ABB ACS880-07 User manual

—
ABB INDUSTRIAL DRIVES
ACS880-07 drives (45 to 710 kW, 50 to 700 hp)
Hardware manual

ACS880-07 drives (45 to 710 kW, 50
to 700 hp)
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
9. Start-up
3AUA0000105718 Rev G
EN
EFFECTIVE: 2020-11-04

Table of contents
1 Safety instructions
15Contents of this chapter ...........................................................................
15Use of warnings and notes .......................................................................
16General safety in installation, start-up and maintenance ....................................
18Electrical safety in installation, start-up and maintenance ...................................
18Electrical safety precautions ..................................................................
19Additional instructions and notes .............................................................
20Optical components ........................................................................
20Printed circuit boards .......................................................................
20Grounding .......................................................................................
22General safety in operation .......................................................................
22Additional instructions for permanent magnet motor drives .................................
22Safety in installation, start-up, maintenance ................................................
23Safety in operation .............................................................................
2 Introduction to the manual
25Contents of this chapter ...........................................................................
25Target audience ....................................................................................
25Categorization by frame size and option code .................................................
26Quick installation, commissioning and operation flowchart ..................................
26Terms and abbreviations ..........................................................................
28Related manuals ...................................................................................
3 Operation principle and hardware description
31Contents of this chapter ...........................................................................
31Product overview ...................................................................................
32Single-line circuit diagram of the drive ......................................................
33Block diagram of the brake and DC options (+D150, +D151 and +H356) .............
34General information on the cabinet layout ..................................................
35Cabinet layout of frames R6 to R8 ...........................................................
36Cabinet layout of frames R6 to R8 with option +C129 ....................................
37Cabinet layout of frames R6 to R8 with options +C129 and +F289 .....................
39Cabinet layout of frame R9 ...................................................................
41Cabinet layout of frame R9 with options +C129 and +F289 .............................
43Cabinet layout of frames R10 and R11 – bottom entry and exit of cables .............
45Cabinet layout of frames R10 and R11 – top entry and exit of cables (option +C129) .
46Overview of power and control connections ................................................
48Door switches and lights ......................................................................
48Main switch-disconnector (Q1) ...............................................................
48Other devices on the door .....................................................................
49Control panel ....................................................................................
49Control by PC tools .........................................................................
49Descriptions of options ............................................................................
49Degree of protection ...........................................................................
49Definitions ....................................................................................
Table of contents 5

50IP22 (UL Type 1) ............................................................................
50IP42 (UL Type 1 Filtered) (option +B054) ...............................................
50IP54 (UL Type 12) (option +B055) .......................................................
50Marine construction (option +C121) .........................................................
50Cooling air intake through bottom of cabinet (option +C128) ............................
50UL Listed (option +C129) ......................................................................
50Channeled air outlet (option +C130) .........................................................
51CSA Approved (option +C134) ...............................................................
51Plinth height (options +C164 and +C179) ..................................................
51Seismic design (option +C180) ...............................................................
51Empty cubicles on right (options +C196…C198) ..........................................
51Empty cubicles on left (options +C199…C201) ............................................
51Resistor braking (options +D150 and +D151) ..............................................
51du/dtfilter (option +E205) .....................................................................
51Sine filter (option +E206) ......................................................................
52Common mode filter (option +E208) .........................................................
52Molded case circuit breaker (MCCB, option +F289) ......................................
52Cabinet heater with external supply (option +G300) ......................................
52Cabinet lighting (option +G301) ..............................................................
52Terminals for external control voltage (option +G307) ....................................
52Output for motor space heater (option +G313) ............................................
53Ready/Run/Fault lights (options +G327…G329) ..........................................
53Halogen-free wiring and materials (option +G330) ........................................
53V-meter with selector switch (option +G334) ...............................................
53A-meter in one phase (option +G335) .......................................................
53Wire markings ...................................................................................
53Standard wiring .............................................................................
54Additional wire markings ...................................................................
54Bottom cable entry/exit (options +H350 and +H352) ......................................
54Top cable entry/exit (options +H351 and +H353) ..........................................
54Cable conduit entry (option +H358) .........................................................
54Additional terminal block X504 (option +L504) .............................................
55
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513, +L536,
+L537) ...........................................................................................
55+L505, +2L505, +L513, +2L513 ..........................................................
55+L536, +L537 ................................................................................
56Thermal protection with Pt100 relays (options +nL506, +nL514) .......................
56Starter for auxiliary motor fan (options +M6xx) ............................................
56What the option contains ..................................................................
57Description ...................................................................................
58Type designation label ............................................................................
59Type designation key ..............................................................................
59Basic codes .....................................................................................
59Option codes ....................................................................................
4 Mechanical installation
65Contents of this chapter ...........................................................................
65Examining the installation site ...................................................................
66Necessary tools ....................................................................................
66Moving the drive in its package ..................................................................
66Horizontal package .............................................................................
68Vertical package ................................................................................
6 Table of contents

69Unpacking the transport package ...............................................................
70Lifting the cabinet ..................................................................................
70Lifting from the cabinet from the horizontal package ......................................
71Lifting the cabinet with crane .................................................................
71Lifting lugs .......................................................................................
71Certificate of conformity ....................................................................
72Declaration of Conformity ..................................................................
73Moving the cabinet after unpacking .............................................................
74Moving the cabinet with rollers ...............................................................
74Moving the cabinet to its final placement with a slate bar ................................
74Moving the cabinet on its back ...............................................................
75Installing the IP54 roof ............................................................................
75Frames R6 to R8 ...............................................................................
76Frame R9 ........................................................................................
76Frames R10 and R11 ..........................................................................
77Attaching the cabinet to the floor and wall or roof .............................................
77General rules ....................................................................................
78Attaching the cabinet (non-marine units) ...................................................
78Alternative 1 – Clamping ...................................................................
79Alternative 2 – Using the holes inside the cabinet .....................................
80Alternative 3 – Cabinets with plinth options +C164 and +C179 ......................
81Attaching the cabinet (marine units) .........................................................
82Miscellaneous ......................................................................................
82Cable duct in the floor below the cabinet ...................................................
82Arc welding ......................................................................................
82Air inlet through the bottom of cabinet (option +C128) ...................................
83Air outlet duct on the cabinet roof (option +C130) .........................................
84Calculating the required static pressure difference ....................................
5 Guidelines for planning the electrical installation
85Contents of this chapter ...........................................................................
85Limitation of liability ................................................................................
85Selecting the supply disconnecting device .....................................................
85Selecting the main contactor .....................................................................
86Examining the compatibility of the motor and drive ...........................................
86Protecting the motor insulation and bearings ..............................................
86Requirements table ............................................................................
89Availability of du/dtfilter and common mode filter by drive type .....................
89Additional requirements for explosion-safe (EX) motors ..............................
89
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ......................................................................................
89Additional requirements for ABB high-output and IP23 motors ......................
89Additional requirements for non-ABB high-output and IP23 motors .................
90Additional data for calculating the rise time and the peak line-to-line voltage .....
91Additional note for sine filters .............................................................
91Selecting the power cables .......................................................................
91General guidelines .............................................................................
92Typical power cable sizes .....................................................................
92Power cable types ..............................................................................
92Preferred power cable types ..............................................................
93Alternate power cable types ...............................................................
94Not allowed power cable types ...........................................................
Table of contents 7

94Additional guidelines, North America ........................................................
95Metal conduit ................................................................................
95Power cable shield .............................................................................
96Planning the resistor braking system ...........................................................
96Selecting the control cables ......................................................................
96Shielding .........................................................................................
96Signals in separate cables ....................................................................
96Signals that can be run in the same cable ..................................................
96Relay cable ......................................................................................
97Control panel to drive cable ...................................................................
97PC tool cable ....................................................................................
97Routing the cables .................................................................................
97General guidelines – IEC ......................................................................
98General guidelines – North America .........................................................
98
Continuous motor cable shield/conduit or enclosure for equipment on the motor
cable ..............................................................................................
99Separate control cable ducts .................................................................
99
Protecting the drive, input power cable, motor and motor cable in short circuit situations
and against thermal overload ....................................................................
99Protecting the drive and input power cable in short-circuit situations ...................
99Protecting the motor and motor cable in short-circuits ....................................
100Protecting the drive and the power cables against thermal overload ...................
100Protecting the motor against thermal overload .............................................
100Protecting the motor against overload without thermal model or temperature sensors .
100Protecting the drive against ground faults ......................................................
100Residual current device compatibility ........................................................
101Implementing the emergency stop function ....................................................
101Implementing the Safe torque off function .....................................................
101Implementing the Prevention of unexpected start-up function ..............................
101Implementing an ATEX-certified motor thermal protection ...................................
102Implementing the functions provided by the FSO-xx safety functions module ............
102Implementing the power loss ride-through function ...........................................
103Supplying power for the auxiliary circuits .......................................................
103Using power factor compensation capacitors with the drive .................................
103Using a safety switch between the drive and the motor ......................................
104Implementing the control of a contactor between drive and motor .........................
104Implementing a bypass connection .............................................................
104Protecting the contacts of relay outputs ........................................................
105Implementing a motor temperature sensor connection ......................................
106Connecting motor temperature sensor to the drive via an option module .............
6 Electrical installation
109Contents of this chapter ...........................................................................
109Safety ................................................................................................
109Measuring the insulation ..........................................................................
109Measuring the insulation of the drive ........................................................
109Measuring the insulation of the input power cable ........................................
110Measuring the insulation of the motor and motor cable ..................................
110Custom brake resistor assembly .............................................................
111Grounding system compatibility check ..........................................................
111Corner-grounded and midpoint-grounded 525…690 V delta systems .................
8 Table of contents

112Connecting the power cables ....................................................................
112Connection diagram ............................................................................
113Layout of the power cable connection terminals and entries (frames R6 to R8) ......
114
Layout of the power cable connection terminals and entries (frames R6 to R8 with
option +C129 ....................................................................................
115
Layout of the power cable connection terminals and entries (frames R6 to R8 with
options +C129+F277+F289) ..................................................................
116
Layout of the input and motor cable connection terminals (frame R9 with option
+E205) ...........................................................................................
117
Layout of the power cable connection terminals and entries (frame R9 with option
+C129) ...........................................................................................
118Layout of the input and motor cable connection terminals (frames R10 and R11) ...
118
Layout of the input and motor cable connection terminals (frames R10 and R11 with
option +C129) ...................................................................................
118Entry of external resistor and DC cables ....................................................
119Connection procedure (IEC) ..................................................................
120Connection procedure (US) ...................................................................
121Grounding the motor cable shield at the motor end .......................................
121DC connection (option +H356) ...............................................................
121Connecting the control cables ...................................................................
122Control cable connection procedure .........................................................
122Grounding the outer shields of the control cables at the cabinet entry .............
124Routing the control cables inside the cabinet (frames R6 to R8) ....................
125Routing the control cables inside the cabinet (frame R9) .............................
126Routing the control cables inside the cabinet (frames R10 and R11) ...............
126Connecting the control unit cables .......................................................
128Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) .......
128
Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963,
+Q964, +Q978,+Q979) ....................................................................
128Wiring the starter for auxiliary motor fan (options +M6xx) ............................
128Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513 and +2L513) .
129Wiring the Pt100 relays (option +nL506) ................................................
130Wiring the Pt100 relays (option +nL514) ................................................
131
Powering the heating and lighting equipment (options +G300, +G301 and
+G313) .......................................................................................
132Wiring ground fault monitoring for IT ungrounded systems (option +Q954) .......
132Setting the voltage range of the auxiliary control voltage transformer (T21) .......
133Connecting a PC ...................................................................................
133Panel bus (Control of several units from one control panel) .................................
136Installing option modules .........................................................................
136Installing option modules ......................................................................
137Installation of an FSO-xx safety functions module beside the ZCU-12 control unit ...
138Installation of an FSO-xx safety functions module onto ZCU-14 ........................
139Safety functions module FSO-xx beside the ZCU-14 control unit .......................
7 Control units of the drive
141Contents of this chapter ...........................................................................
141General ..............................................................................................
142ZCU-12 layout ......................................................................................
143ZCU-14 layout ......................................................................................
144Default I/O diagram of the drive control unit (ZCU-1x) .......................................
Table of contents 9

146Additional information on the connections .....................................................
146External power supply for the control unit (XPOW) .......................................
146DI6 as a PTC sensor input ....................................................................
146AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input .............................
147DIIL input ........................................................................................
147The XD2D connector ..........................................................................
148Safe torque off (XSTO) ........................................................................
148FSO-xx safety functions module connection (X12) ........................................
149Connector data .....................................................................................
151ZCU-1x ground isolation diagram ............................................................
8 Installation checklist
153Contents of this chapter ...........................................................................
153Checklist .............................................................................................
9 Start-up
155Contents of this chapter ...........................................................................
155Start-up procedure .................................................................................
10 Fault tracing
159Contents of this chapter ...........................................................................
159LEDs .................................................................................................
159Warning and fault messages .....................................................................
11 Maintenance
161Contents of this chapter ...........................................................................
161Maintenance intervals .............................................................................
161Descriptions of symbols .......................................................................
161Recommended annual maintenance actions by the user ................................
162Recommended maintenance intervals after start-up ......................................
163Cabinet ..............................................................................................
163Cleaning the interior of the cabinet ..........................................................
163Cleaning the door air inlets (IP22 and IP42) ...............................................
164Replacing the inlet door filters (IP54) ........................................................
164Cleaning the roof outlet filters (IP54) ........................................................
164Replacing the outlet (roof) filters (IP54) .....................................................
165Cleaning the heatsink .............................................................................
165Fans ..................................................................................................
165Replacing cooling fans ........................................................................
166Replacing the cabinet “door" fans ............................................................
167Replacing the cabinet fans (frames R6 to R9) .............................................
168Replacing the drive module main fans (frames R6 to R8) ................................
169Replacing the auxiliary cooling fan of the drive module (frames R6 to R9) ............
170Replacing the drive module main fans (frame R9) ........................................
171Replacing the drive module main fans (frames R10 and R11) ..........................
172Replacing the circuit board compartment cooling fan (frames R10 and R11) .........
173Replacing the IP54 (UL type 12) roof fan of frames R6 to R8 ...........................
174Replacing the IP54 (UL type 12) roof fan of frame R9 ....................................
175Replacing the IP54 (UL type 12) roof fan of frames R10 and R11 ......................
175Replacing the NSIN sine filter cooling fan ..................................................
176Replacing the drive module (frames R6 to R8) ................................................
10 Table of contents

181Replacing the drive module (frame R9) ........................................................
185Replacing the drive module (frames R10 and R11) ...........................................
192Capacitors ...........................................................................................
192Reforming the capacitors ......................................................................
192Control panel .......................................................................................
192Cleaning the control panel ....................................................................
192Replacing the battery ..........................................................................
193ZCU-12 control unit ................................................................................
193Replacing the memory unit of ZCU-12 ......................................................
194Replacing the ZCU-12 control unit battery ..................................................
194ZCU-14 control unit ................................................................................
194Replacing the memory unit of ZCU-14 ......................................................
195Replacing the ZCU-14 control unit battery ..................................................
196
Replacing safety functions modules (FSO-12, option +Q973 and FSO-21, option
+Q972) ..............................................................................................
12 Technical data
197Contents of this chapter ...........................................................................
197Ratings ..............................................................................................
200Definitions .......................................................................................
201Derating .............................................................................................
201Ambient temperature derating ................................................................
201Altitude derating ................................................................................
202Switching frequency derating .................................................................
202Deratings for special settings in the drive control program ...............................
204High speed mode ...............................................................................
207Fuses (IEC) .........................................................................................
209Fuses (UL) ..........................................................................................
210Dimensions and weights ..........................................................................
210Dimensions and weights of sine filter cubicle (option +E206) ...........................
211Free space requirements .........................................................................
211Losses, cooling data and noise ..................................................................
213Cooling data and noise for drives with sine filter (option +E206) ...........................
214Typical power cable sizes .........................................................................
216Terminal and entry data for the power cables .................................................
216IEC ................................................................................................
216US ................................................................................................
223Terminal data for the control cables .............................................................
224Electrical power network specification ..........................................................
224Motor connection data ............................................................................
225Control unit connection data .....................................................................
225Efficiency ............................................................................................
225Protection classes .................................................................................
225Ambient conditions ................................................................................
226Auxiliary circuit power consumption .............................................................
226Materials .............................................................................................
226Cabinet ...........................................................................................
227Package .........................................................................................
227Disposal .............................................................................................
228Applicable standards ..............................................................................
228Markings .............................................................................................
Table of contents 11

229CE marking .........................................................................................
229Compliance with the European Low Voltage Directive ....................................
229Compliance with the European EMC Directive ............................................
230Compliance with the EN 61800-3:2004 .........................................................
230Definitions .......................................................................................
230Category C2 .....................................................................................
230Category C3 .....................................................................................
231Category C4 .....................................................................................
232UL and CSA checklist .............................................................................
232Tightening torques .................................................................................
233Electrical connections ..........................................................................
233Mechanical connections .......................................................................
233Insulation supports .............................................................................
233Cable lugs .......................................................................................
233Disclaimers .........................................................................................
233Generic disclaimer .............................................................................
234Cybersecurity disclaimer ......................................................................
13 Dimension drawings
236
Frames R6 to R8 (IP22, IP42 [+B054], UL Type 1) – with and without options +C129,
+H350, +H352 ......................................................................................
237
Frames R6 to R8 (IP54 / UL Type 12 [+B055]) – with and without options +C129, +H350,
+H352 ...............................................................................................
238
Frame R9 (IP22 and IP42 [+B054], UL Type 1) – with and without options +C129, +H350,
+H352 ...............................................................................................
239
Frame R9 (IP54 / UL Type 12 [+B055]) – with and without options +C129, +H350,
+H352 ...............................................................................................
240Frame R9 marine (IP22, IP42 [+B054], UL Type 1) – option +C121) ......................
241
Frames R6 to R8 with options +F289, +C129 with and without +H350, +H352 (UL Type
1) .....................................................................................................
242
Frames R6 to R8 with options +F289, +C129, with and without +H350, +H352 (UL Type
12 [+B055]) .........................................................................................
243
Frames R10 and R11 (IP22, IP42 [+B054], UL Type 1) – with and without options +C129,
+H350, +H352 ......................................................................................
244
Frames R10 and R11 (IP54 / UL Type 12) – with and without options +C129, +H350,
+H352 ...............................................................................................
14 The Safe torque off function
245Contents of this chapter ...........................................................................
245Description ..........................................................................................
246Compliance with the European Machinery Directive ......................................
247Wiring ................................................................................................
247Activation switch ................................................................................
247Cable types and lengths .......................................................................
247Grounding of protective shields ..............................................................
248Single ACS880-07 drive, internal power supply ...........................................
248Dual-channel connection ..................................................................
248Single-channel connection ................................................................
249Multiple drives ...................................................................................
249Internal power supply ......................................................................
250External power supply ......................................................................
12 Table of contents

251Operation principle .................................................................................
252Start-up including validation test .................................................................
252Competence .....................................................................................
252Validation test reports ..........................................................................
252Validation test procedure ......................................................................
254Use ...................................................................................................
255Maintenance ........................................................................................
255Competence .....................................................................................
256Fault tracing .........................................................................................
257Safety data ..........................................................................................
258Abbreviations ...................................................................................
259TÜV certificate ..................................................................................
259Declaration of conformity ......................................................................
15 Resistor braking
261Contents of this chapter ...........................................................................
261When is resistor braking necessary? ...........................................................
261Operation principle and hardware description .................................................
262Planning the braking system .....................................................................
262Selecting the brake circuit components .....................................................
262Selecting the default brake system components .......................................
262Selecting a custom brake resistor ........................................................
263Selecting and routing the cables of custom resistors ..................................
264Placing the brake resistor .....................................................................
264Protecting the system against thermal overload ...........................................
265Protecting the brake resistor cable against short-circuits ................................
265Mechanical installation of custom brake resistors .............................................
265Electrical installation of custom brake resistors ...............................................
265Measuring the insulation of the custom brake resistor circuit ............................
265Start-up ..............................................................................................
265Parameter settings .............................................................................
266Technical data ......................................................................................
266Ratings ...........................................................................................
268Degree of protection of SAFUR resistors ...................................................
268Terminals and cable entry data ...............................................................
Further information
Table of contents 13

14

Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install, start
up, operate and do maintenance work 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 who do work on the drive.
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 protective equipment: safety shoes with metal toe cap, safety
glasses, protective gloves and long sleeves, etc. Some parts have sharp edges.
•Lift a heavy drive with a lifting device. Use the designated lifting points. See the dimension
drawings.
•Incorrect lifting can cause danger or damage. Obey the local laws and regulations
applicable to lifting, such as requirements for planning the lift, for capacity and condition
of lifting equipment, and for training of personnel.
•Attach 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. Attach the cabinet also to the wall when necessary.
•Do not stand or walk on the cabinet roof. Make sure that nothing presses against the
roof, side or back plates or door. Do not store anything on the roof while the drive is in
operation.
•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.
•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 debris from drilling, cutting and grinding does not enter the drive during
the installation. Electrically conductive debris inside the drive may cause damage or
malfunction.
•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).
16 Safety instructions
3

•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 drive power cycles is five times in ten minutes. Power cycling the drive
too often can damage the charging circuit of the DC capacitors.
•If you have connected safety circuits to the drive (for example, Safe torque off or
emergency stop), validate them at start-up. See separate instructions for the safety
circuits.
• Beware of hot air exiting from the air outlets.
• 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.
• If the drive is in remote control mode, you cannot stop or start the drive with the control
panel.
• Only authorized persons are allowed to repair a malfunctioning drive.
Safety instructions 17

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 electrical professional, do not do installation or
maintenance work.
Go through these steps before you begin any installation or maintenance work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that re-connection is not possible.
Lock out and tag out.
•Open the main disconnecting device of the drive.
•Open the charging switch if present.
•Open the disconnector of the supply transformer. (The main disconnecting device in
the drive cabinet does not disconnect the voltage from the AC input power busbars
of the drive cabinet.)
•Open the auxiliary voltage switch-disconnector (if present), and all other possible
disconnecting devices that isolate the drive from dangerous voltage sources.
•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.
•Disconnect all dangerous external voltages from the control circuits.
•After you disconnect power from the drive, always wait 5 minutes to let the intermediate
circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
18 Safety instructions
3

5. 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).
•Before and after measuring the installation, verify the operation of the voltage tester
on a known voltage source.
•Make sure that the voltage between the drive input power terminals (L1, L2, L3) and
the grounding (PE) busbar is zero.
Measuring holes of the standard drive are shown below.

L1, L2, L3
•Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W)
and the grounding (PE) busbar is zero.
•Make sure that the voltage between the drive DC terminals (UDC+ and UDC-) and
the grounding (PE) terminal is zero.
6. Install temporary grounding as required by the local regulations.
7. 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 electrical professional, do not do installation or
maintenance work.
•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.
•Make sure that the electrical power network, motor/generator, and environmental
conditions agree with the drive data.
•Do not do insulation or voltage withstand tests on the drive.
Safety instructions 19

•If you have a cardiac pacemaker or other electronic medical device, keep away from the
area near motor, drive, and the drive power cabling when the drive is in operation. There
are electromagnetic fields present which can interfere with the function of such devices.
This can cause a health hazard.
•ABB recommends against attaching the cabinet by arc welding. If you have to, obey the
welding instructions in the drive manuals.
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 at a dangerous voltage. (Option +D150)
(Option +D151).
•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.
Optical components
WARNING!
Obey these instructions. If you ignore them, damage to the equipment can occur.
•Handle the fiber optic cables with care.
•When you unplug the fiber optic 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 in).
Printed circuit boards
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 electrical professional, do not do grounding work.
20 Safety instructions
3