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ACS800

Hardware Manual
ACS800-607 Brake Units
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ACS800 Multidrive Manuals

Codes refer to English manuals

General drive manuals (in all deliveries)

ACS800 MultiDrive Safety Instructions (3AFE64760432)
ACS800 MultiDrive Mechanical Installation (3AFE68233402)
ACS800 MultiDrive Planning the Electrical Installation
(3AFE64783742)
Line-side converter manuals (delivered with the converter)
ACS800-307 and ACS800-507 Cabinet-installed Diode Supply
Unit User’s Manual (3AFE68279364)
ACS800-407 and ACS800-807 Cabinet-installed Thyristor Supply
Units (TSU) (3AFE68243688)
ACS800-207 Cabinet-installed IGBT Supply Unit User’s Manual
(3AFE68233810)
ACS800 IGBT Supply Control Program Firmware Manual
(3AFE68315735)
Motor side-converter hardware manual (in all deliveries)
ACS800-107 Inverter Unit Hardware Manual (3AFE68233453)
Motor side-converter firmware manuals, supplements and
guides (delivered with program)
ACS800 System Application Program Firmware Manual
ACS800 Standard Application Program Firmware Manual
(3AFE64527592) and Adaptive Program Application Guide
(3AFE64527274)
Crane Control Program Firmware Manual (3BSE11179)
Master/Follower Application Guide (3AFE64590430)
PFC Application Program Firmware Manual (3AFE64649337)
Extruder Control Program Supplement (3AFE64648543)
Centrifuge Control Program Supplement (3AFE64667246)
Traverse Control Program Supplement (3AFE64618334)
etc.
Option device manuals (delivered with optional equipment)
RAIO-01 Analogue I/O Extension User's Manual (3AFE64484567)
RDIO-01 Digital I/O Extension User's Manual (3AFE64485733)
ACS800-607 Brake Unit Hardware Manual (3AFE68392519)
etc.
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ACS800-607 Brake Units

Hardware Manual

3AFE68392519 REV A
EN
EFFECTIVE: 11.10.2004

 2004 ABB Oy. All Rights Reserved.

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Table of contents

Table of contents

About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake unit selection tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hardware description
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overall view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Attenuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chopper control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Enable input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Relay output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Voltage selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Synchronisation of multiple choppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation
ACS800-607 types: -0320-3+D151…-1920-3+D151, -0400-5+D151…-2400-5+D151, -0400-
7+D151…-2400-7+D151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake resistors in a separate line-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Types: -0320-3…-1920-3, -0400-5…-2400-5, -0400-7…-2400-7 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Resistor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Resistor placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Resistor cable selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Selection of chopper enable input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Before start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Start-up
ACS800-607 types: -0320-3+D151…-1920-3+D151, -0400-5+D151…-2400-5+D151, -0400-
7+D151…-2400-7+D151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Types: -0320-3…-1920-3, -0400-5…2400-5, -0400-7…-2400-7 . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fault tracing
Fault indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Technical data
Abbreviations and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake units: Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Brake units: Dimensions, weight, noise and air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Brake units: DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Chopper enable input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dimensional drawings
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Brake unit ACS800-607 (types: -0320-3…-1920-3, -0400-5…-2400-5, -0400-7…-2400-7) . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Brake unit ACS800-607 (types: -0320-3+D151…-1920-3+D151, -0400-5+D151…-2400-5+ D151,
-0400-7+D151…-2400-7+D151) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Circuit diagrams
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Brake unit ACS800-607, master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Brake unit ACS800-607, slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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About this manual

What this chapter contains

The manual is intended for people responsible for configuring, commissioning and
use of a brake unit of the ACS800 Multidrive.

Safety instructions
Follow all safety instructions delivered with the drive.
Read the complete safety instructions before you install, commission, or use the
drive. The complete safety instructions are given in ACS800 Multidrive Safety
Instructions [3AFE64760432 (English)].
Read the software function specific warnings and notes before changing the default
settings of the function. For each function, the warnings and notes are given in the
section describing the related user-adjustable parameters.
Read task specific safety instructions before starting the task. See the subsection
describing the task.

Reader
The reader of the manual is expected to know the standard electrical wiring
practices, electronic components, and electrical schematic symbols.

Brake unit selection tool

A DriveChopper software for brake unit selection is available from Internet.
See http://www.abb.com.

Contents
The manual consists of the following chapters:
• Hardware description
• Installation
• Start-up
• Fault tracing
• Technical data
• Dimensional drawings
• Circuit diagrams

About this manual

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Other manuals
There is a list of manuals on the inside of the front cover.

About this manual

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9

Hardware description

General
Typically, the ACS800 multidrive is equipped with a brake unit if:
• high capacity braking is needed and the drive cannot be equipped with a
regenerative supply unit
• a backup for the regenerative supply unit is needed.
The brake units include a preselected chopper(s), or chopper(s) and resistor(s).

Overall view
An overall view of an ACS800 multidrive equipped with a brake unit is shown below.
ACS800-607 (types: -0320-3...-1920-3, ACS800-607 (types:-0320-3+D151...-1920-3+D151,
-0400-5...-2400-5, -0400-7...-2400-7) -0400-5+D151...-2400-5+D151, -0400-7+D151...-2400-7+D151)
Brake units: Brake units:
1 DC fuses 1 DC fuses
2 Attenuator 2 Attenuator
3 Brake chopper (NBRA-6xx) 3 Brake chopper (NBRA-6xx)
5a Cooling fan 4 Brake resistors (SAFUR)
6a Chopper cubicle 5a Cooling fan
5b Cooling fan
6a Chopper cubicle
6b Resistor cubicle
Cabinet configuration
SAFUR
SAFUR

SAFUR
SAFUR

SAFUR
SAFUR

SAFUR
SAFUR

SAFUR
SAFUR
NBRA

NBRA

NBRA

NBRA

NBRA

NBRA = Brake chopper type

SAFUR = Brake resistor type
2 × NBRA + 3 × NBRA +
2 × (2 × SAFUR) 3 × (2 × SAFUR)
$ = $ >

 A C T P AR FU NC

E N T E R
D R IV E A C T P AR FU NC D R IV E

E N T E R
A C T P AR FU NC

E N T E R
D R IV E

L O C R E S E T R E F L O C R E S E T R E F L O C R E S E T R E F

R E M R E M R E M

" "

# = # >

Hardware description
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DC fuses
The brake unit is equipped with DC fuses as standard. The fuses protect the
chopper and the brake circuit cables in a cable short-circuit situation.

Attenuator
The attenuator damps the intermediate circuit voltage spikes at the chopper input
terminals, thus decreasing stress on the chopper.

Brake resistors
The brake resistors dissipate the surplus energy conducted by the choppers.
ACS800-607-0320-3+D151…-1920-3+D151, -0400-5+D151…-2400-5+D151 and
-0400-7+D151…-2400-7+D151 brake units are equipped with brake resistors.
ACS800-607-0320-3…-1920-3, -0400-5…-2400-5, -0400-7…-2400-7 brake units
must be equipped with brake resistors by the user.
The resistor types used in ACS800-607 brake units are specified in chapter
Technical data.

Cooling fan
Both the chopper cubicle and the resistor cubicle are equipped with a cooling fan.
The fan is supplied from the Auxiliary Control Unit (ACU) cubicle of the ACS800
multidrive.

Brake chopper
The chopper connects the brake resistor to the intermediate circuit whenever the
voltage in the intermediate circuit (DC bus) exceeds the maximum limit.
The maximum limit is equal to 1.21 · 1.35 · U1max. U1max is dependent on the
chopper voltage selection. With the selection 400 V, U1max is 415 V; with the
selection >500 V, U1max is 500 V (NBRA-65x) or 690 V (NBRA-66x). Energy
consumption by the resistors 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.
The chopper control board supervises system status and detects failures such as:
• brake resistor and resistor cable short circuits
• chopper (IGBT) short circuit
• chopper control board failure
• chopper and resistor overtemperature.

Hardware description
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Chopper control connections

The chopper control connections are described below. See also chapter Circuit
diagrams.

NBRA-658/659,
NBRA-669
X2/X1 Enable input
X1
1 (Normally closed) t°
t° 1 1
Closed = Operation enabled 2 2
X2
2 Open = Operation disabled
V23

V22
Fibre optic cable connection
1
V23 Chopper control signal from another 2 X3
chopper (Receiver) 3
NBRC board
V22 Chopper control signal to another chopper
(Transmitter)

User wiring for ACS800-607

types without factory-installed
resistors

X3 Fault indication relay output

1 normally Continuous current:

open 2 A rms
Switching capacity:
2 common 8 A, 24 VDC
0.4 A, 120 VDC
3 normally
2000 VA, 250 VDC
closed

Enable input
When the contact opens (enable signal is switched off), the chopper stops operating,
and its relay output gives a fault indication.
For protection against overheating, resistors with a thermal switch are used. (All
SAFUR resistors include a thermal switch.) The switch is 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 are
connected in series.
The choppers are equipped with an internal temperature sensitive switch. The
NBRC board enable input is wired via this switch.

Hardware description
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Relay output
The changeover switch opens when a failure is detected or the chopper is not
powered. Upon a fault, the relay either opens the drive main breaker, or gives a fault
indication to the overriding control system. For the actual usage of the relay output,
see the circuit diagrams delivered with the unit.

Fibre optic link

The guided light receiver and transmitter on the chopper control board make the
synchronisation of several choppers possible. See the subsection Synchronisation
of multiple choppers below.

Voltage selection
The voltage is set, according to the mains voltage, with a jumper on the chopper
control board. The voltage is preset at the factory for each chopper. On field the
setting needs to be adjusted only if the chopper is changed.
FIBER

FIBER

FIBER

FIBER
230 V

400 V

>500 V

230 V

400 V

>500 V

230 V

400 V

>500 V

230 V

400 V

>500 V
Drive mains voltage Drive mains voltage Drive mains voltage Chopper controlled by
380 to 415 V 440 to 500 V 525 to 690 V another chopper
(NBRA-65x) (NBRA-65x) (NBRA-66x) (NBRA-65x/66x)

Synchronisation of multiple choppers

Synchronisation of choppers is necessary when there are several choppers in use.
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.
FIBER
(VOLTAGE)

FIBER

FIBER
FIBER

Not connected V23 V22 V23 V22 V23 V22 Not connected
on the master on the last
chopper chopper on
the chain

Master Slave Slave

Hardware description
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Installation

ACS800-607 types: -0320-3+D151…-1920-3+D151,

-0400-5+D151…-2400-5+D151, -0400-7+D151…-2400-7+D151
Mechanical installation
ACS800 Multidrive - the brake unit as one part of the complete drive - is transported
in shipping splits.
For the mechanical installation of the shipping splits see ACS800 Multidrive,
Mechanical Installation (3AFE68233402 [English]).

Electrical installation
The ACS800-607 brake unit is an operational unit after the shipping splits are joined.
No customer setting or wiring is required.

Brake resistors in a separate line-up

A C T

L O C

R E M
P A R

R E S E T
F U N C

R E F
E N T E R
D R IV E A C T

L O C

R E M
P AR

R E S E T
FU NC

R E F
D R IV E

E N T E R
A C T

L O C

R E M
P AR

R E S E T
FU NC

R E F
E N T E R
D R IV E

Basic drive line-up with the brake chopper cubicle.

Separate brake resistor cubicle with an additional

cable lead-through cubicle.

In special cases it is possible to install the brake resistor cubicle(s) of the

ACS800-607 separate from the basic drive line-up. See the figure above. Note that
then the resistor cubicle must be ordered as separate.
When installing follow the instructions given in section Types: -0320-3…-1920-3,
-0400-5…-2400-5, -0400-7…-2400-7 installation below.

WARNING! Never install the brake chopper cubicle separate from the basic
line-up.

Installation
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Types: -0320-3…-1920-3, -0400-5…-2400-5, -0400-7…-2400-7

Installation planning
Resistor selection
The ACS800-607 brake unit must be equipped with a brake resistor by the user.

WARNING! ABB is not responsible for customer resistor selection or protection of

the resistor.

Select the resistor according to the resistor specification given in chapter Technical
data. Consider also the following:
• Each chopper must feed a resistor / resistor assembly of its own.
• The resistance (R) of each brake resistor must be equal to the value specified.
Never use resistance values below the specified value.
• The resistor must withstand the specified brake cycles.
• The ventilation of the space/room in which the resistors are located must meet the
air flow amounts specified.
• The resistor must be equipped with a thermal switch (see section Electrical
installation).

WARNING! If a resistor thermal switch is present, and it is to be connected to the

chopper enable input terminal (X2), ensure that the isolation level and protection of
the switch are sufficient. The switch is at the intermediate circuit potential. This
voltage is extremely dangerous. The normally closed switch/contact should always
be properly isolated (test voltage over 2.5 kV) and shrouded against contact. The
same requirements are valid for the connection cable.

Resistor placement
Select the place for the resistor considering the cooling of the resistor and the
maximum allowed cable length.

WARNING! The resistor exhaust air is hot. Keep flammable materials away from the
exhaust vents. If the exhaust vents are connected to a ventilation system, ensure
material withstands high temperatures.

Cooling: The Resistor dissipates the braking energy to its surroundings. Arrange the
cooling of the resistor in a way that:
• no danger of overheating is caused to the resistor or nearby materials.
• the temperature of the room the resistor is located in does not exceed the allowed
maximum.

Installation
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The cooling air amounts for the standard resistors are specified in chapter Technical
data.
Maximum cable length: See section Electrical installation below.
Resistor cable selection
See chapter Technical data for the cable specification. Consider also the notes in
section Electrical installation below.
Selection of chopper enable input cable
See chapter Technical data for the cable specification.

Mechanical installation
ACS800 multidrive - the brake unit as one part of the complete drive - is transported
in shipping splits. For the mechanical installation of the shipping splits see ACS800
Multidrive, Mechanical Installation (3AFE68233402 [English]).
For the installation of brake resistors follow the instructions by the resistor
manufacturer.

Electrical installation
Before start
This section states the warnings and notes that must be read before starting the
installation and followed during the installation.

WARNING! Ensure that the disconnector of the supply transformer is locked to open
position, i.e. no voltage is, or cannot be connected to the drive inadvertently. Check
also by measuring that there is no voltage connected.

WARNING! The installation work must only be carried out by a qualified electrician.
All safety instructions must be followed during the work. For ACS800 multidrive, the
complete safety instructions are stated in ACS800 Multidrive Safety Instructions
(3AFE64760432 [English]). Negligence of the safety instructions can cause injury or
death.

WARNING! The enable input terminal block of the chopper (X1 and X2) is at the
intermediate circuit potential when the drive is connected to the mains.

Note 1: The following must be considered in order to minimise electromagnetic

interference caused by the rapid current changes in the cables:
• The brake power line must 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.

Installation
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Note 2: The maximum length of the resistor cable is 50 m. The longer the cable, the
higher the inductive load. High inductive load causes voltage peaks over the
semiconductors of the chopper.
Installation instructions
Connect the resistor cable and the thermal switch according to the figure below.
Note the connection of the third conductor and the cable screen. See also the circuit
diagrams delivered with the unit.

X1
1 NBRA-6xx
2
R+ R–

PE

Brake unit
1 2 3

Grounding at the cable lead-through

R+ R–

t°

Resistor(s)

If two resistors are connected in parallel, it is practical to chain the resistors as

shown below. Note that the cable between the chopper and the first resistor must be
able to carry the entire breaking power.

NBRA-6xx Resistor Resistor

R+ R– R+ R– R+ R–

Provide adequate support for the cables below the chopper and resistor units.

Installation
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Start-up

ACS800-607 types: -0320-3+D151…-1920-3+D151, -0400-5+D151…-2400-

5+D151, -0400-7+D151…-2400-7+D151
1. Preliminary actions Information
Check the drive is ready for the brake unit start-up, i.e. the: See list of ACS800 Multidrive
- installation has been done according to the manual. manuals on the inside of the front
cover.
- supply unit commissioning has been done according to the appropriate
supply unit manual
- commissioning of the drive units has been done according to the
appropriate hardware and firmware manuals.
Close all cabinet doors.
2. Power switch-on
WARNING! Before the power switch-on make sure there are inverters connected to the intermediate circuit.
A rule of thumb: the sum of the inverter powers must be at least 30% of the rated power of the brake unit
(Pbr.max -value).
Too few inverters connected results in a low intermediate circuit capacitance. At power switch-on the DC voltage
will overshoot the controller voltage limit, causing an immediate switching to brake mode. High brake current will
blow the inverter DC fuses.
Switch on power to the drive.
3. Operational check
Ensure that running one of the motors to be braked is allowed. Start the Use a low speed at first.
motor and increase the rotation speed.

Deactivate the overvoltage controllers of the inverters. For the drive parameter settings, see
(All inverters) the appropriate firmware manual.
Ensure the stop mode of the motor is ramp stop. Set the deceleration Use a relatively long braking time at
time. (Running inverter) first.
Stop the motor simultaneously monitoring the intermediate circuit voltage The DC voltage level during the
with a DriveWindow PC tool. braking indicates the brake unit
operation:
Successful braking: DC voltage level
is: 1.2 · 1.35 · U1max*
Repeat a restart and stop a few times with higher rotating speeds and Unsuccessful braking: DC voltage
shorter deceleration times. level exceeds 1.21 · 1.35 · U1max*
and inverter trips on overvoltage.
See chapter Fault tracing.

*See chapter Hardware description.

Start-up
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18

Types: -0320-3…-1920-3, -0400-5…2400-5, -0400-7…-2400-7

1. Preliminary actions Information
WARNING! Ensure that the disconnector of the supply transformer is locked to open position, i.e. no voltage is,
or cannot be connected to drive inadvertently. Check also by measuring that there is no voltage connected.

Check that the mechanical and electrical installation of the brake resistor See chapter Installation.
has been inspected and OK.
Check the insulation of the resistor circuit.
Disconnect the resistor cable from the chopper terminals.
Measure the insulation resistance between conductor no. 1 and NBRA-6xx
Protective Earth, and between conductor no. 2 and Protective Earth. R+ R–
Use a measuring voltage of 1 kV DC. The insulation resistance must be
R > 1 MΩ
greater than 1 MΩ. Ω PE

Brake unit
1 2 3

R+ R–

Resistor(s)

Ensure that the surroundings and the inside of the cabinet are free from After the start, the cooling air fans
dust and loose objects like cable trimmings and other waste left from the may suck nearby loose objects into
installation. the unit. This might cause failure and
damage the unit.
Check the drive is ready for the brake unit start-up, i.e. the: See list of ACS800 Multidrive
• installation has been done according to the manual manuals on the inside of the front
• supply unit commissioning has been done according to the cover.
appropriate supply unit manual
• commissioning of the inverter units has been done according to the
appropriate firmware manuals.
Close all cabinet doors.
2. Power switch-on Information
WARNING! Before the power switch-on make sure there are inverters connected to the intermediate circuit. A
rule of thumb: the sum of the inverter powers must be at least 30% of the rated power of the brake unit (Pbr.max
-value).
Not enough inverters connected means low intermediate circuit capacitance. At power switch-on the DC voltage
will overshoot the controller voltage limit, causing an immediate change to braking. High braking current will
blow the inverter DC fuses.
Close the disconnector of the supply transformer.
Switch on power to the drive.

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19

3. Operational checks Information

Ensure that running one of the motors to be braked is allowed. Start the Use a low speed at first.
motor and increase the rotation speed.
Deactivate the overvoltage controllers of the inverters. For the drive parameter settings, see
(All inverters) the appropriate firmware manual.
Ensure the stop mode of the motor is ramp stop. Set the deceleration Use a relatively long braking time at
time. (Running inverter) first.
Stop the motor simultaneously monitoring the intermediate circuit voltage The DC voltage level during the
with a DriveWindow PC tool. braking indicates the brake unit
operation:
Successful braking: DC voltage level
is: 1.2 · 1.35 · U1max*
Repeat the stop a few times with higher rotating speeds and shorter Unsuccessful braking: DC voltage
deceleration times. level exceeds 1.21 · 1.35 · U1max*
and inverter trips on overvoltage.
See chapter Fault tracing.

*See chapter Hardware description.

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Start-up
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Fault tracing

Fault indications
A fault in the resistor brake circuit prevents fast motor deceleration, and may cause
the drive to trip on a fault.
If a fault is detected by the chopper control board (NBRC), the brake chopper
disconnects the brake resistor from the intermediate circuit and the chopper relay
output is de-energised.
Depending on the application, the fault relay either opens the main breaker of the
drive or gives a fault indication to the overriding control system (see the circuit
diagrams delivered with the unit).

Fault Indication Cause Remedy

Main power is switched Chopper or resistor overheated. Check connections. Let equipment cool.
off by the chopper relay
output. No enable input received by NBRC board. Check that enable input is on.

Short circuit in resistor or power cables. Check power cables and resistor.
or
Chopper control board failure. Contact local ABB representative.
Chopper relay output Chopper damaged; it is not able to
gives a fault indication to disconnect resistor from intermediate circuit.
an overriding control
system.

Chopper does not Chopper voltage setting too high. Check voltage setting.
function. Inverter overvoltage control is on. Check parameters of all inverters.

Chopper starts to Chopper voltage setting too low. Check voltage setting.
function at too low a DC
voltage.

Inverter trips on DC Chopper voltage setting is too high. Check voltage setting.
OVERVOLTAGE fault. Check parameters of all inverters.

Brake resistor or The maximum brake 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.

Fault tracing
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Fault tracing
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23

Technical data

Abbreviations and notes

The abbreviations and notes concerning the brake unit tables are listed below.
Brake unit
Pbr.max Maximum brake power per brake unit allowed momentarily
R ACS800-607 with factory-installed resistors: Resistance value
for the used resistor per brake chopper (resistance of one 2 x
Example: ACS800-607-0640-3 SAFURxxxxxxx assembly). See Brake units: Ratings table on next
page.
+
-
ACS800-607 without factory-installed resistors: the minimum
Imax Imax allowed resistance value for the brake resistor per chopper
Irms Irms (recommended resistance). See Brake units: Ratings table on next
page.
NBRA-659

NBRA-659

Imax Peak brake current (DC) per chopper

Pcont. Continuous brake power per brake unit
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.
SAFUR180F460

SAFUR180F460

SAFUR180F460

SAFUR180F460

Duty Cycle (10 s / 60 s)

Irms Total rms DC current (per chopper) during a period of 10 seconds
with brake power Pbr.
Pbr. Short term brake power per brake unit allowed for 10 seconds every
60 seconds
Pbr.
R R

0
10 s 50 s

Pbr.max
Pbr. Duty Cycle (1 min / 5 min)
Pcont. Irms Total rms DC current (per chopper) during a period of 1 minute with
brake power Pbr.
Pbr. Short term brake power per brake unit allowed for one minute every 5
minutes.
Pbr.

0
1 min 4 min

Brake current wave form

Imax
Irms

0
1 min or 10 s 4 min or 50 s

Chopper heat loss is one percent of the brake power.

Technical data
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The degree of protection of the brake unit is IP21/22/42. The degree of protection of
the SAFUR and NBRA-6xx is IP00.
The SAFUR resistors consist of several resistor elements. The resistance of one
element is 8 ohm. The resistors are built in a metal frame.

Technical data
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Brake units: Ratings

Duty cycle Duty cycle
Module (1min/5min) (10s/60s)
Unit type Resistor type
type Pbr. max R Imax Irms Pcont. Pbr. Irms Pbr. Irms
kW ohm A A kW kW A kW A
UN = 400 V (Range 380 - 415 V)
Only as modules ** NBRA658 -* 230 1.7 384 109 70 230 355 230 355
ACS800-607-0320-3 NBRA659 -* 353 1.20 545 149 96 303 468 353 545
ACS800-607-0640-3 2×NBRA659 -* 706 1.20 545 149 192 606 468 706 545
ACS800-607-0960-3 3×NBRA659 -* 1058 1.20 545 149 288 909 468 1059 545
ACS800-607-1280-3 4×NBRA659 -* 1411 1.20 545 149 384 1212 468 1412 545
ACS800-607-1600-3 5×NBRA659 -* 1764 1.20 545 149 480 1515 468 1765 545
ACS800-607-1920-3 6×NBRA659 -* 2117 1.20 545 149 576 1818 468 2118 545
Only as modules ** NBRA658 2×SAFUR210F575 230 1.7 384 65 42 130 200 224 345
ACS800-607-0320-3+D151 NBRA659 2×SAFUR180F460 353 1.20 545 84 54 287 257 287 444
ACS800-607-0640-3+D151 2×NBRA659 2×(2×SAFUR180F460) 706 1.20 545 84 108 333 257 575 444
ACS800-607-0960-3+D151 3×NBRA659 3×(2×SAFUR180F460) 1058 1.20 545 84 162 500 257 862 444
ACS800-607-1280-3+D151 4×NBRA659 4×(2×SAFUR180F460) 1411 1.20 545 84 216 667 257 1150 444
ACS800-607-1600-3+D151 5×NBRA659 5×(2×SAFUR180F460) 1764 1.20 545 84 270 833 257 1437 444
ACS800-607-1920-3+D151 6×NBRA659 6×(2×SAFUR180F460) 2117 1.20 545 84 324 1000 257 1724 444
UN = 500 V (Range 380 - 500 V)
Only as modules ** NBRA658 -* 268 2.15 380 101 81 268 331 268 331
ACS800-607-0400-5 NBRA659 -* 403 1.43 571 136 109 317 391 403 498
ACS800-607-0800-5 2×NBRA659 -* 806 1.43 571 136 218 634 391 806 498
ACS800-607-1200-5 3×NBRA659 -* 1208 1.43 571 136 327 951 391 1209 498
ACS800-607-1600-5 4×NBRA659 -* 1611 1.43 571 136 436 1268 391 1612 498
ACS800-607-2000-5 5×NBRA659 -* 2014 1.43 571 136 545 1585 391 2015 498
ACS800-607-2400-5 6×NBRA659 -* 2417 1.43 571 136 654 1902 391 2418 498
Only as modules ** NBRA658 2×SAFUR125F500 268 2.00 408 45 36 111 137 192 237
ACS800-607-0400-5+D151 NBRA659 2×SAFUR200F500 403 1.35 605 67 54 167 206 287 355
ACS800-607-0800-5+D151 2×NBRA659 2×(2×SAFUR200F500) 806 1.35 605 67 108 333 206 575 355
ACS800-607-1200-5+D151 3×NBRA659 3×(2×SAFUR200F500) 1208 1.35 605 67 162 500 206 862 355
ACS800-607-1600-5+D151 4×NBRA659 4×(2×SAFUR200F500) 1611 1.35 605 67 216 667 206 1150 355
ACS800-607-2000-5+D151 5×NBRA659 5×(2×SAFUR200F500) 2014 1.35 605 67 270 833 206 1437 355
ACS800-607-2400-5+D151 6×NBRA659 6×(2×SAFUR200F500) 2417 1.35 605 67 324 1000 206 1724 355
UN = 690 V (Range 525 - 690 V)
ACS800-607-0400-7 NBRA669 -* 404 2.72 414 107 119 298 267 404 361
ACS800-607-0800-7 2×NBRA669 -* 807 2.72 414 107 238 596 267 808 361
ACS800-607-1200-7 3×NBRA669 -* 1211 2.72 414 107 357 894 267 1212 361
ACS800-607-1600-7 4×NBRA669 -* 1615 2.72 414 107 476 1192 267 1616 361
ACS800-607-2000-7 5×NBRA669 -* 2019 2.72 414 107 595 1490 267 2020 361
ACS800-607-2400-7 6×NBRA669 -* 2422 2.72 414 107 714 1788 267 2424 361
ACS800-607-0400-7+D151 NBRA669 2×SAFUR200F500 404 1.35 835 97 54 167 149 287 257
ACS800-607-0800-7+D151 2×NBRA669 2×(2×SAFUR200F500) 807 1.35 835 97 108 333 149 575 257
ACS800-607-1200-7+D151 3×NBRA669 3×(2×SAFUR200F500) 1211 1.35 835 97 162 500 149 862 257
ACS800-607-1600-7+D151 4×NBRA669 4×(2×SAFUR200F500) 1615 1.35 835 97 216 667 149 1150 257
ACS800-607-2000-7+D151 5×NBRA669 5×(2×SAFUR200F500) 2019 1.35 835 97 270 833 149 1437 257
ACS800-607-2400-7+D151 6×NBRA669 6×(2×SAFUR200F500) 2422 1.35 835 97 324 2000 149 1724 257

* The ACS800-607-0320-3…1920-3, -0400-5…2400-5 and 0400-7…2400-7 brake units are not equipped with brake resistors, or resistor cubicles
or fans. The resistors must be selected according to the specifications and installed by the user.
** Available only as modules. No cabinet-installed unit exists.

Technical data
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Brake units: Dimensions, weight, noise and air flow

Unit type Height Width Depth Weight Noise Air flow ER
mm mm mm kg dB m3/h kJ
UN = 400 V (Range 380 - 415 V)
Only as modules * 64 660 -
ACS800-607-0320-3 2130 400 600 110 64 660 -
ACS800-607-0640-3 2130 800 600 220 67 1320 -
ACS800-607-0960-3 2130 1200 600 330 68 1980 -
ACS800-607-1280-3 2130 1600 600 440 69 2640 -
ACS800-607-1600-3 2130 2000 600 550 70 3300 -
ACS800-607-1920-3 2130 2400 600 660 71 3960 -
Only as modules * 66 2500 8400
ACS800-607-0320-3+D151 2130 1200 600 340 66 2500 12000
ACS800-607-0640-3+D151 2130 2400 600 680 69 5000 24000
ACS800-607-0960-3+D151 2130 3600 600 1020 70 7500 36000
ACS800-607-1280-3+D151 2130 4800 600 1360 71 10000 48000
ACS800-607-1600-3+D151 2130 6000 600 1700 72 12500 60000
ACS800-607-1920-3+D151 2130 7200 600 2040 73 15000 72000
UN = 500 V (Range 380 - 500 V)
Only as modules * 64 660 -
ACS800-607-0400-5 2130 400 600 110 64 660 -
ACS800-607-0800-5 2130 800 600 220 67 1320 -
ACS800-607-1200-5 2130 1200 600 330 68 1980 -
ACS800-607-1600-5 2130 1600 600 440 69 2640 -
ACS800-607-2000-5 2130 2000 600 550 70 3300 -
ACS800-607-2400-5 2130 2400 600 660 71 3960 -
Only as modules * 66 2500 7200
ACS800-607-0400-5+D151 2130 1200 600 340 66 2500 10800
ACS800-607-0800-5+D151 2130 2400 600 680 69 5000 21600
ACS800-607-1200-5+D151 2130 3600 600 1020 70 7500 32400
ACS800-607-1600-5+D151 2130 4800 600 1360 71 10000 43200
ACS800-607-2000-5+D151 2130 6000 600 1700 72 12500 54000
ACS800-607-2400-5+D151 2130 7200 600 2040 73 15000 64800
UN = 690 V (Range 525 - 690 V)
ACS800-607-0400-7 2130 400 600 110 64 660 -
ACS800-607-0800-7 2130 800 600 110 67 660 -
ACS800-607-1200-7 2130 1200 600 220 68 1320 -
ACS800-607-1600-7 2130 1600 600 330 69 1980 -
ACS800-607-2000-7 2130 2000 600 440 70 2640 -
ACS800-607-2400-7 2130 2400 600 550 71 3300 -
ACS800-607-0400-7+D151 2130 1200 600 340 66 2500 10800
ACS800-607-0800-7+D151 2130 2400 600 340 69 5000 21600
ACS800-607-1200-7+D151 2130 3600 600 680 70 7500 32400
ACS800-607-1600-7+D151 2130 4800 600 1020 71 10000 43200
ACS800-607-2000-7+D151 2130 6000 600 1360 72 12500 54000
ACS800-607-2400-7+D151 2130 7200 600 1700 73 15000 64800
* Brake chopper (NBRA658) + resistor (2×SAFUR), available only as modules. No cabinet-installed unit exists.

An extra 200 mm wide cabinet is added to units with top cable exit.

Technical data
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Brake units: DC fuses

UN IN
Dynamic brake unit type
DC fuse type MRP code (V) (A) pcs
UN = 400 V (Range 380 - 415 V)
Only as mudules * 170M5142 10028183 1000-1250 630 2
ACS800-607-0320-3 170M5146 10028191 1000-1250 630 2
ACS800-607-0640-3 170M5146 10028191 1000-1250 630 4
ACS800-607-0960-3 170M5146 10028191 1000-1250 630 6
ACS800-607-1280-3 170M5146 10028191 1000-1250 630 8
ACS800-607-1600-3 170M5146 10028191 1000-1250 630 10
ACS800-607-1920-3 170M5146 10028191 1000-1250 630 12
Only as modules * 170M5142 10028183 1000-1250 630 2
ACS800-607-0320-3+D151 170M5146 10028191 1000-1250 630 2
ACS800-607-0640-3+D151 170M5146 10028191 1000-1250 630 4
ACS800-607-0960-3+D151 170M5146 10028191 1000-1250 630 6
ACS800-607-1280-3+D151 170M5146 10028191 1000-1250 630 8
ACS800-607-1600-3+D151 170M5146 10028191 1000-1250 630 10
ACS800-607-1920-3+D151 170M5146 10028191 1000-1250 630 12
UN = 500 V (Range 380 - 500 V)
Only as modules * 170M5142 10028183 1000-1250 630 2
ACS800-607-0400-5 170M5146 10028191 1000-1250 630 2
ACS800-607-0800-5 170M5146 10028191 1000-1250 630 4
ACS800-607-1200-5 170M5146 10028191 1000-1250 630 6
ACS800-607-1600-5 170M5146 10028191 1000-1250 630 8
ACS800-607-2000-5 170M5146 10028191 1000-1250 630 10
ACS800-607-2400-5 170M5146 10028191 1000-1250 630 12
Only as modules * 170M5142 10028183 1000-1250 630 2
ACS800-607-0400-5+D151 170M5146 10028191 1000-1250 630 2
ACS800-607-0800-5+D151 170M5146 10028191 1000-1250 630 4
ACS800-607-1200-5+D151 170M5146 10028191 1000-1250 630 6
ACS800-607-1600-5+D151 170M5146 10028191 1000-1250 630 8
ACS800-607-2000-5+D151 170M5146 10028191 1000-1250 630 10
ACS800-607-2400-5+D151 170M5146 10028191 1000-1250 630 12
UN = 690 V (Range 525 - 690 V)
ACS800-607-0400-7 170M5146 10028191 1000-1250 630 2
ACS800-607-0800-7 170M5146 10028191 1000-1250 630 4
ACS800-607-1200-7 170M5146 10028191 1000-1250 630 6
ACS800-607-1600-7 170M5146 10028191 1000-1250 630 8
ACS800-607-2000-7 170M5146 10028191 1000-1250 630 10
ACS800-607-2400-7 170M5146 10028191 1000-1250 630 12
ACS800-607-0400-7+D151 170M5146 10028191 1000-1250 630 2
ACS800-607-0800-7+D151 170M5146 10028191 1000-1250 630 4
ACS800-607-1200-7+D151 170M5146 10028191 1000-1250 630 6
ACS800-607-1600-7+D151 170M5146 10028191 1000-1250 630 8
ACS800-607-2000-7+D151 170M5146 10028191 1000-1250 630 10
ACS800-607-2400-7+D151 170M5146 10028191 1000-1250 630 12
* Brake chopper (NBRA658) + resistor (2×SAFUR), available only as modules. No cabinet-installed unit exists.

Technical data
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Resistor cable
A recommended copper cable for connecting the user-defined resistor to the brake
unit:
• 400 V brake unit: 3 x 95 mm2 + 50 mm2
• 500 V brake unit: 3 x 95 mm2 + 50 mm2
• 690 V brake unit: 3 x 120 mm2 + 70 mm2

Cable shield
To effectively suppress radiated and conducted radio-frequency emissions, the
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
minimum requirement for the cable shield is shown below. It consists of a concentric
layer of copper wires with an open helix of copper tape.

Copper wire screen Helix of copper tape Inner insulation

Insulation jacket

Cable core

Chopper enable input cable

Requirements for the cable connecting resistor temperature sensor to the enable
input of the brake chopper:
• twisted pair cable (shielding is recommended)
• rated operating voltage between a core and ground > 750 (U0)
• insulation test voltage > 2.5 kV.

Technical data
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Dimensional drawings

Overview
The basic dimensional drawings are given in the following pages.
The dimensions are in millimetres. To convert to inches use the formula:
25.4 mm = 1 in.
Note: The actual configuration may differ from this basic configuration. Each delivery
includes the valid delivery specific drawings.

Dimensional drawings
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Brake unit ACS800-607 (types: -0320-3…-1920-3, -0400-5…-2400-5, -0400-7…-2400-7)

The figures below show the layout and dimensions of the brake unit
equipped with one chopper.

Dimensional drawings
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Dimensional drawings
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Brake unit ACS800-607 (types: -0320-3+D151…-1920-3+D151, -0400-5+D151…-2400-5+

D151, -0400-7+D151…-2400-7+D151)
The figures below show the layout and dimensions of the brake unit equipped with
one chopper and two resistors.

Dimensional drawings
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Dimensional drawings
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Dimensional drawings
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Circuit diagrams

Overview
The following pages show the basic circuit diagrams for the ACS800-607-
0640-3+D151 brake unit. The system consists of two parallel units both including a
brake chopper and two brake resistors.
One chopper – the first in the chain – acts as the master for the other. The switching
of the slave chopper is controlled by the master via a fibre optic link.
With minor modifications the basic connections are valid also for the other standard
brake unit:
• If there is only one brake chopper and brake resistors, no fibre optic master/slave
link used.
• If there are no factory-installed brake resistors, the corresponding resistor
connections are to be done by the user.
Note: The actual configuration may differ from this basic configuration. Each delivery
includes the valid delivery specific drawings.

Circuit diagrams
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Brake unit ACS800-607, master

The figure below shows the circuit diagram of an ACS800-607-0640-3 master unit.
The master chopper controls the slave (see following page).

Circuit diagrams
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Brake unit ACS800-607, slave

The figure below shows the circuit diagram of an ACS800-607-0640-3 slave unit.
The slave chopper is controlled by the master (see previous page).

Circuit diagrams
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Circuit diagrams
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EFFECTIVE: 11.10.2004
3AFE68392519 REV A

ABB Oy
AC Drives
P.O. Box 184
FI-00381 HELSINKI
FINLAND
Telephone +358 10 22 11
Fax +358 10 22 23380
Internet http://www.abb.com