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Chapter 2 – Overview

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Installation and Start-up Guide for NBRA-6xx

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Summary of Contents for ACS 600

Page 1: ...ACS 600 Installation and Start up Guide NBRA 6xx Braking Choppers ...

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Page 3: ...ã 1997 ABB Industry Oy All Rights Reserved NBRA 6xx Braking Choppers Installation and Start up Guide 3AFY 58920541 R0225 EN EFFECTIVE 1997 10 20 SUPERSEDES 1996 02 13 ...

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Page 5: ...f situations that can result in serious physical injury and or serious damage to equipment with the following symbols Notes Readers are notified of the need for special attention or additional information available on the subject 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 s...

Page 6: ...DC 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 ...

Page 7: ...s 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 65...

Page 8: ...nnections 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 ...

Page 9: ...de 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 instruc...

Page 10: ...Chapter 1 Introduction to This Guide 1 2 Installation and Start up Guide for NBRA 6xx ...

Page 11: ...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 50...

Page 12: ...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 ...

Page 13: ...ng 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 ...

Page 14: ...210F575 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 0...

Page 15: ...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 IP0...

Page 16: ... 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 ...

Page 17: ...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 ...

Page 18: ...Chapter 2 Overview 2 8 Installation and Start up Guide for NBRA 6xx ...

Page 19: ...L 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 da...

Page 20: ...e 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 Figure 3 2 Master Slave connection of multiple choppers WARNING Do not touch the printed circuits They are extremely sensitive to electrostatic discharge Master FIBER Slave Slav...

Page 21: ...d 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 1...

Page 22: ...Chapter 3 Voltage Selection and Mechanical Installation 3 4 Installation and Start up Guide for NBRA 6xx Mechanical Installation NBRA 654 664 Figure 3 3 Mounting the braking chopper NBRA 654 664 ...

Page 23: ...Mounting Instructions for NBRA 654 664 Ensure that the chopper voltage level is set correctly see page 3 1 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...

Page 24: ...hapter 3 Voltage Selection and Mechanical Installation 3 6 Installation and Start up Guide for NBRA 6xx Mechanical Installation NBRA 655 656 666 Figure 3 4 Mounting the braking choppers NBRA 655 656 666 ...

Page 25: ...e 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 asse...

Page 26: ...Chapter 3 Voltage Selection and Mechanical Installation 3 8 Installation and Start up Guide for NBRA 6xx Mechanical Installation NBRA 657 667 Figure 3 5 Mounting the braking chopper NBRA 657 667 ...

Page 27: ...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 u...

Page 28: ...ion 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 ...

Page 29: ...d 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...

Page 30: ...ngerous 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 X2 X3 1 2 1 2 3 NBRC X3 Fault Indication Relay Output 1 normally open Continuous current 2 A RMS Switching capacity 8 A 24 V d c 0 4 A 120 V d c 2000 VA 250 V a c 2 common 3 normally closed ...

Page 31: ... 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 Figure 4 2 Examples of using the chopper relay output Example 1 ACS 600 U1 V1 W1 L1 L2 L3 Fuses 1 2 3 4 5 6 1 2 13 14 1 2 3 4 0 1 K S1 ...

Page 32: ...ARNING 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 F...

Page 33: ...nductors is used it is recommended to 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 ins...

Page 34: ...t 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 conne...

Page 35: ...0 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 Figure 4 4 Top NBRA 654 664 power connections Bottom Earthing connections ACS 600 U2 V2 W2 U1 V1 W1 1 2 3 UDC UDC NBRA 6x4 R R R Braking Resistor R R PE Copper Sleeve Screen Earthing Clamp 2 3 3 2 1 1 Screen Earthing Clamp ...

Page 36: ...ductor no 1 to the R terminal Connect conductor no 2 to the R terminal Connections at the braking chopper 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 outerm...

Page 37: ...rthing 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 ...

Page 38: ...he 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 Figure 4 6 Top NBRA 655 656 666 power connections Bottom Resistor cable earthing NBRA 6xx R Braking Resistor ACS 600 U2 V2 W2 U1 V1 W1 R R 1 2 3 UDC UDC R R PE PE 1 2 3 3 2 1 Copper Sleeve Clamp Screen Earthing ...

Page 39: ...ing 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 B...

Page 40: ...usbars 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 ...

Page 41: ...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 Figure 4 8 Top NBRA 657 667 power connections Bottom Resistor cable earthing R Braking Resistor ACS 600 R 1 2 3 R U1 V1 W1 U2 V2 W2 UDC UDC NBRA 6x7 PE R R PE 1 2 3 ...

Page 42: ...te 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 ...

Page 43: ...e 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 Figure 4 10 Examples of NBRA 658 659 669 power connections ACS 600 PE F5 2 F5 1 UDC UDC UDC UDC R R R R ACS 604 NBRA 6xx F5 2 F5 1 UDC UDC UDC UDC R R R R 1 2 3 1 2 3 1 2 Braking Resistor s R R Braking Resistor s NBRA 6xx 1 2 3 Cabinet Cabinet A B ...

Page 44: ...ably connected to the chassis the cable screens and third conductors if 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 3 From ACS 600 To Resistor s 1 1 2 3 2 137 mm 161 mm 35 Nm 6 Nm NBRA 6...

Page 45: ... switched off by the chopper relay output Chopper or resistor overheated see below Short circuit in resistor or power cables No Enable input received by NBRC board Chopper control board failure Chopper damaged it is not able to disconnect resistor from intermediate circuit Check connections Let equipment cool Check power cables and resistor Check that Enable input is on see Chapter 4 Electrical In...

Page 46: ...Chapter 5 Fault Tracing 5 2 Installation and Start up Guide for NBRA 6xx ...

Page 47: ...pendix 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 ...

Page 48: ...Appendix A Dimensions A 2 Installation and Start up Guide for NBRA 6xx Braking Chopper NBRA 658 659 669 Weight 26 kg ...

Page 49: ...sions Installation and Start up Guide for NBRA 6xx A 3 Braking Resistor SACE08RE44 Braking Resistor SACE15RExx SACE_ _RE_ _ 350 365 Weight 6 kg approx 260 290 131 Ø 6 Ø 6 SACE15RExx 260 290 350 365 Ø 6 Weight 6 kg 131 ...

Page 50: ...istors SAFUR80F500 SAFUR90F575 Braking Resistors SAFUR180F460 SAFUR125F500 SAFUR200F500 SAFUR210F575 234 300 600 Ø 7 345 R R 550 Weight SAFUR80F500 14 kg SAFUR90F575 12 kg 234 300 1320 Ø 7 345 R R 1270 Weight SAFUR180F460 32 kg SAFUR125F500 25 kg SAFUR200F500 30 kg SAFUR210F575 27 kg ...

Page 51: ...e 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 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 all...

Page 52: ...he reference cycle Example 3 Duration of a braking cycle is three minutes The braking time is 10 seconds Result The maximum allowed braking power for the cycle is equal to the Maximum Braking Power PBRmax given for the reference cycle PBRmax t PBR 600 s PBR PBRmax 60 s 4 40 s 0 375 PBRmax tbr T Duration of the braking cycle 1 2 PBR PBRmax O K T Duration of the braking cycle tbr PBRmax t PBR 600 s ...

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Page 54: ...B Industry Oy Drive Products and Systems P O Box 211 FIN 00381 Helsinki FINLAND Telephone 358 10 222 000 Telefax 358 10 222 2681 NBRA 6xx EN 3AFY 58920541 R0225 EFFECTIVE 1997 10 20 SUPERSEDES 1996 02 13 ...

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