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Table of Contents
Related Manuals for ABB NBRA-6 Series
Summary of Contents for ABB NBRA-6 Series
- Page 1 ACS 600 Installation and Start-up Guide NBRA-6xx Braking Choppers...
- Page 3 NBRA-6xx Braking Choppers Installation and Start-up Guide 3AFY 58920541 R0225 EFFECTIVE: 1997-10-20 SUPERSEDES: 1996-02-13 ã 1997 ABB Industry Oy. All Rights Reserved.
- Page 5 Safety Instructions This chapter states the safety instructions which must be followed Overview 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. This manual distinguishes two sorts of safety instructions. Warnings Warnings and Notes are used to inform of conditions which can, if proper steps are not taken, lead to a serious fault condition, physical injury or death.
- Page 6 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.
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Page 7: Table Of Contents
Table of Contents Safety Instructions Table of Contents Chapter 1 – Introduction to This Guide Intended Audience ............1-1 What This Guide Contains . - Page 8 Table of Contents Chapter 4 – Electrical Installation Overview ..............4-1 Power Cable Selection and Routing .
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Page 9: Chapter 1 - Introduction To This Guide
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. - Page 10 Chapter 1 – Introduction to This Guide Installation and Start-up Guide for NBRA-6xx...
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Page 11: Chapter 2 - Overview
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. -
Page 12: Accessories
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). -
Page 13: Braking Resistors
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. - Page 14 Chapter 2 – Overview Table 2-1 ACS 600 ratings for resistor braking. Cable Braking Braking Resistor(s) Braking (Copper) Power ACS 600 Chopper Type No. of Rcont BRmax Type Type [ohm] [kJ] [kW] Elements* [kW] 400 V a.c. Units -0005-3 NBRA-653 SACE08RE44 44.0 210.0...
- Page 15 Chapter 2 – Overview Cable Braking Braking Resistor(s) Braking (Copper) Power ACS 600 Chopper Type No. of Rcont BRmax Type Type [ohm] [kJ] [kW] Elements* [kW] (continued) 690 V a.c. Units: -0009-6 NBRA-663 SACE08RE44 44.0 3x6+6 -0011-6 NBRA-663 SACE08RE44 44.0 3x6+6 12.9 -0016-6...
- Page 16 Chapter 2 – Overview Table 2-2 Braking circuit cable and fuse ratings for NBRA-658, NBRA-659 and NBRA-669. Fuse (Ultrarapid) Chopper Cable (Cu) Resistor Cable (Cu) Braking ACS 600 Chopper DIN 43653 Single-core Multicore Single- Multicore Type Type Type core [mm 400 V a.c.
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Page 17: Selecting The Correct Acs 600/Chopper/Resistor Combination
Chapter 2 – Overview Selecting the Correct 1. Calculate the maximum power (P ) 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: >... - Page 18 Chapter 2 – Overview Installation and Start-up Guide for NBRA-6xx...
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Page 19: Chapter 3 - Voltage Selection And Mechanical Installation
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. -
Page 20: Synchronisation Of Multiple Choppers
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. -
Page 21: Mechanical Installation Nbra-653/663
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. -
Page 22: Mechanical Installation Nbra-654/664
Chapter 3 – Voltage Selection and Mechanical Installation Mechanical Installation NBRA-654/664 Figure 3-3 Mounting the braking chopper NBRA-654/664. Installation and Start-up Guide for NBRA-6xx... - Page 23 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.
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Page 24: Mechanical Installation Nbra-655/656/666
Chapter 3 – Voltage Selection and Mechanical Installation Mechanical Installation NBRA-655/656/666 Figure 3-4 Mounting the braking choppers NBRA-655/656/666. Installation and Start-up Guide for NBRA-6xx... - Page 25 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.
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Page 26: Mechanical Installation Nbra-657/667
Chapter 3 – Voltage Selection and Mechanical Installation Mechanical Installation NBRA-657/667 Figure 3-5 Mounting the braking chopper NBRA-657/667. Installation and Start-up Guide for NBRA-6xx... - Page 27 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.
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Page 28: Mechanical Installation Nbra-658/659/669
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. -
Page 29: Chapter 4 - Electrical Installation
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. •... -
Page 30: Control Connections
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 (Normally closed) Closed = Operation enabled ° Open = Operation disabled *The NBRA-658, NBRA-659 and NBRA-669 are equipped with an internal temperature sensitive switch. -
Page 31: Relay Output
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. -
Page 32: Enable Input
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. -
Page 33: Power Connections Nbra-653/663
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. - Page 34 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). •...
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Page 35: Power Connections Nbra-654/664
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. - Page 36 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).
- Page 37 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.
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Page 38: Power Connections Nbra-655/656/666
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. - Page 39 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.)
- Page 40 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.
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Page 41: Power Connections Nbra-657/667
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. - Page 42 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.)
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Page 43: Power Connections Nbra-658/659/669
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. - Page 44 Chapter 4 – Electrical Installation 35 Nm 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).
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Page 45: Chapter 5 - Fault Tracing
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. - Page 46 Chapter 5 – Fault Tracing Installation and Start-up Guide for NBRA-6xx...
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Page 47: Appendix A - Dimensions
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... -
Page 48: Braking Chopper Nbra-658/659/669
Appendix A – Dimensions Braking Chopper NBRA-658/659/669 Weight: 26 kg Installation and Start-up Guide for NBRA-6xx... -
Page 49: Braking Resistor Sace08Re44
Appendix A – Dimensions Braking Resistor SACE08RE44 Ø 6 SACE_ _RE_ _ Ø 6 Weight: 6 kg (approx.) Braking Resistor SACE15RExx SACE15RExx Ø 6 Weight: 6 kg Installation and Start-up Guide for NBRA-6xx A- 3... -
Page 50: Braking Resistors Safur80F500, Safur90F575
Appendix A – Dimensions Braking Resistors SAFUR80F500, SAFUR90F575 Weight: SAFUR80F500: 14 kg SAFUR90F575: 12 kg Ø 7 Braking Resistors SAFUR180F460, SAFUR125F500, SAFUR200F500, SAFUR210F575 Weight: SAFUR180F460: 32 kg SAFUR125F500: 25 kg SAFUR200F500: 30 kg SAFUR210F575: 27 kg R+ R- Ø 7 Installation and Start-up Guide for NBRA-6xx... -
Page 51: Appendix B - Maximum Braking Power
Appendix B – Maximum Braking Power How to Calculate? The Maximum Braking Power (P ) for each standard BRmax 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). - Page 52 Appendix B – Maximum Braking Power Example 2 Duration of a braking cycle is three minutes. The braking time is 40 seconds. · 60 s BRmax < = 0.375 · P BRmax 4 · 40 s BRmax 600 s T = Duration of the braking cycle <...
- Page 54 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...