ACS 600 Installation and

Start-up Guide

NBRA-6xx Braking Choppers

 NBRA-6xx Braking Choppers

Installation and Start-up Guide

3AFY 58920541 R0225

EN
EFFECTIVE: 1997-10-20
SUPERSEDES: 1996-02-13

1997 ABB Industry Oy. All Rights Reserved.

 Safety Instructions

Overview This chapter states the safety instructions which must be followed
when installing and operating the NBRA-6xx Braking Chopper. The
material in this chapter must be studied before attempting any work on,
or with, the braking chopper.

Warnings and Notes This manual distinguishes two sorts of safety instructions. Warnings
are used to inform of conditions which can, if proper steps are not
taken, lead to a serious fault condition, physical injury or death. Notes
are used when the reader is required to pay special attention or when
there is additional information available on the subject. Notes are less
crucial than Warnings, but should not be disregarded.

Warnings Readers are informed of situations that can result in serious physical
injury and/or serious damage to equipment with the following symbols:

Dangerous Voltage Warning: warns of situations

in which a high voltage can cause physical injury
and/or damage equipment. The text next to this
symbol describes ways to avoid the danger.

General Warning: warns of situations which can

cause physical injury and/or damage equipment by
means other than electrical. The text next to this
symbol describes ways to avoid the danger.

Electrostatic Discharge Warning: warns of

situations in which an electrostatic discharge can
damage equipment. The text next to this symbol
describes ways to avoid the danger.

Notes Readers are notified of the need for special attention or additional
information available on the subject with the following symbols:

CAUTION! Emphasises a matter in order to draw special

attention to it.
Note: Gives additional information or points out more
information available on the subject.

Installation and Start-up Guide for NBRA-6xx iii

Safety Instructions

General Safety
Instructions

WARNING! All electrical installation and maintenance work on

the ACS 600 should be carried out by qualified electricians. Exercise
appropriate care when working with the unit. Neglecting these
instructions can cause physical injury and death.
The drive and adjoining equipment must be properly earthed.
Do not attempt any work on a powered ACS 600. After switching off the
mains, always allow the intermediate circuit capacitors 5 minutes to
discharge before working on the frequency converter, the motor or the
motor cable. It is good practice to check (with a voltage indicating
instrument) that the frequency converter is in fact unpowered before
beginning work.
The ACS 600 motor cable terminals are at a dangerously high voltage
when mains power is applied, regardless of motor operation.
The ACS 600 intermediate circuit terminals (UDC+, UDC) are at a
dangerously high voltage when the mains power of the ACS 600 is
applied.
The input busbars and terminals up to the fuse switch of the ACS 607
are at a dangerously high voltage when mains power is applied,
regardless of the position of the fuse switch handle in the cabinet door.
The terminals UDC+, UDC, R+, and R of the braking chopper are at
a dangerously high voltage when it is connected to the ACS 600 with
the mains power applied.
The terminals R+, and R of the braking resistor are at a dangerously
high voltage when the resistor is connected to a powered braking
chopper.
The enable input terminal block of the braking chopper is at a
dangerously high voltage when the chopper is connected to the
ACS 600 with the mains power applied.
Dangerous voltages from external control circuits may be present
inside the ACS 600 even when its mains power is shut off.

More Warnings and Notes are printed at appropriate instances along

the text.
The General Safety Instructions given in the Installation and Start-up
Manual of the ACS 600 frequency converter should be studied before
attempting any work on or with the unit.

iv Installation and Start-up Guide for NBRA-6xx

 Table of Contents

Safety Instructions

Table of Contents

Chapter 1 Introduction to This Guide

Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
What This Guide Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2 Overview
Resistor Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Braking Chopper NBRA-6xx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Delivery Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Braking Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Rating Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Selecting the Correct ACS 600/Chopper/Resistor Combination . . . . . . . . . . . . . . . . . . . . . . 2-7

Chapter 3 Voltage Selection and Mechanical Installation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Voltage Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Synchronisation of Multiple Choppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mechanical Installation NBRA-653/663 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Mechanical Installation NBRA-654/664 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Mechanical Installation NBRA-655/656/666 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Mechanical Installation NBRA-657/667 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Mechanical Installation NBRA-658/659/669 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Installation and Start-up Guide for NBRA-6xx v

Table of Contents

Chapter 4 Electrical Installation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Power Cable Selection and Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fibre Optic Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Power Connections NBRA-653/663 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Power Connections NBRA-654/664 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Power Connections NBRA-655/656/666 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Power Connections NBRA-657/667 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Power Connections NBRA-658/659/669 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Chapter 5 Fault Tracing

Fault Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Appendix A Dimensions
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Braking Chopper NBRA-653/663 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Braking Chopper NBRA-658/659/669 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Braking Resistor SACE08RE44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Braking Resistor SACE15RExx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Braking Resistors SAFUR80F500, SAFUR90F575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Braking Resistors SAFUR180F460, SAFUR125F500, SAFUR200F500, SAFUR210F575 . . . A-4

Appendix B Maximum Braking Power

How to Calculate? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

vi Installation and Start-up Guide for NBRA-6xx

 Chapter 1 Introduction to This Guide

Intended Audience The Guide is intended for the people responsible for installing,
commissioning and servicing the braking chopper of an ACS 600
product family frequency converter. The user is expected to have a
basic knowledge of electrical fundamentals, electrical wiring practices
and ACS 600 family frequency converters.

What This Guide Safety Instructions are placed on the first few pages of the Guide.
Contains Safety Instructions describe the formats for various warnings and
notations used in this guide. This chapter also states the General
Safety Instructions.
Chapter 1 Introduction to This Guide contains a description of this
Guide.
Chapter 2 Overview contains a short description of resistor braking,
braking choppers and braking resistors. The standard braking chopper
and braking resistor available for each ACS 600 type are given in the
rating tables.
Chapter 3 Voltage Selection and Mechanical Installation
describes how to set the chopper voltage level and install the chopper.
Chapter 4 Electrical Installation contains instructions for power
cable selection and routing, control connections, and power
connections.
Chapter 5 Fault Tracing contains information on chopper and
resistor fault indications, and fault tracing.
Appendix A contains the dimensional drawings of the braking
choppers and braking resistors to be installed outside the ACS 600
housing.
Appendix B contains the calculation instructions for the maximum
allowed braking power.

Related Publications The Installation and Start-up Manual and the Programming Manual
of the frequency converter.

Installation and Start-up Guide for NBRA-6xx 1-1

Chapter 1 Introduction to This Guide

1-2 Installation and Start-up Guide for NBRA-6xx

 Chapter 2 Overview

Resistor Braking The deceleration time of an AC drive can be decreased by using

resistor braking. For this, the frequency converter has to be equipped
with a braking chopper and a braking resistor.
The standard braking choppers and braking resistors available for the
ACS 600 units are given in Table 2-1.
The choppers and the resistors are rated so that the power equal to the
short-term overload capacity of the ACS 600 can be handled during
braking. The short-term overload capacity for a Normal Use rated
ACS 600 is 110 % of the rated output power (current), and, for a
Heavy-duty Use rated ACS 600, 150 % of the rated output power
(current).

Braking Chopper The NBRA-6xx Braking Choppers are optional devices for ACS 600
NBRA-6xx Family frequency converters.
The chopper connects the braking resistor to the intermediate circuit of
the frequency converter whenever the voltage in the intermediate
circuit exceeds the maximum limit.
The maximum limit is equal to 1.21 1.35 U1max. U1max is dependent
on the chopper voltage selection (see Chapter 3 Voltage Selection
and Mechanical Installation). With the selection 400V, U1max is 415 V;
with the selection 500V, U1max is 500 V; with the selection >500V
(NBRA-66x), U1max is 690V. Energy consumption by resistor losses
lowers the voltage until the resistor can be disconnected. This limit is
equal to 1.19 1.35 U1max. The energy generated by the motor during
a fast deceleration of the drive typically causes the voltage to rise in the
intermediate circuit.
Note: Drive Parameter 20.5 (20.7 for ACP 600) OVERVOLTAGE CTRL
must be set to OFF to enable chopper operation.
The chopper control board supervises system status and detects
failures such as:
braking resistor and resistor cable short circuits
chopper (IGBT) short circuit
chopper control board failure.

Installation and Start-up Guide for NBRA-6xx 2-1

Chapter 2 Overview

There is an enable input and a relay output on the chopper control

board. The input can be connected to a temperature sensitive switch
mounted in the resistor assembly to protect the resistor against
overtemperature (see Chapter 4 Electrical Installation for more
information). The relay output indicates chopper faults.
The chopper can be controlled from an external control location via a
fibre optic link. Using the link it is possible to synchronise several
braking choppers. In standard applications the fibre optic link is not
used.

Accessories It is highly recommended to equip the ACS 600 with a main contactor
controlled by the chopper relay output. This configuration also requires
a manual start/stop switch for system start-up. For more information,
see Chapter 4 Electrical Installation.

Delivery Check The package contains:

Braking chopper type NBRA-6xx
(check the correct type with Table 2-1)
Installation and Start-up Guide for NBRA-6xx (this document).

Warranty See the Installation and Start-up Manual delivered with the frequency
converter for warranty information.

2-2 Installation and Start-up Guide for NBRA-6xx

 Chapter 2 Overview

Braking Resistors Standard resistors are available for each ACS 600 / NBRA-6xx
combination. These resistors are specified in Table 2-1, and their
dimensions given in Appendix A. (Some combinations require the use
of two parallel-connected resistors.) Other resistors with a resistance
not below the minimum allowed resistance value (R) may also be used.

WARNING! Never use a braking resistor with a resistance value below

the minimum allowed resistance value specified for that particular
ACS 600 / braking chopper combination. The chopper and the
frequency converter are not able to handle the overcurrent caused by
the low resistance.

If the heat dissipation capacity (ER) of the standard braking resistor is

not sufficient for the application, it is possible to use a four resistor
assembly in which two standard resistors are connected in parallel and
two in series. This implementation does not change the total resistance
of the resistor assembly.

Fuses The NBRA-658, NBRA-659 and NBRA-669 require the use of braking
circuit fuses. Other units do not require the fuses if all of the following
provisions are fulfilled:
the ACS 600 mains cable is protected with fuses
the cable and the fuses are of the type specified for that particular
converter model in its Installation and Start-up Manual
the braking chopper circuit cables are as specified in this Guide.
The fuses in the braking circuit protect the chopper and the braking
circuit cables in a cable short-circuit situation. The fuses do not protect
the cables, the chopper or the resistor against overload. Overload
protection can be implemented by wiring the temperature sensor of the
resistor to the Enable Input of the chopper and simultaneously
connecting the Relay Output of the chopper to the main contactor
control circuit of the ACS 600.
The fuses must be installed as near as possible to the ACS 600
intermediate circuit terminals (UDC+ and UDC). Unprotected cable
length must not exceed 0.5 metres.

Rating Tables The standard braking choppers, braking resistors, cables and fuses are
specified in Tables 2-1 and 2-2. (See also Chapter 4 Electrical
Installation.)
The Maximum Braking Power of the ACS 600 / NBRA-6xx combination
is given for a reference braking cycle (the drive brakes for one minute
every ten minutes). If the actual cycle does not correspond to the
reference cycle, the maximum allowed braking power must be
calculated. See Appendix B Maximum Braking Power for
instructions.

Installation and Start-up Guide for NBRA-6xx 2-3

Chapter 2 Overview

Table 2-1 ACS 600 ratings for resistor braking.

Cable Braking
Braking Braking Resistor(s)
ACS 600 (Copper) Power
Chopper
Type R ER PRcont No. of A PBRmax
Type Type
[ohm] [kJ] [kW] Elements* [mm 2] [kW]

400 V a.c. Units

-0005-3 NBRA-653 SACE08RE44 44.0 210.0 1 2 3x6+6 5.0
-0006-3 NBRA-653 SACE08RE44 44.0 210.0 1 2 3x6+6 6.2
-0009-3 NBRA-653 SACE08RE44 44.0 210.0 1 2 3x6+6 8.3
-0011-3 NBRA-653 SACE15RE22 22.0 420.0 2 4 3x6+6 11.0
-0016-3 NBRA-653 SACE15RE22 22.0 420.0 2 4 3x6+6 14.4
-0020-3 NBRA-654 SACE15RE13 13.0 435.0 2 4 3x6+6 19.7
-0025-3 NBRA-654 SACE15RE13 13.0 435.0 2 4 3x6+6 26.9
-0030-3 NBRA-655 SAFUR90F575 8.0 1800 4.5 9 3x25+16 33.2
-0040-3 NBRA-655 SAFUR90F575 8.0 1800 4.5 9 3x25+16 39.0
-0050-3 NBRA-655 SAFUR90F575 8.0 1800 4.5 9 3x25+16 52.8
-0060-3 NBRA-656 SAFUR80F500 6.0 2400 6 12 3x35+16 65.6
-0070-3 NBRA-656 SAFUR125F500 4.0 3600 9 18 3x35+16 79.5
-0100-3 NBRA-657 SAFUR125F500 4.0 3600 9 18 3x70+35 94.2
-0120-3 NBRA-657 SAFUR200F500 2.7 5400 13.5 27 3x70+35 128.3
-0140-3 NBRA-658 SAFUR200F500 2.7 5400 13.5 27 see Table 2-2 154.5
-0170-3 NBRA-658 2xSAFUR125F500 2.0 7200 18.0 2x18 see Table 2-2 190.7
-0210-3 NBRA-658 2xSAFUR210F575 1.70 8400 21.0 2x21 see Table 2-2 229.5
-0260-3 NBRA-659 2xSAFUR200F500 1.35 10800 27.0 2x27 see Table 2-2 282.3
-0320-3 NBRA-659 2xSAFUR180F460 1.2 12000 30 2x30 see Table 2-2 352.8
-0400-3 2xNBRA-658 2x(2xSAFUR210F575) 2x1.70 2x8400 2x21.0 2x(2x21) see Table 2-2 436.1
-0490-3 2xNBRA-659 2x(2xSAFUR200F500) 2x1.35 2x10800 2x27.0 2x(2x27) see Table 2-2 536.3
-0610-3 2xNBRA-659 2x(2xSAFUR180F460) 2x1.2 2x12000 2x30 2x(2x30) see Table 2-2 670.3

500 V a.c. Units:

-0006-5 NBRA-653 SACE08RE44 44.0 210.0 1 2 3x6+6 6.3
-0009-5 NBRA-653 SACE08RE44 44.0 210.0 1 2 3x6+6 7.8
-0011-5 NBRA-653 SACE08RE44 44.0 210.0 1 2 3x6+6 10.4
-0016-5 NBRA-653 SACE15RE22 22.0 420.0 2 4 3x6+6 14.0
-0020-5 NBRA-653 SACE15RE22 22.0 420.0 2 4 3x6+6 18.5
-0025-5 NBRA-654 SACE15RE13 13.0 435.0 2 4 3x6+6 25.2
-0030-5 NBRA-654 SACE15RE13 13.0 435.0 2 4 3x6+6 31.4
-0040-5 NBRA-655 SAFUR90F575 8.0 1800 4.5 9 3x25+16 42.6
-0050-5 NBRA-655 SAFUR90F575 8.0 1800 4.5 9 3x25+16 50.1
-0060-5 NBRA-655 SAFUR90F575 8.0 1800 4.5 9 3x25+16 62.6
-0070-5 NBRA-656 SAFUR80F500 6.0 2400 6 12 3x35+16 72.6
-0100-5 NBRA-656 SAFUR80F500 6.0 2400 6 12 3x35+16 88.4
-0120-5 NBRA-657 SAFUR125F500 4.0 3600 9 18 3x70+16 122.1
-0140-5 NBRA-657 SAFUR125F500 4.0 3600 9 18 3x70+16 147.3
-0170-5 NBRA-658 SAFUR200F500 2.7 5400 13.5 27 see Table 2-2 181.1
-0210-5 NBRA-658 SAFUR200F500 2.7 5400 13.5 27 see Table 2-2 220.7
-0260-5 NBRA-658 2xSAFUR125F500 2.0 7200 18.0 2x18 see Table 2-2 268.1
-0320-5 NBRA-659 2xSAFUR210F575 1.7 8400 21.0 2x21 see Table 2-2 335.0
-0400-5 NBRA-659 2xSAFUR200F500 1.35 10800 27.0 2x27 see Table 2-2 402.8
-0490-5 2xNBRA-658 2x(2xSAFUR125F500) 2x2.0 2x7200 2x18.0 2x(2x18) see Table 2-2 509.3
-0610-5 2xNBRA-659 2x(2xSAFUR210F575) 2x1.7 2x8400 2x21.0 2x(2x21) see Table 2-2 636.5
-0760-5 2xNBRA-659 2x(2xSAFUR200F500) 2x1.35 2x10800 2x27.0 2x(2x27) see Table 2-2 765.3

(continued)

2-4 Installation and Start-up Guide for NBRA-6xx

 Chapter 2 Overview

Cable Braking
Braking Braking Resistor(s)
ACS 600 (Copper) Power
Chopper
Type R ER PRcont No. of A PBRmax
Type Type
[ohm] [kJ] [kW] Elements* [mm2] [kW]

(continued)

690 V a.c. Units:

-0009-6 NBRA-663 SACE08RE44 44.0 210 1 2 3x6+6 8.5
-0011-6 NBRA-663 SACE08RE44 44.0 210 1 2 3x6+6 12.9
-0016-6 NBRA-663 SACE08RE44 44.0 210 1 2 3x6+6 13.8
-0020-6 NBRA-663 SACE15RE22 22.0 420 2 4 3x6+6 19.8
-0025-6 NBRA-664 SACE15RE13 13.0 435 2 4 3x6+6 29.1
-0030-6 NBRA-664 SACE15RE13 13.0 435 2 4 3x6+6 35.0
-0040-6 NBRA-666 SACE15RE13 13.0 435 2 4 3x25+16 40.2
-0050-6 NBRA-666 SAFUR90F575 8.0 1800 4.5 9 3x25+16 53.0
-0060-6 NBRA-666 SAFUR90F575 8.0 1800 4.5 9 3x25+16 65.4
-0070-6 NBRA-666 SAFUR90F575 8.0 1800 4.5 9 3x35+16 80.1
-0100-6 NBRA-667 SAFUR80F500 6.0 2400 6 12 3x70+16 94.4
-0120-6 NBRA-667 SAFUR125F500 4.0 3600 9 18 3x70+35 132.5
-0140-6 NBRA-669 SAFUR210F575 3.4 4200 10.5 21 see Table 2-2 158.1
-0170-6 NBRA-669 SAFUR200F500 2.7 5400 13.5 27 see Table 2-2 193.4
-0210-6 NBRA-669 SAFUR200F500 2.7 5400 13.5 27 see Table 2-2 228.5
-0260-6 NBRA-669 2xSAFUR125F500 2.0 7200 18.0 2x18 see Table 2-2 275.9
-0320-6 NBRA-669 2xSAFUR210F575 1.7 8400 21.0 2x21 see Table 2-2 346.7
-0400-6 NBRA-669 2xSAFUR200F500 1.35 10800 27.0 2x27 see Table 2-2 403.7
-0490-6 2xNBRA-669 2x(2xSAFUR125F500) 2x2.0 2x7200 2x18.0 2x(2x18) see Table 2-2 524.2
-0610-6 2xNBRA-669 2x(2xSAFUR210F575) 2x1.7 2x8400 2x21.0 2x(2x21) see Table 2-2 658.7
-0760-6 2xNBRA-669 2x(2xSAFUR200F500) 2x1.35 2x10800 2x27.0 2x(2x27) see Table 2-2 767.0
R Resistance value for the listed resistor type. Note: This is also the minimum allowed resistance value for the braking
resistor.
ER Energy pulse that the resistor assembly will withstand (400 s duty cycle). This energy will heat the resistor element
from 40 C to the maximum allowable temperature.
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy E R dissipates in 400 seconds.
A Conductor cross-sectional areas for the copper cable to be used for connecting the braking resistor and the chopper
(or the chopper and the ACS 600). The cable should have a concentric conductor (screen). The standard cables with
three-phase conductors and a concentric conductor are given. A two-conductor screened cable may also be used if
available.
PBRmax Maximum braking power of the ACS 600 equipped with the standard chopper and the standard resistor. The drive and
the chopper will withstand this braking power for one minute every ten minutes. Note: The braking energy transmitted
to the resistor during any period shorter than 400 seconds may not exceed ER.

* The SACE04RE40 resistor consists of four resistor elements connected in parallel. The resistance of one element is 160 ohm.
The SACE15RE13 resistor consists of four resistor elements connected in parallel. The resistance of one element is 52 ohm.
The SACE15RE22 resistor consists of four resistor elements connected in parallel. The resistance of one element is 88 ohm.
The SAFUR resistors consist of several resistor elements. The resistance of one element is 8 ohm.
The NBRA-653 and -663 are to be installed outside the converter module. Their degree of protection is IP54.
The NBRA-654, -655, -656, -657, -664, -666 and -667 are to be installed inside the converter module.
The NBRA-658, -659 and -669 are to be installed outside the converter module. Their degree of protection is IP00.
All braking resistors are to be installed outside the converter module.
The SACE braking resistors are built in an IP21 metal housing.
The SAFUR braking resistors are built in an IP00 metal frame.

Installation and Start-up Guide for NBRA-6xx 2-5

Chapter 2 Overview

Table 2-2 Braking circuit cable and fuse ratings for NBRA-658, NBRA-659 and NBRA-669.

Braking Fuse (Ultrarapid) Chopper Cable (Cu) Resistor Cable (Cu)

ACS 600 1) 2) 2)
Chopper Inom DIN 43653 Single- Multicore Single- Multicore
Type
Type [A] Type core [mm2] [mm2] core [mm2] [mm2]

400 V a.c. Units

-0140-3 NBRA-658 315 170M5140 50 3x70+35 50 3x70+35
-0170-3 NBRA-658 400 170M5142 70 3x95+50 50 3x50+25
-0210-3 NBRA-658 400 170M5142 70 3x95+50 50 3x50+25
-0260-3 NBRA-659 500 170M5144 95 3x120+70 50 3x70+35
-0320-3 NBRA-659 630 170M5146 120 3x185+95 70 3x95+50
-0400-3 2xNBRA-658 400 170M5142 70 3x95+50 50 3x50+25
-0490-3 2xNBRA-659 500 170M5144 95 3x120+70 50 3x70+35
-0610-3 2xNBRA-659 630 170M5146 120 3x185+95 70 3x95+50

500 V a.c. Units:

-0170-5 NBRA-658 315 170M5140 50 3x70+35 50 3x70+35
-0210-5 NBRA-658 400 170M5142 70 3x95+50 70 3x95+50
-0260-5 NBRA-658 400 170M5142 70 3x95+50 50 3x50+25
-0320-5 NBRA-659 500 170M5144 95 3x120+70 50 3x70+35
-0400-5 NBRA-659 630 170M5146 120 3x185+95 70 3x95+50
-0490-5 2xNBRA-658 400 170M5142 70 3x95+50 50 3x50+25
-0610-5 2xNBRA-659 500 170M5144 95 3x120+70 50 3x70+35
-0760-5 2xNBRA-659 630 170M5146 120 3x185+95 70 3x95+50

690 V a.c. Units:

-0140-6 NBRA-669 250 170M5138 35 3x50+25 35 3x50+25
-0170-6 NBRA-669 315 170M5140 50 3x70+35 50 3x70+35
-0210-6 NBRA-669 400 170M5142 70 3x95+50 70 3x95+50
-0260-6 NBRA-669 400 170M5142 70 3x95+50 50 3x50+25
-0320-6 NBRA-669 500 170M5144 95 3x150+70 50 3x95+50
-0400-6 NBRA-669 630 170M5146 120 3x185+95 70 3x95+50
-0490-6 2xNBRA-669 400 170M5142 70 3x95+50 50 3x50+25
-0610-6 2xNBRA-669 500 170M5144 95 3x150+70 50 3x95+50
-0760-6 2xNBRA-669 630 170M5146 120 3x185+95 70 3x95+50

ACS 600

NBRA-6xx

Braking
Resistor(s)

1)
Ultrarapid Bussmann fuses (UN = 1250 V). Fuses with the same ratings from other manufacturers can also be used.
The type of the base for these fuses is 170H3005 (1400 V, 630 A, 110 mm).
2) In order for the installation to comply with the EMC Directive, unscreened single-core cable can only be used if routed inside a
cabinet that efficiently suppresses the radiated RFI emissions.

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 Chapter 2 Overview

Selecting the Correct 1. Calculate the maximum power (Pmax) generated by the motor during
ACS 600/Chopper/ braking.
Resistor Combination
2. Select a suitable ACS 600* / braking chopper / braking resistor
combination for the application. The following condition must be met:

PBRmax > Pmax

See Table 2-1 and Table 2-2 for PBRmax. The PBRmax values in the tables are
specified for the reference braking cycle (one minute of braking, nine minutes of
rest). If the actual duty cycle does not correspond to the reference cycle, the
maximum allowed braking power PBR must be used instead. See Appendix B
Maximum Braking Power for the calculation of PBR .

3. Check the resistor selection. The energy generated by the motor

during a 400-second period must not exceed the resistor heat
dissipation capacity ER (see Table 2-1 and Table 2-2).
If the ER value is not sufficient, it is possible to use a four-resistor assembly in which
two standard resistors are connected in parallel, two in series. The ER value of the
four-resistor assembly is four times the value specified for the standard resistor.

Note: A resistor other than the standard resistor can be used.

However, the following conditions must be met:
Resistor resistance value must not be below the resistance value of
the standard resistor.
Resistor resistance value must not restrict the braking capacity
needed. The condition is met when:
2
UDC
Pmax <
R

Pmax = Maximum power (Pmax) generated by the motor during

braking.
UDC = Voltage over the resistor during braking =
1.35 1.2 415 V d.c. (mains voltage is 380 to 415 V a.c)
1.35 1.2 500 V d.c. (mains voltage is 440 to 500 V a.c)
1.35 1.2 690 V d.c. (mains voltage is 525 to 690 V a.c)
R = Resistor resistance value (ohm)

Resistor heat dissipation capacity (ER) must be sufficient for the

application (see step 3. above).

*Selection of the ACS 600 is affected also by other factors (eg. the output power required during
acceleration). See ACS 600 Technical Catalogue for more information on selecting the ACS 600.

Installation and Start-up Guide for NBRA-6xx 2-7

Chapter 2 Overview

2-8 Installation and Start-up Guide for NBRA-6xx

 Chapter 3 Voltage Selection and
Mechanical Installation

Overview This chapter contains braking chopper voltage selection instructions

and mechanical installation instructions. The voltage selection for the
NBRA-6xx is described on the first page of the chapter. The procedure
is the same for all the choppers. Mechanical installation instructions
are given separately for each chopper type starting from page 3-3.

Note: Drive Parameter 20.5 (20.7 for ACP 600) OVERVOLTAGE CTRL
must be set to OFF to enable chopper operation.

Voltage Selection The voltage level must be selected before the braking chopper is
mounted. The voltage is set, according to the mains voltage, with a
jumper on the chopper control board. (The front cover of the chopper
has to be removed to access the jumper.)

CAUTION! Incorrect jumper setting or missing jumper may cause

braking chopper malfunctioning or damage to the chopper or resistor.
FIBER

FIBER

FIBER

FIBER
230V

400V

500V

230V

400V

500V

230V

400V

>500V

230V

400V

500V
ACS 600 mains voltage ACS 600 mains voltage ACS 600 mains voltage Chopper controlled by
380 to 415 V 440 to 500 V 525 to 690 V another chopper (see
Figure 3-2)

Figure 3-1 Braking chopper voltage selection.

Installation and Start-up Guide for NBRA-6xx 3-1

Chapter 3 Voltage Selection and Mechanical Installation

Synchronisation of The FIBER position is used if two (or more) choppers are connected to
Multiple Choppers the same intermediate circuit and must be synchronised. One chopper
the first in the chain acts as the master for the other choppers. The
voltage selection jumper of the master is set to the appropriate voltage,
while the slaves are set to FIBER.

(VOLTAGE)

FIBER

FIBER
V22 V23 V22 V23

Master Slave Slave

Figure 3-2 Master/Slave connection of multiple choppers.

WARNING! Do not touch the printed circuits. They are extremely

sensitive to electrostatic discharge.

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 Chapter 3 Voltage Selection and Mechanical Installation

Mechanical Installation
NBRA-653/663
WARNING! Before starting the installation work inside the ACS 600:
Switch off the ACS 600 power supply. Wait for five minutes to ensure
that the intermediate circuit is discharged. Switch off dangerous
voltages connected from external circuits to the digital inputs and to the
relay outputs of the ACS 600.

WARNING! Do not touch the printed circuit boards. The integrated

circuits are extremely sensitive to electrostatic discharge.

The dimensional drawing of the NBRA-653/663 is presented in

Appendix A.

Installation Site The NBRA-653/663 is protected to IP54. This must be considered

when selecting the installation site.
The following restrictions should also be noted:
Leave 150 mm free space below and above the braking chopper.
To prevent the chopper overheating, do not mount the chopper
directly above the braking resistor.
Leave 300 mm free space below and above the ACS 600 unit.
The maximum lengths of the chopper and resistor cables are 5 m
and 10 m respectively.

Mounting Instructions Ensure that the chopper voltage level is set correctly (see page 3-1).
for NBRA-653/663
Check the intended installation site for sufficient room. Mark the
locations for the four holes.
Make holes in the four positions. Make sure the dust from drilling
does not enter the unit you are installing or other equipment at the
installation site.
Insert screws in the holes. Use plugs if necessary.
Lift the chopper onto the screws on the wall.
Tighten the screws.

Installation and Start-up Guide for NBRA-6xx 3-3

Chapter 3 Voltage Selection and Mechanical Installation

Mechanical Installation
NBRA-654/664

Figure 3-3 Mounting the braking chopper NBRA-654/664.

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 Chapter 3 Voltage Selection and Mechanical Installation

WARNING! Before starting the installation work inside the ACS 600:
Switch off the ACS 600 power supply. Wait for five minutes to ensure
that the intermediate circuit is discharged. Switch off dangerous
voltages connected from external circuits to the digital inputs and to the
relay outputs of the ACS 600.

WARNING! Do not touch the printed circuit boards. The integrated

circuits are extremely sensitive to electrostatic discharge.

Mounting Instructions Ensure that the chopper voltage level is set correctly (see page 3-1).
for NBRA-654/664
Remove the frequency converter front cover.
Remove the 4 chopper mounting screws from the assembly plate of
the ACS 600.
Loosen the screws (9 pcs.) which fasten the gland plate of the
ACS 600 to the frame. The screws can be removed if there is
otherwise not enough space to install the chopper.
Place the chopper onto the assembly plate and at the same time
insert the UDC+ and UDC busses into the corresponding terminals
of the ACS 600.
Tighten the mounting screws through the chopper mounting holes to
3 Nm.
Tighten the UDC+ and UDC terminals of the ACS 600 to 2 Nm.
Tighten the mounting screws (9 pcs.) of the ACS 600 gland plate to
2 Nm.

Installation and Start-up Guide for NBRA-6xx 3-5

Chapter 3 Voltage Selection and Mechanical Installation

Mechanical Installation
NBRA-655/656/666

Figure 3-4 Mounting the braking choppers NBRA-655/656/666.

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 Chapter 3 Voltage Selection and Mechanical Installation

WARNING! Before starting the installation work inside the ACS 600:
Switch off the ACS 600 power supply. Wait for five minutes to ensure
that the intermediate circuit is discharged. Switch off dangerous
voltages connected from external circuits to the digital inputs and to the
relay outputs of the ACS 600.

WARNING! Do not touch the printed circuit boards. The integrated

circuits are extremely sensitive to electrostatic discharge.

Mounting Ensure that the chopper voltage level is set correctly (see page 3-1).
Instructions for
Remove the frequency converter front cover.
NBRA-655/656/666
Remove the protective plate covering the opening to the cooling
channel. (Two of these screws will be used for chopper mounting.)
Remove the screw from the PE terminal of the ACS 600. (This
screw will be used for chopper PE connection.)
Place the chopper onto the assembly plate by inserting the cooling
element into the cooling channel. Pull the chopper downwards to fit
the edge of the opening to the slot on the side of the chopper. The
chopper is placed correctly when:
the lower part of the chopper is locked by the edge of the
assembly plate
the two mounting holes in the upper part of the chopper are
aligned with the screw holes in the assembly plate
the UDC+, UDC and PE busses of the ACS 600 match the
corresponding terminals of the chopper.
Insert the two screws removed from the ACS 600 assembly plate
into the two chopper mounting holes. Fasten the screw removed
from the ACS 600 PE terminal to the PE bus. Insert the screws
supplied with the NBRA-6XX into the UDC+ and UDC busses.
Turn each screw to ensure the correct positioning of the chopper.
Tighten the mounting screws to 4 Nm.
Tighten the screws on the UDC+ and UDC busses to 6 Nm.
Tighten the screw on the PE bus to 6 Nm.

WARNING: If you remove the braking chopper from the ACS 600, also
remove the screws from the UDC+ and UDC busses. Screws left in
the busses may cause a short circuit in the intermediate circuit.

Installation and Start-up Guide for NBRA-6xx 3-7

Chapter 3 Voltage Selection and Mechanical Installation

Mechanical Installation
NBRA-657/667

Figure 3-5 Mounting the braking chopper NBRA-657/667.

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 Chapter 3 Voltage Selection and Mechanical Installation

WARNING! Before starting the installation work inside the ACS 600:
Switch off the ACS 600 power supply. Wait for five minutes to ensure
that the intermediate circuit is discharged. Switch off dangerous
voltages connected from external circuits to the digital inputs and to the
relay outputs of the ACS 600.

WARNING! Do not touch the printed circuit boards. The integrated

circuits are extremely sensitive to electrostatic discharge.

Mounting Instructions Ensure that the chopper voltage level is set correctly (see page 3-1).
for NBRA-657/667
Remove the frequency converter front plate.
Remove the protective plate covering the opening to the cooling
channel. The same screws are to be used for chopper mounting.
Remove the screws from the UDC+ and UDC busses of the
chopper. The same screws are to be used for connecting the
busses to the intermediate circuit of the ACS 600.
Place the chopper onto the assembly plate by inserting the cooling
element into the cooling channel. Pull the chopper upwards to fit the
edge of the assembly plate opening to the slot on the upper side of
the chopper. The chopper is placed correctly when:
the upper part of the chopper is locked by the edge of the
assembly plate
the two mounting holes in lower part of the chopper are aligned
with the screw holes in the assembly plate
the UDC+ and UDC busses of the ACS 600 match the
corresponding terminals of the chopper.
Insert the screws through the mounting holes in the UDC+ bus and
the UDC bus. Turn each screw to ensure the correct positioning of
the chopper.
Tighten the chopper mounting screws to 10 Nm.
Tighten the UDC+ and UDC bus screws to 6 Nm.

Installation and Start-up Guide for NBRA-6xx 3-9

Chapter 3 Voltage Selection and Mechanical Installation

Mechanical Installation
NBRA-658/659/669

WARNING! Before starting the installation work inside the ACS 600:
Switch off the ACS 600 power supply. Wait for five minutes to ensure
that the intermediate circuit is discharged. Switch off dangerous
voltages connected from external circuits to the digital inputs and to the
relay outputs of the ACS 600.

WARNING! Do not touch the printed circuit boards. The integrated

circuits are extremely sensitive to electrostatic discharge.

The dimensional drawing of the NBRA-658/659/669 is presented in

Appendix A.

Installation Site The degree of protection of the NBRA-658/659/669 is IP00. This must
be taken into account when selecting the installation site. Installation in
a cabinet is highly recommended.
The following restrictions should also be observed:
Leave 150 mm free space below and above the braking chopper.
Leave 300 mm free space below and above the ACS 600 unit.
Leave enough space for the fuses.
To prevent the chopper from overheating, do not mount it directly
above the braking resistor(s).
The maximum lengths of the chopper and resistor cables are 5 m
and 10 m respectively.

Mounting Instructions Ensure that the chopper voltage level is set correctly (see page 3-1).
for NBRA-658/659/669
Check the intended installation site for sufficient room. Mark the
locations for the four holes.
Make holes in the four positions. Ensure that the dust from drilling
does not enter the unit you are installing or other equipment at the
installation site.
Insert screws in the holes. Use plugs if necessary. Tighten the
screws far enough to be able to carry the weight of the chopper.
Lift the chopper onto the mounting screws.
Tighten the screws.

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 Chapter 4 Electrical Installation

Overview This chapter contains instructions for electrical installation.

Power cable selection and routing (for all chopper types) are
described on this page.
The control connections (for all chopper types) are described on
pages 4-2 to 4-4.
The power connections are described on pages 4-5 to 4-16. The
installation instructions are given separately for each chopper.

Note: Drive Parameter 20.5 (20.7 for ACP 600) OVERVOLTAGE CTRL
must be set to OFF to enable chopper operation.

Power Cable Standard screened three-conductor and single-conductor power

Selection and Routing cables are specified in Tables 2-1 and 2-2. Two-conductor screened
cables can also be used.
Under the converter, chopper and resistor units, provide adequate
support for the cables.
The following should be considered in order to minimise electromag-
netic interference caused by the rapid current changes in the cables:
The braking power line should be completely screened, either by
cable screen or metallic enclosure. Unscreened single-core cable
can only be used if routed inside a cabinet that efficiently suppresses
the radiated RFI emissions.
The cables should be installed away from other cable routes.
Long parallel runs with other cables should be avoided. The minimum
parallel cabling separation distance should be 0.3 metres.
Cables should cross at right angles.
The maximum lengths of the chopper and resistor cables are 5 m and
10 m respectively. The longer the cables, the higher the inductive load.
High load inductance causes voltage peaks over the semiconductors of
the chopper.

5 m max. 10 m max.
ACS 600 NBRA-6xx Resistor(s)

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Chapter 4 Electrical Installation

Control Connections The chopper control connections are shown below. The chopper is also
operational without the control connections.
NBRA-653/654/655/656/657,
X2/X1* Enable Input NBRA-663/664/666/667

1 (Normally closed)
Closed = Operation enabled 1
2 t X2
Open = Operation disabled 2

*The NBRA-658, NBRA-659 and NBRA-669 are V23

equipped with an internal temperature sensitive
switch. In these units, NBRC terminal block X2
is wired via this switch to a separate terminal V22
block (X1), shown in the NBRA-658/659/669
dimensional drawing. 1
2 X3
3

Fibre Optic Cable Connection NBRC

(Refer to page 3-2)

V23 Chopper control signal from another

NBRA-658/659,
chopper (Receiver)
NBRA-669
V22 Chopper control signal to another
chopper (Transmitter) X1
1 t
t 1
2 X2
2

X3 Fault Indication Relay Output V23

1 normally open Continuous current: 2 A RMS V22

Switching capacity:
2 common 8 A, 24 V d.c. 1
0.4 A, 120 V d.c. 2 X3
3 normally closed 3
2000 VA, 250 V a.c.
NBRC

Figure 4-1 Control connections.

The use of the relay output for controlling the main contactor of the
ACS 600 is highly recommended (see page 4-3). The enable input and
the fibre optic connection are optional (see page 4-4).
The terminals for the control connections are on the chopper control
board (NBRC), located inside the chopper housing. The front plate of
the chopper must be removed to access the terminals.

WARNING! Before starting the installation work inside the ACS 600:
Switch off the ACS 600 power supply. Wait for five minutes to ensure
that the intermediate circuit is discharged. Switch off dangerous
voltages connected from external circuits to the digital inputs and to the
relay outputs of the ACS 600.

WARNING! Do not touch the printed circuits. They are extremely

sensitive to electrostatic discharge.

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 Chapter 4 Electrical Installation

Relay Output The relay output indicates chopper faults. The changeover switch
opens when a failure is detected or the chopper is unpowered.

WARNING! In a chopper failure, always switch off the power supply to

the ACS 600. This is the only way to guarantee safe operation in case
of a chopper failure since the chopper is unable to disconnect the
resistor from the intermediate circuit.

It is highly recommended that the ACS 600 be equipped with a main

contactor and a manual control switch (or switches). See Figure 4-2
below for connection examples.

Example 1: Example 2:

L1 L2 L3 L1 L2 L3

1
0 K 1
OFF
2
Fuses Fuses
S1
2

13 1 3 5 1 3 5 13 3
S1

0
1
K
1 3
ON
2 4 14 2 4 6 2 4 6 14 4
K X X
1 X NBRC 1
ACS 600 ACS 600 NBRC
3 3 1
0 Control Control
Board X3 U1 V1 W1 U1 V1 W1 Board
X3
2 2

K1
4

K1

Figure 4-2 Examples of using the chopper relay output.

Installation and Start-up Guide for NBRA-6xx 4-3

Chapter 4 Electrical Installation

Enable Input By default, the Enable input terminal block X2 (X1 on NBRA-658/659/
669) is short-circuited with a jumper connection, and the enable signal
is present all the time. The signal can be given externally by connecting
a break contact to the terminal block as shown in Figure 4-1. When the
contact opens (enable signal is switched off), the chopper stops
operating, and its relay output gives a fault indication.
The NBRA-658, NBRA-659 and NBRA-669 are equipped with an
internal temperature sensitive switch. In these units, NBRC terminal
block (Enable input) is wired via this switch to a separate terminal block
(X1), shown in the dimensional drawing.

WARNING! The Enable input terminal block is at intermediate circuit

potential when the ACS 600 is connected to the mains. This voltage is
extremely dangerous and may cause serious damage or injuries if the
isolation level and protection conditions for the external switch are not
sufficient. The normally closed switch/contact should always be
properly isolated (over 2.5 kV) and shrouded against contact.

For protection against overheating, resistors with a thermal switch

should be used. (All SACE and SAFUR resistors include a thermal
switch.) The switch should be connected to the enable input of the
chopper: if the resistor overheats, the switch opens and interrupts the
chopper enable input signal. If two resistors are used, the thermal
switches should be connected in series.

Fibre Optic Link The guided light receiver and transmitter on the chopper control board
make the synchronisation of several choppers possible. Refer to
page 3-2.

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 Chapter 4 Electrical Installation

Power Connections
NBRA-653/663

WARNING! Before installation, switch off the mains supply to the

ACS 600. Wait five minutes to ensure that the intermediate circuit is
discharged. Switch off all dangerous voltages connected to the inputs
or the outputs of the ACS 600.

NBRA-6x3
UDC+

UDC

U1 V1 W1 U2 V2 W2

UDC+

UDC
R+ R

ACS 600
1 2 3
3 1 2

1 2 3

R+ R PE

R
Braking Resistor

Figure 4-3 NBRA-653/663 power connections.

Notes on NBRA-653/663 If a cable with fine wire conductors is used, it is recommended to

Power Connections terminate the conductors with cable ferrules. The ferrules are pressed
onto stripped conductor ends before inserting into terminals.
The tightening torque for the UDC+ and UDC terminals of the
ACS 600 is 1.5 to 1.8 Nm. All other terminals are tightened
to 1 Nm. (For braking resistor terminal tightening torques, consult
resistor documentation.)
If more space for the installation work inside the chopper is required,
the front section of the bottom plate can also be removed. (Do not
remove the gland plate, ie. the rear bottom plate.)

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Chapter 4 Electrical Installation

Cabling Procedure At each end of both the ACS 600 cable and the resistor cable, twist
the screen wires together and connect them to the PE/chassis
terminal, along with conductor no. 3 (if present).
At both ends of the ACS 600 cable, connect conductor no. 1 to the
UDC+ terminal, and conductor no. 2 to the UDC terminal.
At both ends of the resistor cable, connect conductor no. 1 to the R+
terminal, and conductor no. 2 to the R terminal.
If clamping cable glands are used at cable entries, tighten them only
after making the terminal connections.

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 Chapter 4 Electrical Installation

Power Connections
NBRA-654/664

WARNING! Before installation, switch off the mains supply to the

ACS 600. Wait five minutes to ensure that the intermediate circuit is
discharged. Switch off all dangerous voltages connected to the inputs
or the outputs of the ACS 600.

UDC+
UDC
U1 V1 W1 U2 V2 W2

NBRA-6x4

R+

R
ACS 600

3 2 1

PE
R+ R

Braking Resistor R

2
2
3
1
1

Copper Sleeve

Screen Earthing Clamp

Figure 4-4 Top: NBRA-654/664 power connections.

Bottom: Earthing connections.

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Chapter 4 Electrical Installation

ACS 600 Connection Ensure that the UDC+ and UDC busses are properly connected to the
corresponding terminals of the ACS 600 (see Chapter 3 Voltage
Selection and Mechanical Installation).
Note: The braking chopper must be earthed to ACS 600 chassis by
connecting a separate wire between a chopper earthing terminal and
an ACS 600 chassis terminal (see Figure 4-4 on previous page).
Resistor Cable Connections at the braking resistor:
Connection
(For terminal tightening torques, consult resistor documentation.)
Twist the screen wires together and connect them to the earthing
terminal, along with conductor no. 3 (if present).
Connect conductor no. 1 to the R terminal.
Connect conductor no. 2 to the R+ terminal.

Connections at the braking chopper:

80 mm

Screen
1
2
3
Gland Plate

10 mm
35 mm

170 mm

Figure 4-5 Resistor cable stripping diagram (braking chopper end).

All lengths are approximate.

Cut and strip the cable as shown in Figure 4-5 above.

Lead the cable through the cable entry into the converter unit.
Slip the copper sleeve (inserted into the earthing clamp at the
factory) onto the outermost insulation of the cable so that insulation
and sleeve edges are aligned (see Figure 4-4).
Bend the screen wires evenly backwards onto the copper sleeve.
Unfasten the screen earthing clamp and slip it onto the screen wires
at the copper sleeve. Replace the clamp and tighten the fastening
screw to 3 Nm.
Twist the screen wires together and connect them to one of the
earthing terminal posts on the chopper as shown in Figure 4-4.
Tighten the terminal to 1 Nm.

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 Chapter 4 Electrical Installation

Connect conductor no. 3 (if present) to one of the earthing terminal

posts on the chopper as shown in Figure 4-4.
Tighten the terminal to 1 Nm.
Connect conductor no. 1 to the R terminal.
Tighten the terminal to 1 Nm.
Connect conductor no. 2 to the R+ terminal.
Tighten the terminal to 1 Nm.
If a clamping cable gland is used at the cable entry, tighten it only
after making the terminal connections.

Installation and Start-up Guide for NBRA-6xx 4-9

Chapter 4 Electrical Installation

Power Connections
NBRA-655/656/666

WARNING! Before installation, switch off the mains supply to the

ACS 600. Wait five minutes to ensure that the intermediate circuit is
discharged. Switch off all dangerous voltages connected to the inputs
or the outputs of the ACS 600.

UDC+

UDC
U1 V1 W1 U2 V2 W2

R+
R

NBRA-6xx

ACS 600
1
2
3

R+ R PE

Braking Resistor

1 2

Screen Earthing
Clamp
2
Copper Sleeve 3
1
PE

Figure 4-6 Top: NBRA-655/656/666 power connections.

Bottom: Resistor cable earthing.

4-10 Installation and Start-up Guide for NBRA-6xx

 Chapter 4 Electrical Installation

ACS 600 Connection Ensure that the UDC+ and UDC busses of the chopper are properly
connected to the corresponding terminals of the ACS 600 (see Chapter
3 Voltage Selection and Mechanical Installation).
Resistor Cable Connections at the braking resistor:
Connection
(For terminal tightening torques, consult resistor documentation.)
Twist the screen wires together and connect them to the earthing
terminal, along with conductor no. 3 (if present).
Crimp cable lugs of appropriate size onto conductors 1 and 2.
Connect conductor no. 1 to the R+ terminal.
Connect conductor no. 2 to the R terminal.

Connections at the braking chopper:

Screen
1
2
3
Gland Plate

70 mm

190 mm

Figure 4-7 Resistor cable stripping diagram (braking chopper end).

All lengths are approximate and may vary according to the
cable lugs used.

Cut and strip the cable as shown in Figure 4-7 above.

Lead the cable through the cable entry into the converter unit.
Slip the copper sleeve (inserted into the earthing clamp at the
factory) onto the outermost insulation of the cable so that insulation
and sleeve edges are aligned (see Figure 4-6).
Bend the screen wires evenly backwards onto the copper sleeve.
Unfasten the screen earthing clamp and slip it onto the screen wires
at the copper sleeve. Replace the clamp and tighten the fastening
screw to 3 Nm.
Twist the screen wires together and connect to the earthing clamp
on the chopper as shown in Figure 4-6. Tighten the screws to 3 Nm.
Connect conductor no. 3 (if present) to the earthing clamp on the
chopper (below the screen earthing clamp) as shown in Figure 4-6.
Tighten the screws to 3 Nm.

Installation and Start-up Guide for NBRA-6xx 4-11

Chapter 4 Electrical Installation

Crimp cable lugs onto conductors 1 and 2. (The screws on the R+

and R busbars of the chopper are M8.)
Connect conductor no. 1 to the R+ terminal of the chopper. Support
the back nut with a tool and tighten to 6 Nm.
Connect conductor no. 2 to the R terminal of the chopper. Support
the back nut with a tool and tighten to 6 Nm.
If a clamping cable gland is used at the cable entry, tighten it only
after making the terminal connections.

4-12 Installation and Start-up Guide for NBRA-6xx

 Chapter 4 Electrical Installation

Power Connections
NBRA-657/667

WARNING! Before installation, switch off the mains supply to the

ACS 600. Wait five minutes to ensure that the intermediate circuit is
discharged. Switch off all dangerous voltages connected to the inputs
or the outputs of the ACS 600.

UDC+ UDC

NBRA-6x7

U1 V1 W1 R+ R U2 V2 W2

PE

ACS 600
1 2 3

PE
R+ R

Braking Resistor

1 2

Figure 4-8 Top: NBRA-657/667 power connections.

Bottom: Resistor cable earthing.

Installation and Start-up Guide for NBRA-6xx 4-13

Chapter 4 Electrical Installation

ACS 600 Connection Ensure that the UDC+ and UDC busses of the chopper are properly
connected to the corresponding terminals of the ACS 600 (see
Chapter 3 Voltage Selection and Mechanical Installation).
Resistor Cable Connections at the braking resistor:
Connection
(For terminal tightening torques, consult resistor documentation.)
Twist the screen wires together and connect them to the earthing
terminal, along with conductor no. 3 (if present).
Crimp cable terminals of appropriate type onto conductors 1 and 2.
Connect conductor no. 1 to the R+ terminal.
Connect conductor no. 2 to the R terminal.

Connections at the braking chopper:

Screen
1
2
3
Gland Plate

85 mm

115 mm

Figure 4-9 Resistor cable stripping diagram (braking chopper end).

All lengths are approximate and may vary according to the
cable lugs used.

Cut and strip the cable as shown in Figure 4-9 above.

Cut an opening in the grommet at the cable entry. For best results,
cut along the appropriate diameter marking.
Lead the cable through the bushing into the converter unit.
Place the strain relief onto the cable insulation and tighten to 6 Nm.
Twist the screen wires together and connect to the earthing clamp
on the ACS 600 PE bus, along with conductor no. 3 (if present).
Side view
Tighten the clamp to 6 Nm.
Crimp cable lugs onto conductors 1 and 2. (The screws on the R+
and R busbards of the chopper are M8.)
Connect conductor no. 1 to the R+ terminal of the chopper. Support
the back nut with a tool and tighten to 16 Nm.
Connect conductor no. 2 to the R terminal of the chopper. Support
min. 150 mm

the back nut with a tool and tighten to 16 Nm.

Leave enough free space to make subsequent servicing (eg.
replacement of the converter cooling fan) easier. (See picture on
left.)

4-14 Installation and Start-up Guide for NBRA-6xx

 Chapter 4 Electrical Installation

Power Connections
NBRA-658/659/669

WARNING! Before installation, switch off the mains supply to the

ACS 600. Wait five minutes to ensure that the intermediate circuit is
discharged. Switch off all dangerous voltages connected to the inputs
or the outputs of the ACS 600.

ACS 600 ACS 604

UDC+ UDC PE UDC+ UDC

F5.1 F5.2 F5.1 F5.2

Cabinet
1 2 3

1 2 3

UDC+ UDC

Cabinet
NBRA-6xx
UDC+ UDC
R+ R

NBRA-6xx
R+ R
1 2 3
1 2

R+ R
R+ R

Braking Resistor(s)
Braking Resistor(s)

A B

Figure 4-10 Examples of NBRA-658/659/669 power connections.

Installation and Start-up Guide for NBRA-6xx 4-15

Chapter 4 Electrical Installation

35 Nm
137 mm
161 mm

2 1 1 2
3 3

6 Nm

From ACS 600 To Resistor(s)

Figure 4-11 Cabling inside NBRA-658/659/669.

Notes on When the NBRA unit is installed in a metal cabinet and reliably
NBRA-658/659/669 connected to the chassis, the cable screens (and third conductors, if
Power Connections present) can be earthed at the cabinet entry point (see example B
on previous page).
The UDC+ and UDC terminals of the ACS 604 unit are M10
(tightening torque: 35 Nm).
When two resistors are connected in parallel, it is practical to chain
the resistors as shown below.

NBRA-6xx Resistor Resistor

R+ R R+ R R+ R

4-16 Installation and Start-up Guide for NBRA-6xx

 Chapter 5 Fault Tracing

Fault Indications A fault in the resistor braking circuit prevents fast motor deceleration. It
can also cause the frequency converter to trip under fault.
If a fault is detected by the chopper control board (NBRC) the braking
chopper disconnects the braking resistor from the intermediate circuit
and the changeover switch of the relay output is released. The relay
output indicates following faults:
braking resistor or resistor cable short circuit,
braking chopper (IGBT) short circuit,
chopper control board failure,
the chopper enable input signal switched off.
Note that the chopper will not be able to switch off a short circuit
current. If the relay output is used as recommended in Chapter 4
Electrical Installation, the main contactor of the ACS 600 will open
upon a fault.

Fault Indication Cause Remedy

Mains supply of Chopper or resistor overheated (see below). Check connections. Let equipment cool.
ACS 600 is switched off
Short circuit in resistor or power cables. Check power cables and resistor.
by the chopper relay
output. No Enable input received by NBRC board. Check that Enable input is on (see Chapter 4
Electrical Installation).
Chopper control board failure. Contact local ABB representative.
Chopper damaged; it is not able to
disconnect resistor from intermediate circuit.

Chopper does not Chopper voltage setting too high. Check voltage setting. (See Chapter 3
function. Voltage Selection and Mechanical Installation)
Drive Parameter 20.5 (20.7 for ACP 600) is Set Parameter 20.5 (20.7 for ACP 600) to
set to ON. OFF.

ACS 600 trips on Chopper voltage setting too low. Check the voltage setting. (see
UNDERVOLTAGE fault. Chapter 3 Voltage Selection and
Mechanical Installation)

Braking resistor or The maximum braking cycle exceeded or Check duty cycle and resistor cooling.
chopper overheats. resistor cooling insufficient.
Chopper voltage setting incorrect or jumper Ensure that voltage setting is correct and
missing. jumper is properly in place.

Installation and Start-up Guide for NBRA-6xx 5-1

Chapter 5 Fault Tracing

5-2 Installation and Start-up Guide for NBRA-6xx

 Appendix A Dimensions

Overview The dimensions of the standard braking choppers and braking resistors
to be installed outside the ACS 600 housing are given in the following
pages.
The dimensions are in millimetres.

Braking Chopper
NBRA-653/663

Weight: 2.9 kg

Installation and Start-up Guide for NBRA-6xx A-1

Appendix A Dimensions

Braking Chopper
NBRA-658/659/669

Weight: 26 kg

A-2 Installation and Start-up Guide for NBRA-6xx

 Appendix A Dimensions

Braking Resistor
SACE08RE44
260
6

SACE_ _RE_ _

365
350
6
290 131

Weight: 6 kg (approx.)

Braking Resistor
SACE15RExx 260

SACE15RExx

365
350

6
290 131

Weight: 6 kg

Installation and Start-up Guide for NBRA-6xx A- 3

Appendix A Dimensions

Braking Resistors
SAFUR80F500, 234
SAFUR90F575

600

550
Weight:
SAFUR80F500: 14 kg
SAFUR90F575: 12 kg
R+ R-

7
300 345

Braking Resistors
SAFUR180F460, 234
SAFUR125F500,
SAFUR200F500,
SAFUR210F575
1320

1270

Weight:
SAFUR180F460: 32 kg
SAFUR125F500: 25 kg
SAFUR200F500: 30 kg
SAFUR210F575: 27 kg

R+ R-

7
345
300

A-4 Installation and Start-up Guide for NBRA-6xx

 Appendix B Maximum Braking Power

How to Calculate? The Maximum Braking Power (PBRmax) for each standard
ACS 600/braking chopper combination is given in Table 2-1 and
Table 2-2 in Chapter 2 Overview. The rated value is specified for a
reference braking cycle (ten minute braking cycle: one minute braking,
nine minutes at rest). If the actual braking cycle does not correspond to
the reference cycle, the maximum allowed braking power must be
calculated.

1. Braking energy transferred during any ten minute period must be

less than or equal to the energy transferred during the reference
braking cycle.

2. The braking power must not exceed the rated maximum value
PBRmax.

1. n PBR tbr < PBRmax 60 s

2. PBR < PBRmax

n = Number of braking pulses during

a ten minute period
PBR = Maximum allowed braking power (kW).
tbr = Braking time (s)
PBRmax = Maximum Braking Power
for a reference cycle (kW)

Example 1 Duration of a braking cycle is 30 minutes. The braking time is

15 minutes.
Result: If the braking time exceeds ten minutes the braking is
considered continuous. The allowed continuous braking power is ten
percent of the Maximum Braking Power (PBRmax).

Installation and Start-up Guide for NBRA-6xx B-1

Appendix B Maximum Braking Power

Example 2 Duration of a braking cycle is three minutes. The braking time is

40 seconds.

PBRmax 60 s
1. PBR < = 0.375 PBRmax
4 40 s
PBR

PBRmax

t
tbr 600 s
T = Duration of the braking cycle

2. PBR < PBRmax O.K.

Result: The maximum allowed braking power for the cycle is 37 % of

the rated value given for the reference cycle.

Example 3 Duration of a braking cycle is three minutes. The braking time is

10 seconds.

PBRmax 60 s
1. PBR < = 1.5 PBRmax
4 10 s

PBR

PBRmax

t
tbr 600 s

T = Duration of the braking cycle

2. PBR > PBRmax Not allowed.

Result: The maximum allowed braking power for the cycle is equal to
the Maximum Braking Power (PBRmax) given for the reference cycle.

B-2 Installation and Start-up Guide for NBRA-6xx

 SUPERSEDES: 1996-02-13
EFFECTIVE: 1997-10-20
3AFY 58920541 R0225
NBRA-6xx/EN

ABB Industry Oy
Drive Products and Systems
P.O.Box 211
FIN-00381 Helsinki
FINLAND
Telephone: +358 10 222 000
Telefax: +358 10 222 2681