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ABB ZGAB-592 3AUA0000078548 Brake Control Board
1. Product Description
An industrial-grade brake control board designed for precise, safe control of electric motor brakes in heavy-duty automation systems. The ABB ZGAB-592 3AUA0000078548 integrates advanced braking logic, real-time current monitoring, and multi-level safety protection to regulate brake engagement/disengagement for AC/DC motors. It supports seamless integration with ABB drives (e.g., ACS880, ACS580) and third-party motor control systems, delivering consistent braking torque and preventing brake wear or overheating. Ideal for harsh industrial environments such as material handling (cranes, hoists), conveyor systems, and heavy machinery where reliable, emergency-stop capable braking is critical.
2. Detailed Specifications
2.1 Brake Control Performance
- Brake Type Compatibility: DC electromagnetic brakes (90-240 V DC); AC brakes (230/400 V AC, via external rectifier)
- Control Signal Input: 0-10 V DC analog signal / 24 V DC digital signal (start/stop, emergency stop); 4-20 mA DC (proportional braking torque control)
- Braking Current Regulation: 0.5-15 A (adjustable via potentiometer/software; ±5% current accuracy)
- Response Time: <100 ms (brake engagement/disengagement; meets emergency stop EN ISO 13849-1 requirements)
- Torque Control Mode: Two modes – "Quick Stop" (for emergency braking) and "Soft Stop" (for gradual deceleration to prevent load shock)
2.2 Electrical Parameters
- Supply Voltage: 24 V DC ±15% (control circuit); 90-240 V DC / 230/400 V AC (brake power circuit, selectable via DIP switch)
- Max Brake Output Power: 300 W (DC brakes); 500 W (AC brakes, with external rectifier)
- Control Circuit Current: Typical 100 mA, Maximum 200 mA (24 V DC)
- Input Impedance: 10 kΩ (analog signal inputs); 2 kΩ (digital signal inputs)
- Isolation: 2 kV AC isolation between control circuit and brake power circuit (prevents electrical interference)
2.3 Safety & Protection Features
- Overcurrent Protection: Latching shutdown when brake current exceeds 120% of set value (resets via manual reset button or remote signal)
- Overheating Protection: Built-in NTC thermistor (triggers alarm at 85°C; shuts down at 95°C to prevent board/brake damage)
- Emergency Stop (E-Stop) Integration: Complies with EN ISO 13849-1 Category 3, PL d (supports direct connection to E-Stop circuits)
- Brake Fault Detection: Monitors brake coil open/short circuit, low supply voltage, and abnormal current drift (triggers relay output alarm)
- Under Voltage Lockout: Disables brake output if control voltage <19.5 V DC (prevents weak braking due to low power)
2.4 Operating Environment
- Operating Temperature: -25°C ~ +70°C (derates 1% per °C above 60°C for brake current)
- Storage Temperature: -40°C ~ +85°C
- Relative Humidity: 5% ~ 95% (non-condensing; no derating required)
- Vibration Resistance: 10-500 Hz, 2 g acceleration (IEC 60068-2-6; compatible with heavy machinery vibration)
- Shock Resistance: 30 g acceleration, 11 ms duration (IEC 60068-2-27; withstands load impact during braking)
- EMC Compliance: EN 61000-6-2 (industrial immunity), EN 61000-6-4 (industrial emissions)
2.5 Physical & Installation
- Dimensions: 180×120×40 mm (Length×Width×Height)
- Mounting Type: DIN rail mounting (EN 50022 standard) / Panel mounting (via integrated screw holes)
- Weight: Approximately 450 g
- Control signals: Phoenix-style screw terminals (0.5-1.5 mm² cables; torque 0.4-0.6 N·m)
- Brake power: High-current terminals (2.5-6 mm² cables; torque 1.0-1.2 N·m)
- LED Indicators: 5 status LEDs (green: power on; yellow: brake engaged; red: overcurrent/overheat; blue: E-Stop active; orange: fault)
2.6 Compatibility & Certifications
- System Compatibility: ABB ACS880/ACS580/ACS380 drives; third-party PLCs (Siemens S7, Rockwell Allen-Bradley) via analog/digital signals
- Certifications: CE (EN 61010-1), UL 508, CSA C22.2 No. 14, EN ISO 13849-1 (PL d, Category 3), IEC 61800-5-1 (motor safety)
3. Advantages & Features
- Dual Brake Compatibility: Supports both DC and AC brakes (with rectifier), adapting to diverse motor systems (e.g., hoists, conveyors).
- Safety-Certified E-Stop: EN ISO 13849-1 PL d compliance ensures reliable emergency braking, critical for load-carrying machinery (cranes).
- Precise Current Regulation: ±5% current accuracy maintains consistent braking torque, reducing brake wear and extending service life.
- Dual Stop Modes: "Quick Stop" (emergency) and "Soft Stop" (gradual) prevent load shock and equipment damage (e.g., fragile goods transport).
- Comprehensive Fault Monitoring: Real-time detection of overcurrent, overheating, and brake faults enables proactive maintenance, minimizing downtime.
4. Application Fields
- Material Handling: Cranes, hoists, and elevators (controls brake engagement to prevent load dropping during power loss; E-Stop compliance for operator safety).
- Conveyor Systems: Heavy-duty industrial conveyors (mining, logistics) – "Soft Stop" mode prevents material spillage; overcurrent protection avoids brake jamming.
- Heavy Machinery: Construction equipment (excavators, loaders) and manufacturing presses – regulates brake torque for precise machine positioning.
- Industrial Motors: High-inertia motors (pumps, fans) – controls deceleration rate to avoid mechanical stress on gears and shafts.
- Automated Warehouses: Automated guided vehicles (AGVs) and stacker cranes – fast brake response for collision avoidance; low-power standby mode saves energy.
5. Precautions
- Mount on a DIN rail or panel with 50 mm clearance on all sides for heat dissipation (critical for overheating protection).
- Separate brake power cables (high-current) from control signal cables (low-current) by at least 30 cm to reduce electromagnetic interference.
- Use copper cables of appropriate gauge: 2.5-6 mm² for brake power; 0.5-1.5 mm² for control signals.
- Securely ground the board via the dedicated ground terminal (ensures safety and EMC compliance).
- Verify brake voltage compatibility (DC/AC) before connecting – incorrect voltage will damage the brake coil.
- Set brake current based on the motor’s rated braking torque (refer to brake manufacturer specs); avoid overcurrent (causes coil overheating).
- Test "E-Stop" function after installation to confirm compliance with EN ISO 13849-1 (ensure brake engages within 100 ms).
- Inspect terminals quarterly for corrosion or loose connections (tighten to specified torque if needed).
- Clean the board with a dry, soft brush (no liquids) to remove dust – dust accumulation increases overheating risk.
- Replace the board if the red fault LED remains lit after reset (indicates permanent internal damage, e.g., failed current sensor).
- Do not disassemble the board (voids warranty and risks electrical shock – internal components carry high voltage).
The structure and details of the product：
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