ABB ACS880-37 User manual

—
ABB INDUSTRIAL DRIVES
ACS880-37 drives (160 to 3200 kW)
Hardware manual

ACS880-37 drives (160 to 3200 kW)
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
9. Start-up
3AXD50000020437 Rev C
EN
Original instructions
EFFECTIVE: 2021-01-18

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 ..................................................................
20Additional instructions and notes .............................................................
20Optical components ........................................................................
21Printed circuit boards .......................................................................
21Grounding .......................................................................................
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 .................................................
26Use of component designations .................................................................
26Quick installation, commissioning and operation flowchart ..................................
27Terms and abbreviations ..........................................................................
28Related manuals ...................................................................................
3 Operation principle and hardware description
29Contents of this chapter ...........................................................................
29Supply unit ..........................................................................................
30AC voltage and current waveforms ..........................................................
30Charging .........................................................................................
30Inverter unit .........................................................................................
31Overview circuit diagram of the drive ...........................................................
32Cabinet line-up and layout examples ...........................................................
32Frame 1×R8i+1×R8i ...........................................................................
34Frame 2×R8i+2×R8i ...........................................................................
36Frame 3×R8i+3×R8i (with main breaker, option +F255) ..................................
38Auxiliary control cubicle (ACU) layout .......................................................
40Overview of power and control connections ...................................................
41Door switches and lights ..........................................................................
42Main disconnecting device (Q1.1) ...........................................................
42Auxiliary voltage switch [Q21] ................................................................
42Grounding (earthing) switch [Q9], optional .................................................
42Other devices on the door .....................................................................
43Control panel ....................................................................................
43Control by PC tools .........................................................................
Table of contents 5

44Descriptions of options ............................................................................
44Degree of protection ...........................................................................
44Definitions ....................................................................................
44IP22 (UL Type 1) ............................................................................
44IP42 (UL Type 1 Filtered) (option +B054) ...............................................
44IP54 (UL Type 12) (option +B055) .......................................................
44Marine construction (option +C121) .........................................................
45Cooling air intake through bottom of cabinet (option +C128) ............................
45UL Listed (option +C129) ......................................................................
45Channeled air outlet (option +C130) .........................................................
45CSA Approved (option +C134) ...............................................................
45Plinth height (options +C164 and +C179) ..................................................
45Seismic design (option +C180) ...............................................................
45Empty cubicles on left (options +C199…C201) ............................................
46EMC filter (option +E202) .....................................................................
46du/dtfilter ........................................................................................
46Sine filter (option +E206) ......................................................................
46Cabinet heater with external supply (option +G300) ......................................
46Cabinet lighting (option +G301) ..............................................................
46Terminals for external control voltage (option +G307) ....................................
47Output for motor space heater (option +G313) ............................................
47Supply connection by busbars (option +G317) ............................................
47Ready/Run/Fault lights (options +G327…G329) ..........................................
47Halogen-free wiring and materials (option +G330) ........................................
47V-meter with selector switch (option +G334) ...............................................
47A-meter in one phase (option +G335) .......................................................
47Wire markings ...................................................................................
47Standard wiring .............................................................................
48Additional wire markings ...................................................................
48Voltage measurement with BAMU auxiliary measurement unit (option +G442) ......
48Common mode filter temperature monitoring (option +G453) ...........................
49Bottom cable entry/exit (options +H350 and +H352) ......................................
49Top cable entry/exit (options +H351 and +H353) ..........................................
49Cable conduit entry (option +H358) .........................................................
49Common motor terminal cubicle (option +H359) ..........................................
49Common output terminals (option +H366) ..................................................
50Additional terminal block X504 (option +L504) .............................................
50
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513, +L536,
+L537) ...........................................................................................
50+L505, +2L505, +L513, +2L513 ..........................................................
50+L536, +L537 ................................................................................
51Thermal protection with Pt100 relays (options +nL506, +nL514) .......................
51Starter for auxiliary motor fan (options +M6xx) ............................................
51What the option contains ..................................................................
52Description ...................................................................................
53Type designation label ............................................................................
53Type designation key ..............................................................................
54Option codes ....................................................................................
4 Mechanical installation
59Contents of this chapter ...........................................................................
59Examining the installation site ...................................................................
6 Table of contents

60Necessary tools ....................................................................................
60Examining 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 ............................................................
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 ............................................................
67Attaching the cabinet to the floor and wall or roof .............................................
67General rules ....................................................................................
68Attaching the cabinet (non-marine units) ...................................................
68Alternative 1 – Clamping ...................................................................
69Alternative 2 – Using the holes inside the cabinet .....................................
69Alternative 3 – Cabinets with plinth options +C164 and +C179 ......................
70Attaching the cabinet (marine units) .........................................................
71Joining cabinet sections together ................................................................
73Miscellaneous ......................................................................................
73Cable duct in the floor below the cabinet ...................................................
73Arc welding ......................................................................................
73Air inlet through the bottom of cabinet (option +C128) ...................................
74Air outlet duct on the cabinet roof (option +C130) .........................................
75Calculating the required static pressure difference ....................................
76Lifting lugs and bars ...............................................................................
76Certificate of conformity .......................................................................
76Declaration of Conformity .....................................................................
5 Guidelines for planning the electrical installation
79Contents of this chapter ...........................................................................
79Limitation of liability ................................................................................
79Selecting the supply disconnecting device .....................................................
79Selecting the main contactor or breaker ........................................................
80Examining the compatibility of the motor and drive ...........................................
80Protecting the motor insulation and bearings ..............................................
80Requirements table ............................................................................
83Availability of du/dtfilter and common mode filter by drive type .....................
83Additional requirements for explosion-safe (EX) motors ..............................
83
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ......................................................................................
83Additional requirements for braking applications .......................................
83Additional requirements for the regenerative and low harmonics drives ...........
83Additional requirements for ABB high-output and IP23 motors ......................
83Additional requirements for non-ABB high-output and IP23 motors .................
84Additional data for calculating the rise time and the peak line-to-line voltage .....
85Additional note for sine filters .............................................................
85Selecting the power cables .......................................................................
85General guidelines .............................................................................
86Typical power cable sizes .....................................................................
Table of contents 7

86Power cable types ..............................................................................
86Preferred power cable types ..............................................................
87Alternate power cable types ...............................................................
88Not allowed power cable types ...........................................................
88Power cable shield .............................................................................
89Selecting the control cables ......................................................................
89Shielding .........................................................................................
89Signals in separate cables ....................................................................
89Signals that can be run in the same cable ..................................................
89Relay cable ......................................................................................
89Control panel to drive cable ...................................................................
90PC tool cable ....................................................................................
90Routing the cables .................................................................................
90General guidelines – IEC ......................................................................
91
Continuous motor cable shield/conduit or enclosure for equipment on the motor
cable ..............................................................................................
91Separate control cable ducts .................................................................
91
Protecting the drive, input power cable, motor and motor cable in short circuit situations
and against thermal overload ....................................................................
91Protecting the input cabling and the drive upon a short-circuit ..........................
91Protecting the motor and motor cable in short-circuits ....................................
91Protecting the drive and the power cables against thermal overload ...................
92Protecting the motor against thermal overload .............................................
92Protecting the motor against overload without thermal model or temperature sensors .
92Protecting the drive against ground faults ......................................................
92Residual current device compatibility ........................................................
93Implementing the emergency stop function ....................................................
93Implementing the Safe torque off function .....................................................
93Implementing the Prevention of unexpected start-up function ..............................
93Implementing an ATEX-certified motor thermal protection ...................................
94Implementing the functions provided by the FSO-xx safety functions module ............
94Implementing the power loss ride-through function ...........................................
95Implementing a bypass connection .............................................................
95Supplying power for the auxiliary circuits .......................................................
95Using power factor compensation capacitors with the drive .................................
96Using a safety switch between the drive and the motor ......................................
96Implementing the control of a contactor between drive and motor .........................
96Protecting the contacts of relay outputs ........................................................
97Implementing a motor temperature sensor connection ......................................
98Connecting motor temperature sensor to the drive via an option module .............
6 Electrical installation
99Contents of this chapter ...........................................................................
99Warnings ............................................................................................
99Measuring the insulation ..........................................................................
99Measuring the insulation of the drive ........................................................
99Measuring the insulation of the motor and motor cable ..................................
100Compatibility check - IT (ungrounded) earthing system ......................................
100Attaching the device stickers to the cabinet door .............................................
100Checking the settings of transformers T21, T101 and T111 .................................
101T21 and T101 tap settings (400…500 V units) .............................................
101T21 and T101 tap settings (690 V units) ....................................................
8 Table of contents

102T111 tap settings ...............................................................................
103Connecting the control cables ...................................................................
103Control cable connection procedure .........................................................
103Grounding the outer shields of the control cables at the cabinet entry .............
105Routing the control cables inside the cabinet ...........................................
105Connecting control cabling ................................................................
106Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) .......
107
Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963,
+Q964, +Q978,+Q979) ....................................................................
107Wiring the starter for auxiliary motor fan (options +M6xx) ............................
107Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513 and +2L513) .
108Wiring the Pt100 relays (option +nL506) ................................................
109Wiring the Pt100 relays (option +nL514) ................................................
110
Powering the heating and lighting equipment (options +G300, +G301 and
+G313) .......................................................................................
110Wiring ground fault monitoring for IT ungrounded systems (option +Q954) .......
111
Connecting the motor cables (units without common motor terminal cubicle or sine output
filter) ..................................................................................................
111Motor connection diagram (without option +H366) ........................................
112Motor connection diagram (with option +H366) ............................................
113Procedure .......................................................................................
113Removing the inverter module(s) .........................................................
116Removing the fan carriage of an inverter module ......................................
118Connecting the motor cables ..............................................................
121Re-installing the fan carriage of an inverter module ...................................
121Re-inserting the inverter modules into the cubicle .....................................
122
Connecting the motor cables (units with common motor terminal cubicle or sine output
filter) ..................................................................................................
122Output busbars .................................................................................
122Connection diagram ............................................................................
122Procedure .......................................................................................
123Connecting an external brake resistor assembly ..............................................
124Connecting the input power cables ..............................................................
124Connection diagram ............................................................................
124Layout of the input cable connection terminals and cable entries .......................
124Connection procedure .........................................................................
127Connecting a PC ...................................................................................
127Panel bus (Control of several units from one control panel) .................................
130Installing option modules .........................................................................
130
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface
modules ..........................................................................................
130Installation of an FSO-xx safety functions module onto BCU ............................
132Wiring of option modules ......................................................................
7 Control units of the drive
133Contents of this chapter ...........................................................................
133General ..............................................................................................
134BCU-x2 layout ......................................................................................
136Default I/O diagram of the supply control unit .................................................
138Default I/O diagram of the inverter control unit (A41) .........................................
139Additional information on the connections .....................................................
139External power supply for the control unit (XPOW) .......................................
Table of contents 9

139DI6 as a PTC sensor input ....................................................................
140AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input .............................
140DIIL input ........................................................................................
141The XD2D connector ..........................................................................
141Safe torque off (XSTO, XSTO OUT) .........................................................
141FSO-xx safety functions module connection (X12) ........................................
141SDHC memory card slot .......................................................................
142Connector data .....................................................................................
144BCU-x2 ground isolation diagram ............................................................
8 Installation checklist
145Contents of this chapter ...........................................................................
145Checklist .............................................................................................
9 Start-up
147Contents of this chapter ...........................................................................
147Start-up procedure .................................................................................
149Switching off the drive .............................................................................
10 Fault tracing
151Contents of this chapter ...........................................................................
151Control unit LEDs ..................................................................................
151Control panel and panel platform/holder LEDs ................................................
152Warning and fault messages .....................................................................
11 Maintenance
153Contents of this chapter ...........................................................................
153Maintenance intervals .............................................................................
156Cabinet ..............................................................................................
156Cleaning the interior of the cabinet ..........................................................
156Cleaning the door air inlets (IP22 and IP42) ...............................................
157Replacing the inlet door filters (IP54) ........................................................
157Cleaning the roof outlet filters (IP54) ........................................................
157Replacing the outlet (roof) filters (IP54) .....................................................
158Power connections and quick connectors ......................................................
158Retightening the power connections ........................................................
159Fans ..................................................................................................
160Replacing R8i module cooling fan (speed-controlled version) ...........................
161Replacing R8i module cooling fan (direct-on-line version) ...............................
163Replacing the fan of the LCL filter (BLCL-1x-x) ............................................
164Replacing the fan of the LCL filter (BLCL-2x-x) ............................................
165Replacing the circuit board compartment fan ..............................................
166Replacing the cooling fan in the auxiliary control cubicle .................................
167Replacing the cooling fan in the incoming cubicle .........................................
167Replacing a roof fan (IP54/UL type 12) .....................................................
168Replacing the brake chopper and resistor cubicle fans (options +D150 and +D151) .
169Supply and inverter modules .....................................................................
169Replacing a supply or inverter module ......................................................
169Cleaning the heatsink ..........................................................................
169Activating the reduced run of the inverter unit .............................................
171Returning the module ......................................................................
10 Table of contents

172LCL filter .............................................................................................
172Replacing the LCL filter ........................................................................
176Capacitors ...........................................................................................
176Reforming the capacitors ......................................................................
177Fuses ................................................................................................
177Replacing the AC and DC fuses in cabinet .................................................
178Control panel .......................................................................................
178Cleaning the control panel ....................................................................
178Replacing the battery ..........................................................................
180Control units ........................................................................................
180BCU control unit types .........................................................................
180Replacing the memory unit ...................................................................
180Replacing the BCU control unit battery .....................................................
181Functional safety components ...................................................................
12 Technical data
183Contents of this chapter ...........................................................................
183Ratings ..............................................................................................
184Definitions .......................................................................................
185Derating ..........................................................................................
185Ambient temperature derating ............................................................
185Altitude derating .............................................................................
186Switching frequency derating .............................................................
186Output frequency derating .................................................................
187Derating for output voltage boosting .....................................................
188Frame sizes and power module types ..........................................................
189Fuses ................................................................................................
189AC fuses .........................................................................................
190DC fuses .........................................................................................
191Fuses on CVAR varistor board ...............................................................
191Brake chopper DC fuses ......................................................................
191Dimensions and weights ..........................................................................
191Free space requirements .........................................................................
192Cooling data, noise ................................................................................
193Sine output filter data ..............................................................................
194Input cable sizes ...................................................................................
196Output cable sizes .................................................................................
197Terminal and lead-through data for the power cables ........................................
197Terminal data for the supply and inverter control units .......................................
197Terminal data for block X504 .....................................................................
197Electrical power network specification ..........................................................
198Motor connection data ............................................................................
199Efficiency ............................................................................................
199Optical components ...............................................................................
199Protection classes .................................................................................
200Ambient conditions ................................................................................
200Materials .............................................................................................
200Cabinet ...........................................................................................
201Package .........................................................................................
201Disposal ..........................................................................................
201Applicable standards ..............................................................................
202Markings .............................................................................................
Table of contents 11

203EMC compliance (IEC/EN 61800-3) ............................................................
203Definitions .......................................................................................
203Category C2 .....................................................................................
204Category C3 .....................................................................................
205Category C4 .....................................................................................
205Compliance with the European Machinery Directive .........................................
208UL and CSA checklist .............................................................................
209Tightening torques .................................................................................
209Electrical connections ..........................................................................
209Mechanical connections .......................................................................
209Insulation supports .............................................................................
209Cable lugs .......................................................................................
209Disclaimers .........................................................................................
209Generic disclaimer .............................................................................
210Cybersecurity disclaimer ......................................................................
13 Dimensions
211Cabinet line-up dimensions .......................................................................
212Dimension tables ...............................................................................
216Weights ..........................................................................................
217Dimension drawing examples ................................................................
217Frame 1×R8i+1×R8i ........................................................................
218Frame 1×R8i+1×R8i, top cable entry/exit (+H351+H353) ............................
219Frame 1×R8i+1×R8i with brake choppers and resistors (+D150+D151) ...........
220Frame 1×R8i+1×R8i with sine output filter (+E206) ...................................
221Frame 2×R8i+2×R8i (eg. ACS880-37-1110A-3), IP22 ................................
222Frame 2×R8i+2×R8i (eg. ACS880-37-1210A-3), IP54 ................................
223
Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal
cubicle (+H359), 1/2 ........................................................................
224
Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal
cubicle (+H359), 2/2 ........................................................................
225
Frame 2×R8i+2×R8i with main breaker (+F255) and top entry/top exit
(+H351+H353), 1/2 .........................................................................
226
Frame 2×R8i+2×R8i with main breaker (+F255) and top entry/top exit
(+H351+H353), 2/2 .........................................................................
227Frame 3×R8i+3×R8i, 1/2 ..................................................................
228Frame 3×R8i+3×R8i, 2/2 ..................................................................
229Frame 3×R8i+3×R8i with common motor terminal cubicle (+H359), 1/2 ...........
230Frame 3×R8i+3×R8i with common motor terminal cubicle (+H359), 2/2 ...........
231Dimensions of empty cubicles (options +C199, +C200, +C201) ....................
233Location and size of input terminals .............................................................
233Frame 1×R8i+1×R8i, bottom cable entry ...................................................
233Frame 1×R8i+1×R8i, top cable entry (+H351) .............................................
234
Frame 2×R8i+2×R8i with main switch/disconnector (400 mm), bottom cable entry
(+H353) ..........................................................................................
234Frame 2×R8i+2×R8i with main switch/disconnector (600 mm), bottom cable entry ...
235Units with main breaker (600 mm, +F255), bottom cable entry .........................
235Units with main breaker (600 mm, +F255), top cable entry (+H351) ...................
236Units with main breaker (1000 mm), top cable entry ......................................
237Units with main breaker (1000 mm), bottom cable entry (+H350) ......................
12 Table of contents

237Location and size of output terminals ...........................................................
237Units without common motor terminal cubicle .............................................
237Frame 1×R8i+1×R8i (without sine output filter) ........................................
238Inverter module cubicle with two R8i modules, bottom cable exit ...................
239Inverter module cubicle with two R8i modules, top cable exit ........................
240Inverter module cubicle with three R8i modules, bottom cable exit .................
241Inverter module cubicle with three R8i modules, top cable exit ......................
242Brake chopper cubicle .....................................................................
243Sine filter cubicle, 1000 mm, bottom cable exit .........................................
244Sine filter cubicle, 1000 mm, top cable exit .............................................
245Units with common motor terminal cubicle (+H359) ......................................
245Cubicle width 300 mm, bottom cable exit ...............................................
246Cubicle width 300 mm, top cable exit ....................................................
247Cubicle width 400 mm, bottom cable exit ...............................................
248Cubicle width 400 mm, top cable exit ....................................................
249Cubicle width 600 mm, bottom cable exit ...............................................
250Cubicle width 600 mm, top cable exit ....................................................
14 The Safe torque off function
251Contents of this chapter ...........................................................................
251Description ..........................................................................................
252Compliance with the European Machinery Directive ......................................
253Wiring ................................................................................................
253Activation switch ................................................................................
253Cable types and lengths .......................................................................
253Grounding of protective shields ..............................................................
254Dual-channel connection with internal power supply .....................................
255Single-channel connection of activation switch ............................................
256Multiple drives ...................................................................................
256Internal power supply ......................................................................
257External power supply ......................................................................
258Operation principle .................................................................................
259Start-up including validation test .................................................................
259Competence .....................................................................................
259Validation test reports ..........................................................................
259Validation test procedure ......................................................................
261Use ...................................................................................................
263Maintenance ........................................................................................
263Competence .....................................................................................
264Fault tracing .........................................................................................
265Safety data ..........................................................................................
266Abbreviations ...................................................................................
266TÜV certificate ..................................................................................
267Declaration of conformity ......................................................................
15 Resistor braking
269Contents of this chapter ...........................................................................
269Operation principle .................................................................................
270Factory-installed brake choppers and resistors ...............................................
270Technical data ......................................................................................
270Definitions .......................................................................................
Table of contents 13

270SAFUR resistor data ...........................................................................
270Terminals and cable lead-through data of factory-installed chopper/resistor cubicles .
271Planning the braking system .....................................................................
271Verifying the load capacity of the braking equipment .....................................
271Custom resistor .............................................................................
271Calculating the maximum braking power for a custom duty cycle ...................
272Selecting and routing the cables of a custom resistor ....................................
272Minimizing electromagnetic interference ................................................
272Maximum cable length .....................................................................
273Placing the brake resistor .....................................................................
273Protecting the brake system against thermal overload ...................................
273Thermal protection of the resistors .......................................................
273Protecting the resistor cable against short-circuits ........................................
273Mechanical installation of custom brake resistors .............................................
274Electrical installation of custom brake resistors ...............................................
274Connection diagram ............................................................................
274Connection procedure .........................................................................
275Brake system start-up .............................................................................
276Maintenance ........................................................................................
276Replacing the brake resistor cabinet fan ....................................................
Further information
14 Table of contents

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.
•The lifting bars attached to large drive cabinets are heavy. Be careful when removing or
reinstalling the bars. Whenever possible, use a lifting device attached to the designated
lifting points.
•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.
•Do not use the module extraction/installation ramp with plinth heights which exceeds the
maximum allowed height.
•Secure the module extraction/installation ramp carefully.
16 Safety instructions
3

•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.
max.
•Do not roll the module on its wheels for a longer distance than what is required for inserting
or extracting the module. To move the module to or from the vicinity of the cabinet, lay
the module on its side on a pallet or equivalent, and use a forklift or pallet truck.
•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.
•Wear protective gloves and long sleeves! Some parts have sharp edges.
•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.
Safety instructions 17

•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 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.
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.
18 Safety instructions
3

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.)
•Close the grounding switch or switches ([Q9], option +F259) if present. Do not use
excessive force as the switch has electromagnetic interlocking.
•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.
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.
•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. In cabinet-built drives, measure between the
drive DC busbars (+ and -) and the grounding (PE) busbar.
6. If the drive is not equipped with a grounding switch, 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.
Safety instructions 19

￭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.
•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).
20 Safety instructions
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