ABB ACS880-07 User manual

ABB industrial drives
Hardware manual
ACS880-07 drives (560 to 2800 kW)

Hardware manual
ACS880-07 drives (560 to 2800 kW)
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
9. Start-up
© 2017 ABB Oy. All Rights Reserved. 3AUA0000143261 E
EN
EFFECTIVE: 2017-06-05

Table of contents
1 Safety instructions
15Contents of this chapter ...........................................................................
15Use of warnings and notes .......................................................................
16General safety in installation, start-up and maintenance ....................................
19Electrical safety in installation, start-up and maintenance ...................................
19Electrical safety precautions ..................................................................
19Additional instructions and notes .............................................................
20Grounding .......................................................................................
21Additional instructions for permanent magnet motor drives .................................
21Safety in installation, start-up, maintenance ................................................
21Safety in operation .............................................................................
2 Introduction to the manual
23Contents of this chapter ...........................................................................
23Target audience ....................................................................................
23Contents of the manual ...........................................................................
24Categorization by frame size and option code .................................................
25Quick installation, commissioning and operation flowchart ..................................
26Terms and abbreviations ..........................................................................
26Related manuals ...................................................................................
3 Operation principle and hardware description
29Contents of this chapter ...........................................................................
29Operation principle .................................................................................
30Overview circuit diagram of the drive ........................................................
3112-pulse connection (option +A004) .....................................................
32Cabinet line-up and layout examples ...........................................................
32Frame 1×D8T + 2×R8i .........................................................................
34Frame 2×D7T + 2×R8i (12-pulse connection, option +A004) ............................
36Frame 2×D8T + 3×R8i .........................................................................
38Frame 3×D8T + 4×R8i (with main breaker, option +F255) ...............................
40Auxiliary control cubicle (ACU) layout .......................................................
42Overview of power and control connections ...................................................
43Door switches and lights ..........................................................................
44Main disconnecting device (Q1.1) ...........................................................
44Auxiliary voltage switch (Q21) ................................................................
44Grounding (earthing) switch (Q9.x), optional ...............................................
44Other devices on the door .....................................................................
44Control panel ....................................................................................
45Control by PC tools .........................................................................
45Descriptions of options ............................................................................
45Degree of protection ...........................................................................
45Definitions ....................................................................................
45IP22 (standard) ..............................................................................
46IP42 (option +B054) ........................................................................
46IP54 (option +B055) ........................................................................
Table of contents 5

46Cooling air intake through bottom of cabinet (option +C128) ............................
46Channeled air outlet (option +C130) .........................................................
46Marine construction (option +C121) .........................................................
46UL Listed (option +C129) ......................................................................
46CSA Approved (option +C134) ...............................................................
47Plinth height (options +C164 and +C179) ..................................................
47Seismic design (option +C180) ...............................................................
47Empty cubicles (options +C199…C201) ....................................................
47Resistor braking (options +D150 and +D151) ..............................................
47EMC filters (option + E202) ...................................................................
47Sine filter (option +E206) ......................................................................
47Cabinet heater with external supply (option +G300) ......................................
48Cabinet lighting (option +G301) ..............................................................
48Terminals for external control voltage (option +G307) ....................................
48Output for motor space heater (option +G313) ............................................
48Supply connection by busbars (option +G317) ............................................
48Ready/Run/Fault lights (options +G327…G329) ..........................................
48Halogen-free wiring and materials (option +G330) ........................................
48V-meter with selector switch (option +G334) ...............................................
49A-meter in one phase (option +G335) .......................................................
49Additional wire markings (options +G340 and +G342) ...................................
49Standard wire markings ....................................................................
49Additional wire markings ...................................................................
49Bottom cable entry/exit (options +H350 and +H352) ......................................
50Top cable entry/exit (options +H351 and +H353) ..........................................
50Cable conduit entry (option +H358) .........................................................
50Common motor terminal cubicle (option +H359) ..........................................
50Common output terminal (option +H366) ...................................................
51Additional terminal block X504 (option +L504) .............................................
51
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513, +L536,
+L537) ...........................................................................................
51+L505, +2L505, +L513, +2L513 ..........................................................
52+L536, +L537 ................................................................................
52Thermal protection with Pt100 relays (options +nL506) ..................................
53Starter for auxiliary motor fan (options +M602…M610) ..................................
53What the option contains ..................................................................
53Description ...................................................................................
54Type designation label ............................................................................
54Type designation key ..............................................................................
4 Mechanical installation
59Contents of this chapter ...........................................................................
59Examining the installation site ...................................................................
60Necessary tools ....................................................................................
60Checking the delivery .............................................................................
61Moving and unpacking the drive .................................................................
61Moving the drive in its packaging ............................................................
61Lifting the crate with a forklift ..............................................................
62Lifting the crate with a crane ..............................................................
63Moving the crate with a forklift ............................................................
63Removing the transport package ............................................................
6 Table of contents

64Moving the unpacked drive cabinet ..........................................................
64Lifting the cabinet with a crane ...........................................................
65Moving the cabinet on rollers .............................................................
65Moving the cabinet on its back ............................................................
66Final placement of the cabinet ............................................................
66Fastening the cabinet to the floor and wall or roof (non-marine units) .....................
66General rules ....................................................................................
67Fastening methods .............................................................................
67Alternative 1 – Clamping ......................................................................
68Alternative 2 – Using the holes inside the cabinet .........................................
68Fastening the cabinet to the floor and roof/wall (marine units) ..............................
69Joining shipping splits together ..................................................................
72Miscellaneous ......................................................................................
72Cable duct in the floor below the cabinet ...................................................
72Arc welding ......................................................................................
72Air inlet through the bottom of cabinet (option +C128) ...................................
73Air outlet duct on the cabinet roof (option +C130) .........................................
74Calculating the required static pressure difference ....................................
5 Guidelines for planning the electrical installation
75Contents of this chapter ...........................................................................
75Limitation of liability ................................................................................
75Selecting the supply disconnecting device .....................................................
75Selecting the main contactor or breaker ........................................................
76Examining the compatibility of the motor and drive ...........................................
76Protecting the motor insulation and bearings ..............................................
76Requirements table ............................................................................
79Availability of du/dt filter and common mode filter by drive type .....................
79Additional requirements for explosion-safe (EX) motors ..............................
79
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ......................................................................................
79Additional requirements for braking applications .......................................
79Additional requirements for ABB high-output and IP23 motors ......................
80Additional requirements for non-ABB high-output and IP23 motors .................
81Additional data for calculating the rise time and the peak line-to-line voltage .....
81Additional note for sine filters .............................................................
82Selecting the power cables .......................................................................
82General rules ....................................................................................
82Typical power cable sizes .....................................................................
83Alternative power cable types ................................................................
83Recommended power cable types .......................................................
84Power cable types for limited use ........................................................
84Not allowed power cable types ...........................................................
84Power cable shield .............................................................................
85Additional US requirements ...................................................................
85Conduit .......................................................................................
85Armored cable / shielded power cable ...................................................
85Planning the resistor braking system ...........................................................
85Selecting the control cables ......................................................................
85Shielding .........................................................................................
86Signals in separate cables ....................................................................
86Signals allowed to be run in the same cable ...............................................
Table of contents 7

86Relay cable type ................................................................................
86Control panel cable length and type .........................................................
86Routing the cables .................................................................................
87Separate control cable ducts .................................................................
87Continuous motor cable shield or enclosure for equipment on the motor cable ......
87Implementing thermal overload and short-circuit protection .................................
87Protecting a drive and input power cable in short-circuits ................................
88Protecting the motor and motor cable in short-circuits ....................................
88Protecting the drive and the power cables against thermal overload ...................
88Protecting the motor against thermal overload .............................................
88Protecting the drive against ground faults ......................................................
88Residual current device compatibility ........................................................
89Implementing the emergency stop function ....................................................
89Implementing the Safe torque off function .....................................................
89Implementing the Prevention of unexpected start-up function ..............................
89
Implementing the functions provided by the FSO-xx safety functions module (option
+Q972 or +Q973) ..................................................................................
90Implementing the Power-loss ride-through .....................................................
90Units with main contactor (option +F250) ...................................................
90Implementing a bypass connection .............................................................
91Supplying power for the auxiliary circuits .......................................................
91Using power factor compensation capacitors with the drive .................................
91Implementing a safety switch between the drive and the motor ............................
91Protecting the contacts of relay outputs ........................................................
92Connecting a motor temperature sensor to the drive I/O ....................................
93Drive I/O, I/O extension and encoder interface modules .................................
6 Electrical installation
95Contents of this chapter ...........................................................................
95Warnings ............................................................................................
95Checking the insulation of the assembly .......................................................
95Drive ..............................................................................................
95Input cable .......................................................................................
95Motor and motor cable .........................................................................
96Custom brake resistor assembly .............................................................
96Checking the compatibility with IT (ungrounded) systems ...................................
96Attaching the device stickers to the cabinet door .............................................
96Checking the settings of transformers T21, T101 and T111 .................................
97T21 and T101 tap settings (400…500 V units) .............................................
97T21 and T101 tap settings (690 V units) ....................................................
98T111 tap settings ...............................................................................
99Connecting the control cables ...................................................................
99Control cable connection procedure .........................................................
100Grounding the outer shields of the control cables at the cabinet lead-through ....
102Routing the control cables inside the cabinet ...........................................
103Connecting to the inverter control unit (A41) ...........................................
104Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) .......
104
Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963,
+Q964, +Q978,+Q979) ....................................................................
104Wiring the starter for auxiliary motor fan (options +M602…+M610) .................
105Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513 and +2L513) .
106Wiring the Pt100 relays (option +nL506) ................................................
8 Table of contents

106Wiring the Pt100 relays (option +nL514) ................................................
107
Powering the heating and lighting equipment (options +G300, +G301 and
+G313) .......................................................................................
108Wiring ground fault monitoring for IT ungrounded systems (option +Q954) .......
109
Connecting the motor cables (units without common motor terminal cubicle or sine output
filter) ..................................................................................................
109Motor connection diagram (without option +H366) ........................................
110Motor connection diagram (with option +H366) ............................................
111Procedure .......................................................................................
111Removing the inverter module(s) .........................................................
115Removing and reinstalling the fan carriage of an inverter module ...................
117Connecting the motor cables ..............................................................
119Re-installing the fan carriage of an inverter module ...................................
119Re-inserting the inverter module into the cubicle ......................................
119
Connecting the motor cables (units with common motor terminal cubicle or sine output
filter) ..................................................................................................
119Output busbars .................................................................................
120Connection diagram ............................................................................
120Procedure .......................................................................................
121Connecting an external brake resistor assembly ..........................................
121Connecting the input power cables ..............................................................
121Connection diagram, 6-pulse units ..........................................................
122Connection diagram, 12-pulse units .........................................................
122Layout of the input cable connection terminals and lead-throughs .....................
122Connection procedure .........................................................................
124Connecting a PC ...................................................................................
125Panel bus (Control of several units from one control panel) .................................
126Installing option modules .........................................................................
126
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface
modules ..........................................................................................
126Mechanical installation of an FSO-xx safety functions module ..........................
127Wiring of optional modules ....................................................................
7 Control units of the drive
129What this chapter contains .......................................................................
129General ..............................................................................................
130Control unit layout and connections .........................................................
132Default I/O diagram of the supply control unit (A51) ......................................
133Default I/O diagram of the inverter control unit (A41) .....................................
134External power supply for the control unit (XPOW) .......................................
134DI6 as a PTC sensor input ....................................................................
134AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input .............................
135DIIL input ........................................................................................
135Drive-to-drive link (XD2D) .....................................................................
136Safe torque off (XSTO, XSTO OUT) .........................................................
136FSO-xx safety functions module connection (X12) ........................................
136SDHC memory card slot .......................................................................
136Connector data .....................................................................................
139Ground isolation diagram .....................................................................
8 Installation checklist
141Contents of this chapter ...........................................................................
Table of contents 9

141Warnings ............................................................................................
141Checklist .............................................................................................
9 Start-up
143Contents of this chapter ...........................................................................
143Start-up procedure .................................................................................
10 Fault tracing
147Contents of this chapter ...........................................................................
147LEDs .................................................................................................
147Warning and fault messages .....................................................................
11 Maintenance
149Contents of this chapter ...........................................................................
149Maintenance intervals .............................................................................
151Cabinet ..............................................................................................
151Cleaning the interior of the cabinet ..........................................................
151Cleaning the door air inlets (IP22 and IP42) ...............................................
151Cleaning the door air inlets (IP54) ...........................................................
152Cleaning the outlet (roof) filters (IP54) ......................................................
152Replacing the outlet (roof) filters (IP54) .....................................................
152Power connections and quick connectors ......................................................
152Retightening the power connections ........................................................
153Fans ..................................................................................................
153Replacing the cooling fan in the auxiliary control cubicle .................................
153Replacing the cooling fan(s) in the incoming cubicle .....................................
154Replacing a roof fan (IP54/UL type 12) .....................................................
155Replacing a supply module (D7T) cooling fan .............................................
156Replacing a supply module (D8T) or inverter module (R8i) cooling fan ................
157Replacing the circuit board compartment fan ..............................................
160Supply and inverter modules .....................................................................
160Replacing a frame D7T supply module .....................................................
163Replacing a frame D8T supply module .....................................................
167Cleaning the heatsink ..........................................................................
168Activating the reduced run of the inverter unit .............................................
170Returning the module ......................................................................
170Capacitors ...........................................................................................
170Reforming the capacitors ......................................................................
171Fuses ................................................................................................
171Replacing the AC and DC fuses in cabinet .................................................
172Replacing the supply module DC fuses (D7T and D8T) ..................................
174Control panel .......................................................................................
174Replacing the control panel battery ..........................................................
174Cleaning .........................................................................................
175Control units ........................................................................................
175BCU control unit types .........................................................................
175Replacing the memory unit ...................................................................
175Replacing the BCU control unit battery .....................................................
12 Technical data
177Contents of this chapter ...........................................................................
10 Table of contents

177Ratings ..............................................................................................
179Definitions .......................................................................................
179Derating ..........................................................................................
179Ambient temperature derating ............................................................
180Altitude derating .............................................................................
180Switching frequency derating .............................................................
180Output frequency derating .................................................................
181Frame sizes and power module types ..........................................................
183Fuses ................................................................................................
183AC fuses .........................................................................................
184DC fuses .........................................................................................
185Supply module internal DC fuses ............................................................
186Brake chopper DC fuses ......................................................................
186Dimensions and weights ..........................................................................
186Free space requirements .........................................................................
186Cooling data and noise ............................................................................
188Sine output filter data ..............................................................................
189Input cable sizes ...................................................................................
191Output cable sizes .................................................................................
192Terminal and lead-through data for the power cables ........................................
192Terminal data for the supply and inverter control units .......................................
192Electrical power network specification ..........................................................
193Motor connection data ............................................................................
193Control unit connection data .....................................................................
193Efficiency ............................................................................................
193Protection classes .................................................................................
193Ambient conditions ................................................................................
194Materials .............................................................................................
195Applicable standards ..............................................................................
197CE marking .........................................................................................
197Compliance with the European Low Voltage Directive ....................................
197Compliance with the European EMC Directive ............................................
197Compliance with the European Machinery Directive ......................................
198Declaration of Conformity (According to Machinery Directive) .......................
200Compliance with EN 61800-3:2004 .............................................................
200Definitions .......................................................................................
200Category C2 .....................................................................................
200Category C3 .....................................................................................
201Category C4 .....................................................................................
202UL and CSA markings ............................................................................
202UL and CSA checklist ..........................................................................
202RCM marking .......................................................................................
202EAC (Eurasian Conformity) marking ............................................................
202Tightening torques .................................................................................
202Electrical connections ..........................................................................
203Mechanical connections .......................................................................
203Insulation supports .............................................................................
203Cable lugs .......................................................................................
204Disclaimers .........................................................................................
204Generic disclaimer .............................................................................
204Cybersecurity disclaimer ......................................................................
Table of contents 11

13 Dimensions
205Cabinet line-up dimensions .......................................................................
206Dimension tables ...............................................................................
212Weights ..........................................................................................
213Dimension drawing examples ................................................................
213Frame 2×D7T + 2×R8i, 12-pulse (+A004) ..............................................
214Frame 1×D8T + 2×R8i (IP22) .............................................................
215Frame 1×D8T + 2×R8i, IP54 (+B055) ...................................................
216Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 1/2 ........
217Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 2/2 ........
218Frame 1×D8T + 2×R8i with brake choppers and resistors (+D150 +D151), 1/2 ...
219Frame 1×D8T + 2×R8i with brake choppers and resistors (+D150 +D151), 2/2 ...
220Frame 1×D8T + 2×R8i with sine output filter (+E206), 1/2 ...........................
221Frame 1×D8T + 2×R8i with sine output filter (+E206), 2/2 ...........................
222Frame 2×D8T + 2×R8i, 12-pulse (+A004) with grounding switch (+F259) .........
223Frame 2×D8T + 3×R8i, 1/2 ................................................................
224Frame 2×D8T + 3×R8i, 2/2 ................................................................
225Frame 2×D8T + 3×R8i with common motor terminal cubicle (+H359), 1/2 ........
226Frame 2×D8T + 3×R8i with common motor terminal cubicle (+H359), 2/2 ........
227Frame 2×D8T + 3×R8i with top entry / top exit (+H351/+H353), 1/2 ................
228Frame 2×D8T + 3×R8i with top entry/top exit, 2/2 .....................................
229Frame 3×D8T + 4×R8i, 1/2 ................................................................
230Frame 3×D8T + 4×R8i, 2/2 ................................................................
231Frame 3×D8T + 4×R8i with common motor terminal cubicle (+H359), 1/2 ........
232Frame 3×D8T + 4×R8i with common motor terminal cubicle (+H359), 2/2 ........
233Frame 3×D8T + 4×R8i with top entry / top exit (+H351/+H353), 1/2 ................
234Frame 3×D8T + 4×R8i with top entry / top exit (+H351/+H353), 2/2 ................
235Frame 4×D8T + 5×R8i (6-pulse) with top entry/exit, UL Listed (+C129), 1/2 ......
236Frame 4×D8T + 5×R8i (6-pulse) with top entry/exit, UL Listed (+C129), 2/2 ......
237Dimensions of empty cubicles (options +C199, +C200, +C201) ........................
237IP22/IP42 .....................................................................................
238IP54 ...........................................................................................
239Location and size of input terminals .............................................................
239400 mm, bottom cable entry ..................................................................
239400 mm, top cable entry .......................................................................
240
600 mm, without main breaker, bottom cable entry (including 12-pulse units with
grounding switch) ...............................................................................
240
600 mm, without main breaker, top cable entry (including 12-pulse units with
grounding switch) ...............................................................................
241600 mm, 12-pulse units without grounding switch, bottom cable entry .................
241600 mm, 12-pulse units without grounding switch, top cable entry .....................
242600 mm, with main breaker, bottom cable entry ...........................................
242600 mm, with main breaker, top cable entry ................................................
2431000 mm (UL/CSA), top cable entry .........................................................
2441000 mm (UL/CSA), bottom cable entry ....................................................
245Location and size of output terminals ...........................................................
245Units without common motor terminal cubicle (no option +H359) .......................
245Inverter module cubicle with two R8i modules, bottom cable exit (no +H353) .....
245Inverter module cubicle with two R8i modules, top cable exit (+H353) .............
246Inverter module cubicle with three R8i modules, bottom cable exit (no +H353) ...
246Inverter module cubicle with three R8i modules, top cable exit (+H353) ...........
247Brake chopper cubicle .....................................................................
12 Table of contents

247Sine filter (+E206) cubicle, 1000 mm, bottom cable exit (no +H353) ...............
248Sine filter (+E206) cubicle, 1000 mm, top cable exit (+H353) ........................
249Units with common motor terminal cubicle (option +H359) ..............................
249Cubicle width 300 mm, bottom cable exit ...............................................
249Cubicle width 300 mm (double-busbar version), bottom cable exit .................
250Cubicle width 300 mm, top cable exit ....................................................
250Cubicle width 300 mm (double-busbar version), top cable exit ......................
251Cubicle width 400 mm, bottom cable exit ...............................................
251Cubicle width 400 mm, top cable exit ....................................................
252Cubicle width 600 mm, bottom cable exit ...............................................
252Cubicle width 600 mm, top cable exit ....................................................
14 The Safe torque off function
253Contents of this chapter ...........................................................................
253Description ..........................................................................................
254Compliance with the European Machinery Directive ......................................
254Wiring ................................................................................................
254Activation switch ................................................................................
254Cable types and lengths .......................................................................
255Grounding of protective shields ..............................................................
255Frame n×R8i inverter unit (internal power supply) ........................................
256Multiple inverter units (internal power supply) ..............................................
257Multiple inverter units (external power supply) .............................................
257Operation principle .................................................................................
258Start-up including acceptance test ..............................................................
258Competence .....................................................................................
258Acceptance test reports .......................................................................
258Acceptance test procedure ...................................................................
259Use ...................................................................................................
260Maintenance ........................................................................................
261Competence .....................................................................................
261Fault tracing .........................................................................................
261Safety data ..........................................................................................
262Abbreviations .......................................................................................
15 Resistor braking
265Contents of this chapter ...........................................................................
265Operating principle .................................................................................
266Factory-installed brake choppers and resistors ...............................................
266Technical data ......................................................................................
266Ratings of chopper/resistor combinations ..................................................
267SAFUR resistor data ...........................................................................
267Terminals and cable lead-through data of factory-installed chopper/resistor cubicles .
267Planning the braking system .....................................................................
267Verifying the load capacity of the braking equipment .....................................
268Custom resistor .............................................................................
268Calculating the maximum braking power for a custom duty cycle ...................
269Selecting and routing the cables of a custom resistor ....................................
269Minimizing electromagnetic interference ................................................
269Maximum cable length .....................................................................
269Placing custom brake resistors ...............................................................
Table of contents 13

269Protecting the brake system against thermal overload ...................................
270Thermal protection of the resistors .......................................................
270Protecting the resistor cable against short-circuits ........................................
270Mechanical installation of custom brake resistors .............................................
270Electrical installation of custom brake resistors ...............................................
270Connection diagram ............................................................................
270Connection procedure .........................................................................
271Brake system start up .............................................................................
14 Table of contents

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:
WARNING!
Electricity warning tells about hazards from electricity which can cause injury or
death, or damage to the equipment.
WARNING!
General warning tells about conditions, other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
1
Safety instructions 15

General safety in installation, start-up and maintenance
These instructions are for all personnel that install and commission 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.
• Keep the drive in its package until you install it. After unpacking, protect the drive from
dust, debris and moisture.
• Use the required personal protection equipment: safety shoes with metal toe cap,
protective gloves, etc.
• Lift the drive with an lifting device. Use the designated lifting points. See the dimension
drawings.
• Secure the drive cabinet to the floor to prevent it from toppling over. The cabinet has a
high center of gravity. When you pull out heavy components or power modules, there
is a risk of overturning. Secure the cabinet also to the wall when necessary.
•Be careful when handling a tall module. The module overturns easily because it is heavy
and has a high center of gravity. Whenever possible, secure the module with chains.
Do not leave an unsupported module unattended especially on a sloping floor.
• Modules running on wheels:
• Do not use the module installation ramp with plinth heights which exceed 50 mm
[1.97 in].
16 Safety instructions

• Secure the module extraction/installation ramp carefully.
• Push the module into the cabinet and pull it from the cabinet 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. Keep your fingers away
from the edges of the front flange of the module.
50 mm max.
• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, and
brake resistors, remain hot for a while after disconnection of the electrical supply.
• Beware of hot air exiting from the air outlets.
• Vacuum clean the area around the drive before the start-up to prevent the drive cooling
fan from drawing the dust inside the drive.
• Make sure that there is sufficient cooling. See the technical data.
• 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 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 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.
• Validate any safety circuits (for example, Safe torque off or emergency stop) in start-up.
See separate instructions for the safety circuits.
• Do not cover the air inlet or outlet when the drive is running.
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.
Safety instructions 17

• When the control location is set to Remote in the control panel, the stop key on the
control panel will not stop the drive.
• Only authorized persons are allowed to repair a malfunctioning drive.
18 Safety instructions

Electrical safety in installation, start-up and maintenance
￭Electrical safety precautions
These electrical safety precautions 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 a potentially fatal electric shock, arc flash or high-energy arc blast exists.
2. Clearly identify the work location.
3. Disconnect all possible voltage sources.
• Open the main switch-disconnector (Q1.1) (or rack out the main breaker, Q1) of
the drive.
• Open the disconnector of the supply transformer. The main switch-disconnector or
breaker of the drive does not remove the voltage from the input busbars of the drive.
•If you have a permanent magnet motor connected to the drive, disconnect the motor
from the drive with a safety switch or by other means.
•Make sure that re-connection 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 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. 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).
• Use a multimeter with an impedance of at least 1 Mohm.
• Make sure that the voltage between the drive input power terminals and the
grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive DC busbars (+ and -) and the
grounding (PE) busbar is close to 0 V.
7. Install temporary grounding as required by the local regulations. Close the grounding
switch or switches (option +F259, Q9) if present.
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.
Safety instructions 19

• If you are not a qualified electrician, do not do electrical installation or maintenance
work.
•Do not install the drive if the electrical power network, motor/generator, or environmental
conditions do not agree with the drive data.
• Do not install a drive with EMC filter (option +E200 or +E202) on an ungrounded power
system or a high resistance-grounded (over 30 ohms) power system.
• We do not recommend that you secure the cabinet by arc welding. If you have to, obey
the separate welding instructions in the drive manuals.
• Do not do insulation or voltage withstand tests on the drive.
Note:
• 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.
•When the input power is on, the drive DC bus is at a dangerous voltage. If brake chopper
and resistor are in use, they are also at a dangerous voltage. (Option +D150)
• 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!
Obey these instructions. If you ignore them, damage to the equipment 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”).
WARNING!
Use a grounding wrist band when you handle printed circuit boards. Do not touch
the boards unnecessarily. The boards contain components sensitive to electrostatic
discharge.
￭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 electrical
planning instructions. Obey the local regulations.
20 Safety instructions