ABB NBRA-6 Series Installation manual

ACS 600 Installation and
Start-up Guide
NBRA-6xx Braking Choppers

ã1997 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

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

Safety Instructions
iv Installation and Start-up Guide for NBRA-6xx
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.

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

Table of Contents
vi Installation and Start-up Guide for NBRA-6xx
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

Installation and Start-up Guide for NBRA-6xx 1-1
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
Contains
Safety Instructions are placed on the first few pages of the Guide.
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.

Chapter 1 – Introduction to This Guide
1-2 Installation and Start-up Guide for NBRA-6xx

Installation and Start-up Guide for NBRA-6xx 2-1
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
NBRA-6xx
The NBRA-6xx Braking Choppers are optional devices for ACS 600
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.

Chapter 2 –Overview
2-2 Installation and Start-up Guide for NBRA-6xx
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.

Chapter 2 –Overview
Installation and Start-up Guide for NBRA-6xx 2-3
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.

Chapter 2 –Overview
2-4 Installation and Start-up Guide for NBRA-6xx
Table 2-1 ACS 600 ratings for resistor braking.
ACS 600
Type
Braking
Chopper
Type
Braking Resistor(s) Cable
(Copper)
Braking
Power
Type R
[ohm]
ER
[kJ]
PRcont
[kW]
No. of
Elements*
A
[mm2]
PBRmax
[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)

Chapter 2 –Overview
Installation and Start-up Guide for NBRA-6xx 2-5
RResistance value for the listed resistor type. Note: This is also the minimum allowed resistance value for the braking
resistor.
EREnergy 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 ERdissipates in 400 seconds.
AConductor 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.
ACS 600
Type
Braking
Chopper
Type
Braking Resistor(s) Cable
(Copper)
Braking
Power
Type R
[ohm]
ER
[kJ]
PRcont
[kW]
No. of
Elements*
A
[mm2]
PBRmax
[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

Chapter 2 –Overview
2-6 Installation and Start-up Guide for NBRA-6xx
Table 2-2 Braking circuit cable and fuse ratings for NBRA-658, NBRA-659 and NBRA-669.
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.
ACS 600
Type
Braking
Chopper
Type
Fuse (Ultrarapid) Chopper Cable (Cu) Resistor Cable (Cu)
Inom
[A]
1) DIN 43653
Type
2) Single-core
[mm2]
Multicore
[mm2]
2) Single-
core [mm2]
Multicore
[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)

Chapter 2 –Overview
Installation and Start-up Guide for NBRA-6xx 2-7
Selecting the Correct
ACS 600/Chopper/
Resistor Combination
1. Calculate the maximum power (Pmax) generated by the motor during
braking.
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 ERvalue 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 ERvalue 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:
•Resistor heat dissipation capacity (ER) must be sufficient for the
application (see step 3. above).
Pmax <
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)
UDC
R
2
*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.

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

Installation and Start-up Guide for NBRA-6xx 3-1
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.
Figure 3-1 Braking chopper voltage selection.
FIBER
230V 400V
500V
ACS 600 mains voltage
380 to 415 V
ACS 600 mains voltage
440 to 500 V
Chopper controlled by
another chopper (see
Figure 3-2)
FIBER
230V 400V
500V
FIBER
ACS 600 mains voltage
525 to 690 V
FIBER
230V 400V
>500V
230V 400V
500V

Chapter 3 –Voltage Selection and Mechanical Installation
3-2 Installation and Start-up Guide for NBRA-6xx
Synchronisation of
Multiple Choppers
The FIBER position is used if two (or more) choppers are connected to
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.
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 Slave
FIBER
V22V22 V23V23
(VOLTAGE)