ABB ACS880-37 User manual

Type
User manual

This manual is also suitable for

ABB industrial drives
Hardware manual
ACS880-17 drives
(132…400 kW, 200…450 hp)
List of related manuals
You can find manuals and other product documents in PDF format on the Internet. See section
Document library on the Internet on the inside of the back cover. For manuals not available in the
Document library, contact your local ABB representative.The code below opens an online listing of
the manuals applicable to this product.
Drive hardware manuals and guides Code (English)
Drive/converter/inverter safety instructions Multilingual code:
3AXD50000037978
ACS880-17 drives (132…400 kW) hardware manual 3AXD50000035158
ACS-AP-X assistant control panels users manual 3AUA0000085685
EMC filter and ground-to-phase varistor disconnecting
instructions, ACS880 frames R1 to R11
3AUA0000125152
Drive firmware manuals and guides
ACS880 primary control program firmware manual 3AUA0000085967
Quick start-up guide for ACS880 drives with primary
control program
3AUA0000098062
ACS880 IGBT supply control program firmware manual 3AUA0000131562
Option manuals and guides
Drive composer start-up and maintenance PC tool users
manual
3AUA0000094606
Bypass connection for ACS880-07, -17, -37 (40...1200 A)
option description
3AXD50000048959
FSO-12 safety functions module user’s manual 3AXD50000015612
FSO-21 safety functions module user’s manual 3AXD500000xxxxx
User’s manual for Prevention of unexpected start-up
(+Q950) for ACS880-07/17/37 drives
3AUA0000145922
User’s manual for Emergency stop, stop category 0
(+Q951) for ACS880-07/17/37 drives
3AUA0000119895
User’s manual for Emergency stop, stop category 1
(+Q952) for ACS880-07/17/37 drives
3AUA0000119896
User’s manual for Prevention of unexpected start-up
(+Q957) for ACS880-07/17/37 drives
3AUA0000119910
User’s manual for Emergency stop, stop category 0
(+Q963) for ACS880-07/17/37 drives
3AUA0000119908
User’s manual for Emergency stop, stop category 1
(+Q964) for ACS880-07/17/37 drives
3AUA0000119909
User’s manual for Emergency stop, configurable stop
category 0 or 1 (+Q978) for ACS880-07/17/37 drives
3AUA0000145920
User’s manual for Emergency stop, configurable stop
category 0 or 1 (+Q979) for ACS880-07/17/37 drives
3AUA0000145921
Manuals and quick guides for I/O extension modules,
fieldbus adapters, etc.
ACS880-17 (132…400 kW, 200…450 hp) manuals
Hardware manual
ACS880-17 drives
(132…400 kW, 200…450 hp)
3AXD50000035158 Rev B
EN
EFFECTIVE: 2018-01-18
2018 ABB Oy. All Rights Reserved.
1. Safety instructions
4. Mechanical installation
Table of contents
6. Electrical installation
9. Start-up
5
Table of contents
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . 21
Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2. Introduction to the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Quick installation, commissioning and operation flowchart . . . . . . . . . . . . . . . . . . . . . . . 25
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3. Operation principle and hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Single-line diagram of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cabinet layout of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connection overview of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
External control cable connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connection terminals of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Door switches and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Main disconnecting device (Q1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Other devices on the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Descriptions of cabinet options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
IP22 (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
IP42 (option +B054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
IP54 (option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6
Channeled air inlet through bottom (option +C128) . . . . . . . . . . . . . . . . . . . . . . . . . 41
Channeled air outlet (option +C130) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Marine construction (option +C121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
UL listed (option +C129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CSA approved (option +C134) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Plinth height (options +C164 and +C179) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Seismic design (option +C180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Empty cubicles (options +C196, +C197, +C198, +C199, +C200, +C201) . . . . . . . . 43
EMC filters (option + E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
du/dt filter (option +E205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Sine filter (option +E206) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Common mode filter (option +E208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cabinet heater with external supply (option +G300) . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cabinet lighting (option +G301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Terminals for external interruptible control voltage (option +G307) . . . . . . . . . . . . . 44
Output for motor space heater (option +G313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ready/Run/Fault lights (options +G327…G329) . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Halogen-free materials and wiring (option G330) . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
V-meter with selector switch (option +G334) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
A-meter in one phase (option +G335) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Additional wire markings (options +G340 and +G342) . . . . . . . . . . . . . . . . . . . . . . . 45
Standard wire markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Bottom cable entry/exit (options +H350 and +H352) . . . . . . . . . . . . . . . . . . . . . . . . 46
Top cable entry/exit (options +H351 and +H353) . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cable conduit entry (option +H358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Additional terminal block X504 (option +L504) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Thermal protection with PTC relays (options +L505, +2L505. +L513, +2L513) . . . . 46
+L505, +2L505, +L513, +2L513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
+L536, +L537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
More information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pt100 relays (options +2L506, +3L506, +5L506, +8L506) . . . . . . . . . . . . . . . . . . . . 48
Starter for auxiliary motor fan (options +M600…+M605) . . . . . . . . . . . . . . . . . . . . . 48
What the option contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Moving and unpacking the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Moving the drive in its packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Moving the crate with a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removing the transport package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Moving the unpacked drive cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Lifting the cabinet with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Moving the cabinet on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Moving the cabinet on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Final placement of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Installing the IP54 roof (option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7
Fastening the cabinet to the floor and wall or roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fastening methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Alternative 1 – Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Alternative 2 – Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fastening the cabinet to the floor and wall or roof (marine units) . . . . . . . . . . . . . . . . . . 65
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Air inlet through the bottom (option +C128) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Air outlet duct on the cabinet roof (option +C130) . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Calculating the required static pressure difference . . . . . . . . . . . . . . . . . . . . . . . . 67
Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5. Guidelines for planning the electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Additional requirements for explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . . 72
Additional requirements for ABB motors of types other than M2_, M3_, M4_,
HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . 73
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . 73
Additional data for calculating the rise time and the peak line-to-line voltage . . . . 74
Additional note for sine filters (option +E206) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Typical cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . 80
Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . 80
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . 80
R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . 80
Protecting the drive and the power cables against thermal overload . . . . . . . . . . . . . 80
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . 82
Implementing the Prevention of unexpected start-up function . . . . . . . . . . . . . . . . . . . . 82
Implementing the functions provided by the FSO-xx safety functions module (option
+Q972 or +Q973) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Supplying power for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . 83
Implementing a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . 84
Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . 86
Drive I/O, I/O extension and encoder interface modules . . . . . . . . . . . . . . . . . . . . . 87
6. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . 90
EMC filter (option +E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Corner-grounded and midpoint-grounded 690 V delta systems . . . . . . . . . . . . . . . . 91
Attaching the device stickers to the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Checking the settings of transformers T21, T101 (frame R11 +B055+C128), T102
(frame R11 +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Transformers of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Grounding the outer shields of the control cables at the cabinet entry . . . . . . . . . 93
Routing the control cables inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Routing the control cables inside R11 cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connecting to the drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Connecting an auxiliary voltage supply (UPS, option +G307) . . . . . . . . . . . . . . . 99
Connecting emergency stop push buttons (options +Q951, +Q952, +Q963,
+Q964, +Q978, +Q979) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Wiring the starter for auxiliary motor fan (options +M600…+M605) . . . . . . . . . . . 99
Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513, +2L513) . . 100
Wiring the Pt100 relays (option +nL506) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Wiring the Pt100 relays (option +nL514) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Powering the heating and lighting equipment (options +G300, +G301 and
+G313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Wiring ground fault monitoring for IT ungrounded systems (option +Q954) . . . . 104
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Connection diagram of frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Layout of power cable connection terminals and cable entries . . . . . . . . . . . . . . . . 106
Power connection terminals and cable entries of frame R11 . . . . . . . . . . . . . . . 106
Connection procedure (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
9
Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . 109
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder
interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Installation of safety functions modules (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . 111
Case 1: FSO-xx safety functions module on Slot 2 . . . . . . . . . . . . . . . . . . . . . . . 111
Case 2: FSO-xx safety functions module next to the control unit . . . . . . . . . . . . 112
7. Control unit of frame R11
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ZCU-14 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
External power supply for the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . 116
DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Checks/Settings with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Powering up the auxiliary circuit of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Setting up the line-side converter parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Setting up the motor-side converter parameters, and performing the first start . . 127
Activating the Run enable signal of the line-side converter (with options +Q951,
+Q952 and +Q978) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
10. Fault tracing
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
11. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
10
Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . 132
Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . 132
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Cleaning the door air inlets (IP22 and IP42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Cleaning the door air inlets (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cleaning the outlet (roof) filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Replacing the outlet (roof) filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Power connections and quick connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Retightening the power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Replacing the cabinet “door” fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Replacing the drive module main fans (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . 137
Replacing the LCL filter module fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Replacing the auxiliary cooling fans of the drive module (frame R11) . . . . . . . . . . 140
Replacing the IP54 (UL Type12) roof fan (options +B055 and +C128, frame R11) 142
Replacing the IP54 (UL Type 12) roof fan (option +B055, frame R11) . . . . . . . . . . 143
Replacing the sine filter cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Replacing the drive and LCL filter modules (frame R11) . . . . . . . . . . . . . . . . . . . . . . . 144
Necessary equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Replacing the drive module (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Replacing the LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Replacing fuses (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Replacing the control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Replacing the memory unit of the motor-side converter control unit (frame R11) . . 160
Replacing the memory unit of the line-side converter control unit (R11) . . . . . . . . 161
12. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . . . 166
Ex motor, sine filter, low noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Dimensions and weights of sine filter cabinet (option +E206) . . . . . . . . . . . . . . . . 168
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Cooling data, noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Sine output filter data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Terminal and exit data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
11
IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Terminal data for the drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Control unit connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Auxiliary circuit power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . 176
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 176
Compliance with EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
EAC (Eurasian Conformity) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
EIP (Electronic Information Products) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
13. Dimensions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
R11 (IP22, UL Type 1, IP42, UL Type 1 Filtered, option +B054) . . . . . . . . . . . . . . . . . 184
R11 (IP54, UL Type 12, option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
R11 (IP22, UL Type 1, IP42, UL Type 1 Filtered, options +C129, +H350, +H352) . . . . 186
R11 (IP54, UL Type 12, options +B055, +C128) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
R11 (IP54, UL Type 12, options +B055, +C129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
R11 (IP54, UL Type 12, options +B055, +C129, +H350, +H352) . . . . . . . . . . . . . . . . . 189
R11 (IP22, UL Type 1, IP42, UL Type 1 Filtered, option +D150) . . . . . . . . . . . . . . . . . 190
R11 (IP22, UL Type 1, IP42, UL Type 1 Filtered, options +D150 +D151) . . . . . . . . . . 191
R11 (IP22, UL Type 1, IP42, UL Type 1 Filtered, option +E206) . . . . . . . . . . . . . . . . . 192
Location and size of power cable connection terminals . . . . . . . . . . . . . . . . . . . . . . . . 193
R11 input and motor cable terminal dimensions – bottom entry and exit . . . . . . . . 193
R11 input and motor cable terminal dimensions – top entry and exit . . . . . . . . . . . . 194
Input cable terminals (R11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Motor cable terminals (R11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Terminals for connecting external resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Sine filter (+E206) cubicle, 400 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Sine filter (+E206) cubicle, 600 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Sine filter (+E206) cubicle, 1000 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
12
14. The Safe torque off function
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 200
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Safety instructions 13
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install and
operate the drive and do maintenance on the drive. If you ignore the safety instructions,
injury, death or damage can occur.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death, or damage to the
equipment. They also tell you how to prevent the danger. Notes draw attention to a
particular condition or fact, or give information on a subject.
The manual uses these warning symbols:
Electricity warning tells about hazards from electricity which can cause injury
or death, or damage to the equipment.
General warning tells about conditions, other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
Electrostatic sensitive devices warning tells you about the risk of
electrostatic discharge which can cause damage to the equipment.
14 Safety instructions
General safety in installation, start-up and maintenance
These instructions are for all personnel that install the drive and do maintenance work on
it.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
Secure the cabinet to the floor to prevent it from toppling over when you pull out drive
and LCL filter modules. The modules are heavy and have a high center of gravity.
Wear protective gloves and long sleeves. Some parts have sharp edges.
Handle the drive and LCL filter modules carefully:
Use safety shoes with a metal toe cap to avoid foot injury.
Lift the module with a lifting device only. Use the designated lifting points.
Frame R11:
Do not tilt the module. It is heavy and its center of gravity is high.
Make sure that the module does not topple over when you move it on the floor: Do not leave
the module unattended on a sloping floor. Extend the support legs: Press each leg a little down
and turn it aside. Whenever possible secure the module also with chains.
Do not use the module installation ramp with plinth heights which exceed the maximum height
marked on the ramp. (The maximum plinth height is 50 mm [1.97 in] when the telescopic ramp
is fully retracted and 150 mm [5.91 in] when the ramp is fully extended.)
Secure the module installation ramp carefully.
2
Safety instructions 15
All frames;
Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,
remain hot for a while after disconnection of the electrical supply.
Beware of hot air exiting from the air outlets.
Keep the drive in its package or protect it otherwise from dust and burr from drilling
and grinding until you install it. Protect also the installed drive against dust and burr.
Electrically conductive debris inside the drive can cause damage or malfunction.
Vacuum clean the area below the drive before the start-up to prevent the drive cooling
fan from drawing the dust inside the drive.
Do not cover the air inlet and outlet when the drive is running.
Make sure that there is sufficient cooling. See section Examining the installation site
(page 55).
Keep the cabinet doors closed when the drive is powered. With the doors open, a risk
of a potentially fatal electric shock, arc flash or high-energy arc blast exists. If you
cannot avoid working on a powered drive, obey the local laws and regulations on live
working (including – but not limited to – electric shock and arc protection).
Before you connect voltage to the drive, make sure that the cabinet doors are closed.
Keep the doors closed during operation.
Before you adjust the drive operation limits, make sure that the motor and all driven
equipment can operate throughout the set operation limits.
Before you activate the automatic fault reset or automatic restart functions of the drive
control program, make sure that no dangerous situations can occur. These functions
reset the drive automatically and continue operation after a fault or supply break. If
these functions are activated, the installation must be clearly marked as defined in
To prevent the drive module from falling, attach its top lifting lugs with chains to the cabinet
frame before you push the module into the cabinet and pull it from the cabinet. Work carefully
preferably with help from another person. Keep a constant pressure with one foot on the base
of the module to prevent the module from falling on its back.
16 Safety instructions
IEC/EN 61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS
AUTOMATICALLY".
The maximum number of drive power-ups is five in ten minutes. Too frequent power-
ups can damage the charging circuit of the DC capacitors.
Make sure that any safety circuits (for example, emergency stop and Safe torque off)
are validated at start-up. See chapter The Safe torque off function (page 199). For
other safety functions, see their separate instructions.
Note:
If you select an external source for the start command and it is on, the drive will start
immediately after fault reset unless you configure the drive for pulse start. See the
firmware manual.
When the control location is not set to Local, the stop key on the control panel will not
stop the drive.
Only authorized persons are allowed to repair a malfunctioning drive.
Electrical safety in installation, start-up and maintenance
Electrical safety precautions
These warnings are for all personnel who do work on the drive, motor cable or motor.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur. If you are not a qualified electrician, do not
do installation or maintenance work. Go through these steps before you begin any
installation or maintenance work.
1. Keep the cabinet doors closed when the drive is powered. With the doors open, a risk
of electric shock and/or arcing exists.
2. Clearly identify the work location.
3. Disconnect all possible voltage sources.
Open the main switch-disconnector (frame R11) (Q1) of the drive. Open the
disconnector of the supply transformer as the main switch-disconnector or breaker
of the drive does not remove the voltage from the input busbars of the drive or V-
meter (option +G334).
Make sure that reconnection is not possible. Lock the disconnectors to open
position and attach a warning notice to them.
Disconnect any external power sources from the control circuits before you do
work on the control cables.
After you disconnect the drive, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you continue.
4. Protect any other energized parts in the work location against contact.
5. Take special precautions when close to bare conductors.
6. Measure that the installation is de-energized.
WARNING! If the measurement requires removal or disassembly of shrouding or
other cabinet structures, obey the local laws and regulations applicable to live
working (including – but not limited to – electric shock and arc protection).
Safety instructions 17
Use a multimeter with an impedance of at least 1 Mohm.
Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is close to 0 V. Measuring holes of the standard
drive in the shroud are shown below.
L1, L2,
L3
PE
Frame R11
18 Safety instructions
Frame R11: Make sure that the voltage of the drive AC busbars between the drive
module and the LCL filter and the grounding (PE) busbar are close to 0 V.
Measuring holes of the standard drive in the shroud are shown below.
PE
AC busbars
Safety instructions 19
Make sure that the voltage between the DC busbars is close to 0 V. You can
measure the voltage through the holes in the cover.
7. Install temporary grounding as required by the local regulations. Connect the AC and
DC busbars to PE with a temporary grounding tool.
8. Ask the person in control of the electrical installation work for a permit to work.
Additional instructions and notes
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
If you are not a qualified electrician, do not do electrical installation or maintenance
work.
Do not install a drive with EMC filter (option +E202) on an ungrounded power system
or a high resistance-grounded (over 30 ohms) power system.
Do not connect the drive to a voltage higher than what is specified on the type
designation label.
We do not recommend that you secure the cabinet by arc welding. If you have to, obey
the instructions on page 67.
Do not do insulation or voltage withstand tests on the drive or its modules.
Note:
Frame R11
DC+
DC-
20 Safety instructions
The motor cable terminals of the drive are at a dangerous voltage when the input
power is on, regardless of whether the motor is running or not.
The DC bus is at a dangerous voltage.
External wiring can supply dangerous voltages to the relay outputs of the control units
of the drive.
The Safe torque off function does not remove the voltage from the main and auxiliary
circuits. The function is not effective against deliberate sabotage or misuse.
WARNING! Use a grounding wrist band when you handle the printed circuit
boards. Do not touch the boards unnecessarily. The boards contain components
sensitive to electrostatic discharge.
WARNING! Obey these instructions. If you ignore them, equipment malfunction
and damage to the fiber optic cables can occur.
Handle fiber optic cables with care.
When you unplug the cables, always hold the connector, not the cable itself.
Do not touch the ends of the fibers with bare hands as the ends are extremely
sensitive to dirt.
Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is
35 mm (1.4”).
Grounding
These instructions are for all personnel who are responsible for the grounding of the drive.
WARNING! Obey these instructions. If you ignore them, injury or death, or
equipment malfunction can occur, and electromagnetic interference can increase.
If you are not a qualified electrician, do not do grounding work.
Always ground the drive, the motor and adjoining equipment. This is necessary for the
personnel safety. Proper grounding also reduces electromagnetic emission and
interference.
Make sure that the conductivity of the grounding conductors is sufficient. See section
Selecting the power cables (page 75). Obey the local regulations.
Connect the power cable shields to protective earth (PE) of the drive to make sure of
personnel safety.
Make a 36 grounding of the power and control cable shields at the cable entries to
suppress electromagnetic disturbances.
In a multiple-drive installation, connect each drive separately to the protective earth
(PE) busbar of the switch board or the transformer.
Note:
You can use power cable shields as grounding conductors only when their conductivity
is sufficient.
As the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you
must use a fixed protective earth connection. See standard EN 61800-5-1, 4.3.5.5.2.
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