Product Introduction – ABB BGAD-12C (3AUA0000112491)

The ABB BGAD-12C (Part No. 3AUA0000112491) is a high-performance braking chopper module designed for use in ABB’s ACS800 drive series and other compatible AC drive systems. Engineered for medium to high power industrial applications, the BGAD-12C is responsible for safely dissipating regenerative energy during motor braking cycles. It ensures efficient energy management and protection of the drive components by redirecting excess voltage to external braking resistors.

This braking unit is vital in dynamic applications such as cranes, elevators, conveyors, and centrifuges, where rapid deceleration can generate high levels of regenerative energy. ABB’s BGAD-12C offers exceptional reliability, compact design, and seamless integration into ABB’s automation and drive solutions.

Product Advantages

• High Energy Dissipation Capability
  Capable of handling high braking power, making it ideal for demanding dynamic load applications.

• Seamless Integration
  Designed for compatibility with ABB ACS800 series drives, reducing engineering and installation complexity.

• Compact Design
  The space-saving construction allows for efficient cabinet integration.

• Overvoltage Protection
  Ensures the drive system remains within safe operational voltage limits during regenerative braking.

• Robust and Durable
  Built with industrial-grade materials for long-term stability under harsh operating conditions.

• Simple Installation and Maintenance
  Comes with mounting and wiring instructions that streamline installation and minimize downtime.

Technical Specifications

Product Applications

• Elevator Systems – Controls braking energy in lifting applications, providing smooth operation and safety.

• Cranes and Hoists – Manages regenerative energy during lifting/lowering loads, preventing voltage surges.

• Centrifuges and Spinners – Handles high deceleration torque where braking demand is frequent.

• Conveyor Systems – Maintains motor control efficiency during frequent starts/stops in production lines.

• Machine Tools – Supports rapid deceleration cycles in cutting, milling, and drilling equipment.

• Winders/Unwinders – Manages braking energy for systems dealing with reel tension.

Compatible Models / Associated Products

• ACS800-01 – Wall-mounted drive series.

• ACS800-02 – Cabinet-built drive with high customization.

• ACS800-04 – Single drive modules for cabinet assembly.

• ACS800-07 – Free-standing drive modules with power regeneration.

• DBR-1500 – Dynamic braking resistor designed for pairing with BGAD-12C.

• REX 521 – Control relay that can be used in conjunction with drive protection.

Installation Instructions

1. Pre-installation Checklist
   Ensure the main drive power is turned off. Verify compatibility between the drive and BGAD-12C braking chopper. Mount in a well-ventilated panel.

2. Mechanical Mounting
   Secure the unit vertically onto a metal mounting plate using standard screws. Allow adequate spacing around the device for ventilation (minimum 100 mm clearance on all sides).

3. Wiring Connections
   Connect the DC bus terminals from the drive to the BGAD-12C input terminals. Ensure correct polarity and tight torque application to avoid arcing.

4. Braking Resistor Connection
   Connect the external braking resistor to the designated terminals. Match the resistor’s power rating to the braking energy requirements.

5. Testing
   After powering up the drive system, perform a test braking cycle under no-load conditions to confirm correct operation.

6. Safety Measures
   Always ground the unit properly. Verify thermal protection is functional. Keep away from moisture and dust ingress.

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Frequently Asked Questions (FAQ)

Q1: What is the purpose of the ABB BGAD-12C braking chopper?
A1: The BGAD-12C is designed to absorb and safely dissipate excess regenerative energy during motor deceleration, preventing overvoltage damage to the drive system.

Q2: Can the BGAD-12C be used with non-ABB drives?
A2: While it is optimized for ABB ACS800 series drives, it may be used with other drives that support DC link braking choppers, provided the voltage and power ratings match.

Q3: What size braking resistor should be used with the BGAD-12C?
A3: The braking resistor size depends on the braking power and duty cycle. ABB typically recommends resistors rated equal to or greater than the chopper’s rated braking power—12 kW in this case.

Q4: How should the BGAD-12C be protected from overheating?
A4: Ensure proper ventilation during installation. Thermal sensors may be installed if the operating environment is subject to high ambient temperatures or continuous braking cycles.

Q5: Is regular maintenance required for the BGAD-12C?
A5: Minimal maintenance is needed. Periodic visual inspections for dust accumulation, loose wiring, and thermal discoloration are recommended to ensure safe operation.

Q6: What are the safety precautions before installation?
A6: Always disconnect power before installation. Use proper grounding, avoid moisture-prone areas, and ensure that all connections comply with electrical safety standards.