Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ................Safety instructions ................Target audience ................... Related manuals .................. Terms and abbreviations ................. 2 Operation principle and hardware description Contents of this chapter ................Product overview ..................
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6 Table of contents Installation stages ................Overview of kits ................Stage 1: Installation of common parts ..........Stage 2: Installation of mounting plate ..........Stage 3: Installation of cooling components ........... Stage 4: Installation of brake module and attenuator ........ Examples: Installing the brake resistors and cooling fan ........
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Table of contents 7 Brake chopper cooling ................Cooling fans ..................Fan kit (with heat exchanger) ..............Coolant piping and fittings ..............DC bus installation parts (for Rittal TS 8 enclosures) ........DC bus installation parts (for Rittal VX25 enclosures) ........Fuses and fuse bases ................
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8 Table of contents CE marking ..................Compliance with the European Low Voltage Directive ........Compliance with the European EMC Directive ........... More information on standards and markings ..........13 Dimension drawings Contents of this chapter ................Brake chopper module NBRW-669 ............Attenuator ..................
Introduction to the manual 9 Introduction to the manual Contents of this chapter This chapter introduces this manual. Safety instructions Follow all safety instructions delivered with the drive. • Read the complete safety instructions before you install, commission, use or service the drive.
3AUA0000127808 Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, etc. You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals not available in the document library, contact your local ABB representative. You can find all documentation related to the multidrive modules on the Internet at...
Introduction to the manual 11 Terms and abbreviations Term Description Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds a certain maximum limit. The voltage rise is typically caused by deceleration (braking) of a high inertia motor.
This chapter introduces the operation principle and construction of the brake unit. Product overview The ACS880-604LC is a liquid-cooled resistor brake unit available in the ACS880 multidrive modules product range. The design presented in this manual has an NBRW-669C liquid-cooled brake chopper module with two brake resistors. The chopper module has a liquid-cooled heat sink which transfers most of the generated heat into the coolant.
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Typically, a drive system is equipped with a brake chopper or brake choppers 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. Standard resistors are available from ABB for each brake chopper module.
Operation principle and hardware description 15 Single-line diagram of the drive system The diagram below shows a typical common DC link drive system. AC supply Input (AC) fuses Supply unit DC link Inverter DC fuses Inverter units. In this example, one of the units ocnsists of two inverter modules connected in parallel Brake chopper DC fuses Attenuator.
16 Operation principle and hardware description Layout The components of the brake chopper module are shown below. UDC+ R+ UDC- Fastening points on back plate (two at the top, two at the bottom) Front cover fastening screws Front cover Chopper control board (NBRC) with control terminals. See section Overview of power and control connections (page 18).
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Operation principle and hardware description 17 UDC- UDC+ Power connection terminals Coolant connections behind main mounting plate (side view). A length of 1.5 m (4.9 ft) of 6/4 mm pipe is attached to each connector.
18 Operation principle and hardware description Overview of power and control connections The diagram below shows the power and control connections of the brake chopper module. NBRC t° UDC- UDC+ t° – Item Description Additional information Chopper enable input See section Protecting the system against thermal overload (page 27).
The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
22 Planning the installation Equipping the drive with a main contactor and manual control switch or switches It is highly recommended to equip the drive with a main contactor and wire it to fault indication relay output X3 on the chopper control board. This configuration also requires a manual start/stop switch(es) for system start-up.
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Planning the installation 23 Example 1 NBRC Example 2 NBRC...
24 Planning the installation Selecting the brake circuit components 1. Calculate the maximum power generated by the motor during braking (P 2. Select a suitable brake chopper and brake resistor combination for the application using the data given under Ratings (page 73).
Planning the installation 25 50 s of rest). If the actual braking cycle does not correspond to the reference cycle, you have to calculate the maximum allowed braking power as shown below. 1. Braking energy transferred during any ten minute period must be less than or equal to the energy transferred during the reference braking cycle: 100 s brmax...
26 Planning the installation Example 3 The duration of a braking cycle is three minutes. The braking time is 10 seconds. · 100 s brmax < 2.5 · P brmax 4 · 10 s brmax 600 s T = Duration of braking cycle 2.
■ EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user-defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer. Placing the brake resistors Install the resistors in a place where they will cool.
28 Planning the installation Protecting the resistor cable against short-circuits The brake unit requires the use of brake circuit fuses. The fuses protect the brake chopper and the brake circuit cables in a cable short-circuit situation. Controlling the brake chopper from an external control location The brake chopper can be controlled from an external control location via a fiber optic link (terminals V22 and V23 on the chopper control board).
Mechanical installation 29 Mechanical installation Contents of this chapter This chapter contains installation instructions and examples. Checking the installation site The brake chopper module must be installed in upright position. The degree of protection of the module is IP00. Take this into account when selecting the installation site. Installation in a cabinet is highly recommended.
30 Mechanical installation Installing the brake chopper module 1. Mark the locations of the four holes onto the installation surface. For the module dimension, see Dimension drawings (page 83). 2. Drill the mounting holes. Make sure that dust and burr from drilling does not enter the module or other equipment at the installation site.
Mechanical installation 31 Examples: Installing the brake chopper module and related components ■ Example: Installation into a Rittal TS 8 or VX25 enclosure Layout drawing Description Brake chopper cubicle, side view Brake chopper cubicle, front view Brake chopper cubicle, front-side view DC fuses DC busbars Cooling fan and heat exchanger...
Air flow out. Use a ventilated roof. Brake resistors Cooling fan mounting plate* Cooling fan Plastic bars on both sides to block airflow** * Not available from ABB. For an illustration, see 3AXD50000008316. ** Not available from ABB. For an illustration, see 3AXD50000008190 and 3AXD50000008209.
Brake resistor cubicle, front view Brake resistor cubicle, side view Mounting rails* Thermal circuit breakers Brake resistors Power connection terminals Cooling fan mounting plate* Cooling fan * Not available from ABB For more information on the dimension, see chapter Dimension drawings (page 83).
The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive system may experience problems that the warranty does not cover.
42 Electrical installation Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do installation or maintenance work.
Electrical installation 43 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 the resistor circuit Do not make any voltage tolerance or insulation resistance tests on the brake chopper modules.
44 Electrical installation Selecting the voltage Before wiring the brake unit, select the voltage level as follows: 1. Remove the chopper front panel by undoing the four screws at the top and bottom of the panel. 2. Set the voltage selection jumper on the chopper control board (see Layout (page 16)) to the appropriate voltage as shown below.
Electrical installation 45 Synchronizing multiple brake choppers When several brake choppers are in use, the first chopper in the chain acts as the master for the other choppers. To synchronize the choppers: 1. Set the voltage selection jumper of the master to the appropriate voltage. 2.
46 Electrical installation Connecting the DC and resistor cables WARNING! Never connect the output terminals of the brake chopper together. It short-circuits the chopper and will damage it. ■ Connection diagram Brake chopper module and resistors in separate Brake chopper module and resistor in the same cubicles cubicle DC link...
Electrical installation 47 ■ Connection procedure 1. If the DC link and the brake unit are located in separate cabinets, ground the DC cable 360 degrees at the cabinet entries. 2. At the brake chopper end, connect the twisted shields (protective earth conductor) of the DC and resistor cables and the third conductors to the grounding terminals.
48 Electrical installation Chopper Resistor Resistor R– R– R– Connecting the thermal switch Connect the thermal switches of the resistors in series to chopper enable input X1 as shown in section Overview of power and control connections (page 18).
Installation checklist 49 Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the brake chopper.
50 Installation checklist Checklist Check the mechanical and electrical installation of the brake chopper before start-up. Go over the checklist together with another person. WARNING! Only qualified electricians are allowed to carry out the work described below. Obey the complete safety instructions for the drive. If you ignore the safety instructions, physical injury or death can occur.
Start-up 51 Start-up Contents of this chapter This chapter contains the start-up procedure of a brake unit. WARNING! Only qualified electricians are allowed to perform the work described in this chapter. Obey all safety instructions in Safety instructions for ACS880 liquid-cooled multidrive cabinets and modules (3AXD50000048633 [English]).
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52 Start-up Action Additional information Check that the insulation of the resistor circuit has been meas- See section Checking the insulation ured and is OK. of the resistor circuit (page 43). Check that the drive is ready for the brake chopper start-up: See the Related manuals (page 10).
Fault tracing 53 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the brake unit. Fault indications A fault in the resistor brake circuit prevents fast motor deceleration and may cause the drive to trip on a fault. If a fault is detected by the chopper control board, the brake chopper disconnects the brake resistor from the intermediate circuit, and the changeover switch of the fault indication relay output is released.
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Short circuit in power cables or res- Check power cables and resistor. istor. Chopper control board failure. Contact local ABB representative. Chopper damaged; it is not able to disconnect resistor from intermedi- ate circuit. Chopper does not function.
Maintenance 55 Maintenance Contents of this chapter This chapter instructs how to maintain the inverter module and how to interpret its fault conditions. The information is valid for ACS880-104LC inverter modules and the cabinet construction examples presented in this manual. WARNING! Only qualified electricians are allowed to do the work described in this chapter.
Replacement Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
Maintenance 57 Maintenance timers and counters The supply and inverter control programs have maintenance timers and counters that can be configured to generate a warning when a pre-defined limit is reached. Each timer/counter can be set to monitor any parameter. This feature is especially useful as a service reminder. For more information, see the supply and inverter control program firmware manuals.
60 Ordering information Brake chopper modules ACS880-604LC-… Ordering code Module type = 690 V (Range 525…690 V) 0400-7 0800-7 1200-7 64260049 NBRW-669C 1600-7 2000-7 2400-7 Brake chopper cooling ■ Cooling fans The cooling fan forces the air inside the cubicle through an air-to-liquid heat exchanger.
Ordering information 61 ■ Coolant piping and fittings The chopper module and the heat exchanger are connected in series so that the flow direction is up, ie. from the cold main line to chopper module, and from chopper module to heat exchanger.
62 Ordering information DC bus installation parts (for Rittal TS 8 enclosures) 120 Ordering information The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat-PLS DC-side components DC bus and ensure its correct placement and alignment inside the cabinet line-up. Note: Common DC Flat-PLS assembly The designs presented in this manual for Rittal TS 8 enclosures employ the Rittal Flat-PLS...
68327466 630 A, 1000 V 10028205 170H3005 170M8635 1600-7 2000-7 2400-7 Brake resistors Each brake chopper module has two resistors of its own. ACS880-604LC-… Ordering code Type Ratings = 690 V (Range 525…690 V) 0400-7 0800-7 1200-7 68759340 SAFUR200F500 200 kW, R = 2.7 ohm...
Internal cooling circuit 65 Internal cooling circuit Contents of this chapter The cooling system of a liquid-cooled drive consists of two circuits: the internal cooling circuit and the external cooling circuit. The internal cooling circuit covers the heat-generating electrical components of the drive and transfers the heat to the cooling unit. In the cooling unit, the heat is transferred to the external cooling circuit which is usually part of a larger external cooling system.
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66 Internal cooling circuit Supply modules Inverter modules To/From cooling unit Air-to-liquid heat exchanger Heat sink Inlet valve Inlet-side drain valve Outlet valve Outlet-side drain valve The coolant used with ACS880 liquid-cooled drive systems is Antifrogen® L 25% or 50% water mixture.
Internal cooling circuit 67 Connection to a cooling unit ■ Connection to an ACS880-1007LC cooling unit Refer 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 changes when the temperature varies.
68 Internal cooling circuit Filling up and bleeding the internal cooling circuit Both 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 excess coolant out of the system.
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Internal cooling circuit 69 13. Start the coolant pump. Let any air remaining in the system out through the bleed valve at the cooling unit. 14. After one to two minutes, stop the pump or block the coolant flow with a valve. 15.
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).
Pressure limits (page 71). The nominal current ratings of drive system modules apply to an Antifrogen® L / water solution of 25/75% (volume). For derating with other ratios, contact your local ABB representative. Incoming coolant temperature: 0…50 °C (32…122 °F): no current derating required Condensation is not allowed.
72 Internal cooling circuit ■ Cooling circuit materials Materials used in the internal cooling circuit are listed below. These are also the only materials that can be used in the external cooling circuit. • stainless steel AISI 316L (UNS 31603) •...
Technical data 73 Technical data Contents of this chapter This chapter contains the technical specifications of the brake chopper module, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Standard brake resistor and cooling fan specifications are also included where applicable.
Technical data 75 ■ Definitions Example: ACS880-604LC-0800-7 Brake unit – Energy pulse that all the resistors of the unit put togeth- er will withstand (400 s duty cycle). This energy will heat the resistor elements from 40°C to the maximum allowable temperature.
Maximum long-term tensile load: 1 N • Flexing: Max. 1000 cycles ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from Avago Technologies’ Versatile Link range. Note that the optical component type is not directly related to the actual communication speed.
Altitude above sea level 0 … 2000 m (0 … 6561.7 ft) no derat- ing. For altitudes over 2000 m (6561.7 ft), contact ABB. Air temperature 0 … +55 °C -40 … +70 °C -40 … +70 °C (+32 … +131 °F), no con- (-40 …...
Technical data 81 ■ Compliance with the European EMC Directive ACS880 multidrive modules: The cabinet builder is in charge for the compliance of the drive with the European EMC Directive. For information on the items to consider, see: • Electrical planning instructions for ACS880 liquid-cooled multidrive cabinets and modules (3AXD50000048634 [English]) •...
Dimension drawings 83 Dimension drawings Contents of this chapter This chapter contains the dimension drawings of the brake chopper module, as well as the standard brake resistors and cooling fans. The dimensions are in millimeters. To convert to inches, use the formula: 25.4 mm = 1 in.
Circuit diagram examples 89 Circuit diagram examples Contents of this chapter This chapter contains example circuit diagrams of a brake unit. The purpose of these diagrams is to help in: • understanding the internal connections and operation of a brake unit, and •...
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.