ABB 3ASC25H705-7

This is the brake chopper module for ABB’s ACS800 and ACS880 series industrial inverters. Its main function is to dissipate the regenerative energy generated when the inverter drives the motor to generate electricity, preventing the inverter’s DC bus voltage from overshooting, thereby protecting the inverter and ensuring stable system operation.

Product Name and Type
Product Name: Brake Chopper Module

Model: 3ASC25H705-7

Series: ABB ACS800/ACS880 Drive System Accessory

Common Alternative Names: Brake Unit, Braking Unit

Main Functions and Principles
Function:

Energy Release: During dynamic motor braking (such as reducing a load or coasting a fan or pump), the motor becomes a generator, converting mechanical energy into electrical energy and feeding it back into the inverter’s DC bus.

Voltage Clamping: Monitors the DC bus voltage in real time. When the voltage exceeds a preset safety threshold (e.g., 720V DC), the chopper automatically activates.

Inverter Protection: This module directs excess energy to an external braking resistor, converting it into heat and dissipating it. This prevents excessive DC bus voltage from causing an inverter overvoltage fault (e.g., F0004) and even damaging the inverter.

Principle:

This module is connected in parallel with the inverter’s DC bus (+DC and -DC).

At its core is a high-power IGBT (insulated gate bipolar transistor) switch.

When excessive bus voltage is detected, the control circuit uses a high-frequency (“chopping”) method to rapidly turn the IGBT on and off.

The IGBT turns on, connecting the externally connected braking resistor to the DC bus circuit. Energy flows through the resistor and is dissipated as heat.

By adjusting the IGBT’s on/off time ratio (duty cycle), braking torque and bus voltage levels can be precisely controlled.

Main features and parameters
Applicable drive series:

ACS800

ACS880

Rated Voltage: Suitable for drives with 380-480V AC three-phase input (corresponding to a DC bus voltage of approximately 540-680V DC).

Maximum Continuous Braking Power: This depends on the power of the connected external braking resistor. The chopper module itself specifies the maximum current it can safely switch.

Peak Braking Power: Also dependent on the external braking resistor, allowing for short periods of time with loads higher than the continuous power rating.

Control: Automatic switching control based on the DC bus voltage.

Mounting:

Built-in: Mounts directly in the cabinet or power unit of certain ACS800/ACS880 drive models as an integrated option.

Wall-mount: Can also be mounted separately on the backplane of a control cabinet.

Connections:

Power Supply: Connects to the positive and negative DC bus terminals (+DC, -DC) of the drive via busbars or cables.

Load terminal: Output terminals for connecting an external braking resistor.

Control signal: May include status feedback signal lines.

Typical Application Scenarios
This module is widely used in applications requiring rapid deceleration or where gravity loads are present, including but not limited to:

Material handling: Cranes, hoists, elevators, and winches (when lowering heavy objects).

Centrifuges: Industrial centrifuges and dehydrators.

Conveyor systems: Inclined conveyors.

Fans and pumps: Rapid stops due to pipeline pressure or fluid inertia.

Machine tools: Rapid braking of spindle motors.

Test benches: Load testing of drive systems.

Sales of the brand:

ABB、EPRO、GE、FOXBORO、Schneider、Rexroth、Honeywell、Bently、YASKAWA other global DCS system and PLC system, servo system of famous industrial brand.

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Company Name: ABB Ltd

Headquarters: Zurich, Switzerland

Established in 1988 (formed by the merger of ASEA from Sweden and BBC Brown Boveri from Switzerland)

Business scope: Electrification, Automation, Robotics and Discrete Automation, Motion Control

Operating scope: Over 100 countries worldwide

In 1988, the merger of Swedish ASEA and Swiss BBC Brown Bovary formed ABB, creating one of the world’s largest engineering groups at the time. This merger was a landmark cross-border merger and acquisition in European industrial history.

Growth and Expansion: Throughout the 1990s and early 2000s, ABB rapidly expanded its global presence and product portfolio through a series of acquisitions and organic growth.

Main Businesses:

Electrification

Process Automation

Motion Control

Robotics and Discrete Automation

China Market: China is ABB’s second-largest market globally and holds a crucial strategic position. ABB has a comprehensive presence in China, including:

R&D: We operate a world-leading R&D center.

Manufacturing: We operate multiple modern factories across China, including in Xiamen, Beijing, and Shanghai.

Sales and Service: Our extensive sales and service network covers the entire country.