…690 V)

63012502170M51460400-7

63012504170M51460800-7

63012506170M51461200-7

63012508170M51461600-7

630125010170M51462000-7

630125012170M51462400-7

Dimensions, weights and free space requirements￭ Brake chopper only

Weight1)DepthWidthHeightACS880-607LC-…

lbkgin.mmin.mmin.mm

UN = 690 V

47421523.6260015.7540078.8220020400-7

55125023.6260031.5080078.8220020800-7

102546523.6260047.24120078.8220021200-7

110250023.6260062.99160078.8220021600-7

157671523.6260078.74200078.8220022000-7

165375023.6260094.49240078.8220022400-71) Coolant included


WeightDepthWidthHeightACS880-607LC-…

lbkgin.mmin.mmin.mm

UN = 690 V

75034023.6260047.24120078.8220020400-7

150068023.6260094.49240078.8220020800-7

2249102023.62600141.73360078.8220021200-7

2998136023.62600188.981)48001)78.8220021600-7

3748170023.62600236.221)60001)78.8220022000-7

4497204023.62600283.461)72001)78.8220022400-71) An additional 300 mm junction section is needed.

60 Technical data

Losses, cooling data and noise￭ Brake chopper only

NoiseCoolantPower loss

Module typeACS880-607LC-…dB(A)

Pres-sureloss

Flow rateVolumeIntoairkW

IntocoolantkW kPa

(PSI)US

gal/minl/minUSgall

UN = 690 V (Range 525…690 V)

65120(17.4)0.421.60.683.10.11.9NBRW-6690400-7

65120(17.4)

2 ×0.422 × 1.62 ×

0.682 × 3.10.23.82 × NBRW-6690800-7

68120(17.4)

3 ×0.423 × 1.63 ×

0.683 × 3.10.45.63 × NBRW-6691200-7

68120(17.4)

4 ×0.424 × 1.64 ×

0.684 × 3.10.57.54 × NBRW-6691600-7

69120(17.4)

5 ×0.425 × 1.65 ×

0.685 × 3.10.69.45 × NBRW-6692000-7

69120(17.4)

6 ×0.426 × 1.66 ×

0.686 × 3.10.711.36 × NBRW-6692400-7


NoiseAir flowResistor typeModule

typeACS880-607LC-…dB(A)ft3/minm3/h

UN = 690 V (Range 525…690 V)

TBA108018402 ×SAFUR200F500

NBRW-6690400-7

TBA255043402 × (2 ×SAFUR200F500)

2 ×NBRW-669

0800-7

TBA364061803 × (2 ×SAFUR200F500)

3 ×NBRW-669

1200-7

TBA472080204 × (2 ×SAFUR200F500)

4 ×NBRW-669

1600-7

TBA580098605 × (2 ×SAFUR200F500)

5 ×NBRW-669

2000-7

TBA6890117006 × (2 ×SAFUR200F500)

6 ×NBRW-669

2400-7

Technical data 61

Terminal and lead-through data for the resistor cable forbrake units with user-defined brake resistors

R+, R-, grounding terminalsACS880-607LC-…

Tightening torqueN·m

ScrewHoledia-metermm

Number ofholes

UN = 690 V (Range 525…690 V)

35M101110400-7

352×M101120800-7

353×M101131200-7

354×M101141600-7

355×M101152000-7

356×M101162400-7

The number of holes in the lead-through plate for the resistor cables is• n × 3 × Ø60 mm (2.36”)

where n = 1…6 parallel-connected brake chopper modules.

Resistor cable sizesResistor cable (Cu)*

Multicoremm2

ACS880-607LC-…

UN = 690 V (Range 525…690 V)

3×95+500400-7

2×(3×95+50)0800-7

3×(3×95+50)1200-7

4×(3×95+50)1600-7

5×(3×95+50)2000-7

6×(3×95+50)2400-7*Size of the cable between the brake chopper and the first resistor which carriesthe entire braking power.

￭ Maximum cable lengthThe maximum cable length of the resistor cable(s) is 50 m (164 ft).

62 Technical data

Protection classes￭ Brake chopper cubicle

IP42 (standard), IP54 (option +B055)Degrees of protection(IEC/EN 60529)

UL Type 1 (standard), UL Type 12 (option +B055). For indoor use only.Enclosure types (UL50)

III, except for auxiliary power connections (fan, control, heating, lighting, coolingunit pump etc) which are category II.

Overvoltage category(IEC/EN 60664-1)

IProtective class(IEC/EN 61800-5-1)

Ambient conditionsEnvironmental limits for the drive are given below. The drive is to be used in a heated,indoor, controlled environment.

Transportationin the protective package

Storagein the protective package

Operationinstalled for stationary

use

--0…2000 m (0…6562 ft)above sea level. For alti-tudes over 2000m, contact

ABB.

Installation site altitude

Output derated above 1000m (3281 ft).

-40 to +70 °C (-40 to +158 °F)

-40 to +70 °C (-40 to +158 °F)

0 … +45 °C(+32 … +113 °F), no con-densation allowed. Output

derated in the range+45 … +55 °C

(+113 … +131 °F).

Air temperature

Max. 95%Max. 95%Max. 95%Relative humidity

No condensation allowed. Maximum allowed relative humidity is 60% in the presenceof corrosive gases.

IEC 60721-3-2:1997IEC 60721-3-1:1997IEC/EN 60721-3-3:2002:Classification of environ-mental conditions - Part 3-3: Classification of groupsof environmental paramet-ers and their severities -Stationary use of weather

protected locations

ContaminationChemical gases: Class

2C2Solid particles: Class 2S2

Chemical gases: Class1C2

Solid particles: Class 1S3(packing must support this,

otherwise 1S2)

Chemical gases: Class3C2

Solid particles: Class 3S2.No conductive dust al-

lowed.

Technical data 63

Transportationin the protective package

Storagein the protective package

Operationinstalled for stationary

use

IEC/EN 60721-3-2:1997IEC/EN 60721-3-1:1997IEC/EN 60721-3-3:2002Vibration2…9 Hz: max. 3.5 mm

amplitude10…57Hz:max. 0.075mm

amplitude10…57Hz:max. 0.075mm

amplitudeIEC/EN 61800-5-1IEC 60068-2-6:2007,EN 60068-2-6:2008 Envir-onmental testing Part 2:Tests –Test Fc: Vibration(sinusoidal)

9…200 Hz: 10 m/s2(32.8 ft/s2)

57…150 Hz: 1 g57…150 Hz: 1 gUnits with marine construc-tion (option +C121): Max.

1 mm (0.04 in)(5 … 13.2 Hz), max. 0.7 g(13.2… 100 Hz) sinusoidal

With packing max.100 m/s2 (328 ft/s2) 11 ms

With packing max.100 m/s2 (328 ft/s2) 11 ms

Not allowedShockIEC 60068-2-27:2008, EN60068-2-27:2009Environmental testing -Part 2-27: Tests - Test Eaand guidance: Shock

64 Technical data

MaterialsCabinet • Zinc coated steel sheet

• Polyester thermosetting powder coating on visible surfaces, color RAL 7035 andRAL 9017

Tin-plated copperBusbars for user powerconnections

See Cooling circuit materials (page 54)Liquid cooling system

Insulating materials and non-metallic items: mostly self-extinctiveFire safety of materials(IEC 60332-1)

Standard package:Package• timber, polyethylene sheet (thickness 0.15mm), stretch film (thickness 0.023mm),PP tape, PET strap, sheet metal (steel)

• for land and air transport when planned storage time is less than 2 months orwhen storage can be arranged in clean and dry conditions less than 6 months

• can be used when products will not be exposed to corrosive atmosphere duringtransport or storage

Container package:• timber, VCI sheet film (PE, thickness 0.10 mm), VCI stretch film (PE, thickness0.04 mm), VCI emitter bags, PP tape, PET strap, sheet metal (steel)

• for sea transport in containers• recommended for land and air transport when storage time prior to installationexceeds 6 months or storage is arranged in partially weather-protected conditions

Seaworthy package:• timber, plywood, VCI sheet film (PE, thickness 0.10 mm), VCI stretch film (PE,thickness 0.04 mm), VCI emitter bags, PP tape, PET strap, sheet metal (steel)

• for sea transport with or without containerization• for long storage periods in environments where roofed and humidity-controlledstorage cannot be arranged

Cabinets are fastened to the pallet with screws and braced from the top end to thepackage walls to prevent swaying inside the package. Package elements are at-tached to each other with screws.

The main parts of the drive can be recycled to preserve natural resources and en-ergy. Product parts and materials should be dismantled and separated.Generally all metals, such as steel, aluminum, copper and its alloys, and preciousmetals can be recycled as material. Plastics, rubber, cardboard and other packagingmaterial can be used in energy recovery. Printed circuit boards and large electro-lytic capacitors need selective treatment according to IEC 62635 guidelines. To aidrecycling, plastic parts are marked with an appropriate identification code.Contact your local ABB distributor for further information on environmental aspectsand recycling instructions for professional recyclers. End of life treatment must followinternational and local regulations.

Disposal

Standards and markingsSee ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions(3AXD50000048634 [English]).

Disclaimers￭ Generic disclaimerThe manufacturer shall have no obligation with respect to any product which (i) has beenimproperly repaired or altered; (ii) has been subjected to misuse, negligence or accident;(iii) has been used in a manner contrary to the manufacturer’s instructions; or (iv) has failedas a result of ordinary wear and tear.

Technical data 65

￭ Cybersecurity disclaimerThis product is designed to be connected to and to communicate information and data viaa network interface. It is Customer's sole responsibility to provide and continuously ensurea secure connection between the product and Customer network or any other network (asthe case may be). Customer shall establish and maintain any appropriate measures (suchas but not limited to the installation of firewalls, application of authentication measures,encryption of data, installation of anti-virus programs, etc) to protect the product, the network,its system and the interface against any kind of security breaches, unauthorized access,interference, intrusion, leakage and/or theft of data or information. ABB and its affiliates arenot liable for damages and/or losses related to such security breaches, any unauthorizedaccess, interference, intrusion, leakage and/or theft of data or information.

66 Technical data

12. Example circuit diagrams

Contents of this chapterThis chapter contains example circuit diagrams of a brake unit.

In an installation with parallel-connected brake chopper modules, one chopper acts as themaster for the others. The switching of the follower chopper(s) is controlled by the mastervia a fiber optic link.

With minor modifications, the basic connections are also valid if there are no factory installedbrake resistors. The corresponding resistor connections are to be done by the user.

Note: The actual configuration can differ from this basic configuration. See the drawingsincluded in the delivery.

Example circuit diagrams 67

Brake unit with one brake chopper module

A

1 2 3 4 5 6 7 8

B

C

D

E

F

ACS880-607LC-0400-7690V 001a

No. of Sheets

.1Rev.

60=SAP Doc. No.

EPLAN Doc. No.

ABB Ref. No.

Resp. Dept.

Item Des.

Sheet

TitlePrep.

App.

Project

Cust. Doc. No.

Cust. Ref. No.

Customer

1 2 3 4 5 6 7 8

A

B

C

D

E

FCircuit diagram

JOLU ACS880-607LC

Jorma Luusua Brake chopper&resistor EFS2

RD10

7509

/ 33

05

18.03.2019

5

3AFE _-

60-

-T121.1/005a/1B

BRAKE MODULENBRW-669C

R-R+

UDC-UDC+ PE

13

14-S121.7

Connections with dashed linesare made by customer

-R121.11

BRAKE RESISTORSAFUR 200F500/K

R+ R-

4 3

-R121.12

BRAKE RESISTORSAFUR 200F500/K

R+ R-

4 3

H07V2-K

120 BK

+60.1

1

2-F12

1.11 63

0A

1

2-F12

1.12 63

0A

-R121.1 ATTENUATOR ASSEMBLYNRCB-010006 -

+

-X121.7 11 12

-X121.7 14

-X121.7 13

WX121.7PTFE2,5

H07V2-K

70 BK

1

-R1P:1 1-R1N:1

2-R1P:2

-R1N:2

+60.2

//:

//:

/005

a/4C

-X12

1.1:

11

/005

a/4C

-X12

1.1:

12


Brake chopper control

A

1 2 3 4 5 6 7 8

B

C

D

E

F

ACS880-607LC-0400-7690V 005a

No. of Sheets

.1Rev.

60=SAP Doc. No.

EPLAN Doc. No.

ABB Ref. No.

Resp. Dept.

Item Des.

Sheet

TitlePrep.

App.

Project

Cust. Doc. No.

Cust. Ref. No.

Customer

1 2 3 4 5 6 7 8

A

B

C

D

E

FCircuit diagram

JOLU ACS880-607LC

Jorma Luusua Brake chopper control EFS2

RD10

7509

/ 33

05

18.03.2019

5

3AFE _-

60-

2

2

>500V

230V400V

Fiber-X4

111

122 Fault -K1

OFF

-X6

1 2Voltage reducer

12

11

1422

21

24

-K122.1//4D

121114

22

2124-K121.1

//3D

+60.1

H05V2-K

1 BK

Twisted pairH07V2-K2,5 BKWH


12-X121.1 11

1

2

3

4

-F122.12AH07V2-K

6 BK

A1

A2

-K122.1//1D

H07V2-K

6 BK

H05V2-K1 BK

H05V2-K

1 BK

-T121.1/001a/2B

BRAKE MODULENBRW-669C

A1

A2

-K121.1//3E

TR

V22

Slav

e co

ntro

l RE

V23

EXT.

con

trol

1-X1

2

214-X25.1

204

-X121.121

22 23

-X121.124

/005a/2F-X121.1:22

/005a/8E-X25.1:204

/005a/8E-X25.1:214

//:

/005a/2C-T121.1:-X3:2

/005a/2E-X25.1:204

/005a/2E-X25.1:214

/001

a/2F

-X12

1.7:

11/0

01a/

4F-X

121.

7:12

2-X3

3 1


External fan voltage supply

A

1 2 3 4 5 6 7 8

B

C

D

E

F

ACS880-607LC-0400-7690V 020a

No. of Sheets

.1Rev.

60=SAP Doc. No.

EPLAN Doc. No.

ABB Ref. No.

Resp. Dept.

Item Des.

Sheet

TitlePrep.

App.

Project

Cust. Doc. No.

Cust. Ref. No.

Customer

1 2 3 4 5 6 7 8

A

B

C

D

E

FCircuit diagram

JOLU ACS880-607LC

Jorma Luusua External supplies EFS2

RD10

7509

/ 33

05

18.03.2019

5

3AFE _-

60-

EXTERNAL FAN VOLTAGE SUPPLYPROVIDED BY USERMAX FUSE <FUSE> A gG

40/63A

L<VOLTAGE>

N

<FREQUENCY>

1

2

3

4

5

6

-Q22.2-Q22.2:PE

GNYE

1

2

3

4-F22.2

1

+60.1

/026

a/1A

-F11

5.10

:1

/026

a/1A

-F11

5.10

:3


Fan control for brake chopper cubicle

A

1 2 3 4 5 6 7 8

B

C

D

E

F

ACS880-607LC-0400-7690V 026a

No. of Sheets

.1Rev.

60=SAP Doc. No.

EPLAN Doc. No.

ABB Ref. No.

Resp. Dept.

Item Des.

Sheet

TitlePrep.

App.

Project

Cust. Doc. No.

Cust. Ref. No.

Customer

1 2 3 4 5 6 7 8

A

B

C

D

E

FCircuit diagram

JOLU ACS880-607LC

Jorma Luusua Fan control for Brake chopper cabinet EFS2

RD10

7509

/ 33

05

18.03.2019

5

3AFE _-

60-

12

46 →

12

46 →

-F115.112*1/2/4/6A

PROTECTION SWITCHMICO 2.6

+24V ON1 ON2

13 14OUT1 OUT2GND

M1~

WHTacho

4

BLGND

1

YEPWM

2

RD10V

3

LBK

CON10

NBL

CON11

PEGNYE

CON12-G115.11

FAN, CENTRIFUGALR3G225-RE07-20

-A115.10CIO-01

01FAN CONTROL KITCIO-01

Not Terminated▌ CIO-01 NODE:

2-X121.1

1-X121.1 13 14

Twisted pair

Twisted pair

Twisted pair Twisted pair

Device wire Device wire Device wire Device wire

H07V2-K

1,5 BK

H07V2-K1,5 BK

+60.1

1

H07V2-K4 GNYE

-X115.11 1 2 PE

13 12 14 11

-W1LiYCY-TP2x2x0,56

-X115.11 FE

-W2LiYCY-TP2x2x0,56

SH WH BN GN

SH

1

2

3

4-F115.10

8A

Device Wire3xAWG20

Device Wire4xAWG22

11

DI1-XDIO1

12

DCOM

13

DO1

21

DI2-XDIO2

22

DCOM

23

DO2

31

DI3-XDIO3

32

DCOM

33

DO3

41

DI4-XDIO4

42

DCOM

43

DO4

1

DI5-XDI1

2

DCOM

3

DI6

4

DCOM

5

DI7-XDI2

6

DCOM

7

DI8

8

DCOM

1

AI1+-XAI1

2

AI1-

3

SHIELD

1

AI2+-XAI2

2

AI2-

3

SHIELD

2

A

1

B-X485

2

GND

1

+24 V-XPOW

3

GND

4

SHIELD

/026

a/6C

-X12

1.1:

1

/026

a/6A

-X12

1.1:

2

//:

//:

/026

a/1B

-A11

5.10

:-XPO

W:1

/026

a/1B

-A11

5.10

:-XPO

W:2

//:

//:

//:

/020a/3D-F22.2:2

/020a/4D-F22.2:4

/027

a/5A

-X12

1.7:

2

/027

a/5A

-X12

1.7:

1

/027a/1A-F115.70:1

/027a/1A:


Fan control for resistor cabinet

A

1 2 3 4 5 6 7 8

B

C

D

E

F

ACS880-607LC-0400-7690V 027a

No. of Sheets

.1Rev.

60=SAP Doc. No.

EPLAN Doc. No.

ABB Ref. No.

Resp. Dept.

Item Des.

Sheet

TitlePrep.

App.

Project

Cust. Doc. No.

Cust. Ref. No.

Customer

1 2 3 4 5 6 7 8

A

B

C

D

E

FCircuit diagram

JOLU ACS880-607LC

Jorma Luusua Fan control for Brake resistor cabinet EFS2

RD10

7509

/ 33

05

18.03.2019

5

3AFE _-

60-

Not Terminated▌

M1~

WHTacho

4

BLGND

1

YEPWM

2

RD10V

3

LBK

CON10

NBL

CON11

PEGNYE

CON12-G115.72

FAN KIT (ACS880-107LC)R3G225-RE07-20

M1~

WHTacho

4

BLGND

1

YEPWM

2

RD10V

3

LBK

CON10

NBL

CON11

PEGNYE

CON12-G115.71

FAN KIT (ACS880-107LC)R3G225-RE07-20

CIO-01 NODE:

SH

WH GN12

11

14

-K115.72//7C

-W11LiYCY-TP2x2x0,56

SH BN

H07V2-KBK

1

2-F115.70

4A

3

4

1

H07V2-K4 GNYE

H07V2-K1,5 BK

12

11

14

-K115.71//6C

H07V2-K4 GNYE

-W10LiYCY-TP2x2x0,56

SH BN WH GN

1-X121.7 2

A1

A2-K115.71

6 A

121114 //3D

A1

A2-K115.72

6 A

121114 //5D

H05V2-K

1 BKH05V2-K1 BK

H05V2-K1 BK

H05V2-K

1 BK

Device wire Device wire Device wire Device wire

H07V2-K4 BK

1

+60.2


Twisted pairH07V2-K1,5 BK

-W9LiYCY-TP2x2x0,56

SH

11

DI1-XDIO1

12

DCOM

13

DO1

21

DI2-XDIO2

22

DCOM

23

DO2

31

DI3-XDIO3

32

DCOM

33

DO3

41

DI4-XDIO4

42

DCOM

43

DO4

1

DI5-XDI1

2

DCOM

3

DI6

4

DCOM

5

DI7-XDI2

6

DCOM

7

DI8

8

DCOM

1

AI1+-XAI1

2

AI1-

3

SHIELD

1

AI2+-XAI2

2

AI2-

3

SHIELD

2

A

1

B-X485

2

GND

1

+24 V-XPOW

3

GND

4

SHIELD

Device Wire3xAWG20

Device Wire4xAWG22

-X115.72 FE

-X115.72 1

13 12 14 11

2 PEDevice Wire

3xAWG20

Device Wire4xAWG22

13 12 14 11-X115.71 FE

-X115.71 1 2 PE

-A115.60CIO-01

02

/027

a/6B

-X12

1.7:

2

/027

a/6B

-X12

1.7:

1

/026a/6C-X121.1:1

/026a/7C-F115.11:OUT1

/027

a/1C

-A11

5.60

:-XPO

W:1

/027

a/1C

-A11

5.60

:-XPO

W:2

/026a/3B-F115.10:2

/026a/3B-F115.10:4

//:

//:

//:

//:

//:

//://://:


Further information—

Product and service inquiriesAddress any inquiries about the product to your local ABB representative, quoting the typedesignation and serial number of the unit in question. A listingof ABBsales, support and servicecontacts can be found by navigating to www.abb.com/searchchannels.

Product trainingFor information on ABB product training, navigate to new.abb.com/service/training.

Providing feedback on ABB manualsYour comments on our manuals are welcome. Navigate tonew.abb.com/drives/manuals-feedback-form.

Document library on the InternetYou can find manuals and other product documents in PDF format on the Internet atwww.abb.com/drives/documents.

a1 (frozen)PDF-WebCreated 2019-06-28, 16:36:36

www.abb.com/searchchannels

new.abb.com/service/training

new.abb.com/drives/manuals-feedback-form

www.abb.com/drives/documents

abbindustrialdrives acs880-607lc1-phasebrakeunits … · 2019-06-28 ·...

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