ABB ACS880-07 User manual

—
ABB INDUSTRIAL DRIVES
ACS880-07 drives (560 to 2800 kW)
Hardware manual

ACS880-07 drives (560 to 2800 kW)
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
9. Start-up
3AUA0000143261 Rev G
EN
Original instructions
EFFECTIVE: 2023-12-31

Table of contents
1 Safety instructions
17Contents of this chapter ........................................................................
17Use of warnings and notes .....................................................................
18General safety in installation, start-up and maintenance ................................
21Electrical safety in installation, start-up and maintenance ..............................
21Electrical safety precautions ...............................................................
22Additional instructions and notes .........................................................
23Printed circuit boards ....................................................................
23Grounding ......................................................................................
24General safetyin operation .....................................................................
24Additional instructions for permanent magnet motor drives ..........................
24Safety in installation, start-up, maintenance ...........................................
25Safety in operation ...........................................................................
2 Introduction to the manual
27Contents of this chapter ........................................................................
27Target audience ...................................................................................
27Categorization by frame size and option code ............................................
28Use of component designations ..............................................................
28Quick installation, commissioning and operation flowchart ............................
29Terms and abbreviations .......................................................................
29Related documents ..............................................................................
3 Operation principle and hardware description
31Contents of this chapter ........................................................................
31Operation principle ..............................................................................
32Overview circuit diagram of the drive ....................................................
3312-pulse connection (option +A004) ..................................................
34Cabinet line-up and layout examples .........................................................
34Frame 1×D8T+2×R8i ..........................................................................
36Frame 2×D7T+2×R8i (12-pulse connection, option +A004) ..........................
38Frame 2×D8T+3×R8i ..........................................................................
40Frame 3×D8T+4×R8i (with main breaker, option +F255) .............................
42Auxiliary control cubicle (ACU) layout ....................................................
44Overview of power and control connections (BCU-x2) ...................................
46Overview of power and control connections (UCU-22…24) .............................
48Door devices .......................................................................................
49Main disconnecting device (Q1.1) ..........................................................
49Auxiliary voltage switch [Q21] ..............................................................
49Grounding (earthing) switch [Q9], optional .............................................
49Other devices on the door ..................................................................
50Control panel ...................................................................................
50Control by PC tools ........................................................................
Table of contents 5

51Descriptions of options .........................................................................
51Degree of protection .........................................................................
51Definitions ..................................................................................
51IP22 (UL Type 1) ............................................................................
51IP42 (UL Type 1 Filtered) (option +B054) .............................................
51IP54 (UL Type 12) (option +B055) ......................................................
51Marine construction (option +C121) ......................................................
52Cooling air inlet through bottom of cabinet (option +C128) ........................
52UL Listed (option +C129) ....................................................................
52Channeled air outlet (option +C130) ......................................................
52CSA Approved (option +C134) ..............................................................
52Plinth height (options +C164 and +C179) ................................................
52Seismic design (option +C180) .............................................................
53Empty cubicles on left (options +C199…C201) .........................................
53Resistor braking (options +D150 and +D151) ...........................................
53EMC filter (option +E202) ...................................................................
53Sine filter (option +E206) ....................................................................
53Cabinet heater with external supply (option +G300) ..................................
53Cabinet lighting (option +G301) ...........................................................
53Terminals for external control voltage (option +G307) ...............................
54Output for motor space heater (option +G313) ........................................
54Supply connection by busbars (option +G317) .........................................
54Ready/Run/Fault lights (options +G327…G329) .......................................
54Halogen-free wiring and materials (option +G330) ....................................
54V-meter with selector switch (option +G334) ...........................................
54Wire markings .................................................................................
54Standard wiring ............................................................................
55Additional wire markings ................................................................
55Common mode filter temperature monitoring (option +G453) ....................
55Bottom cable entry/exit (options +H350 and +H352) .................................
56Top cable entry/exit (options +H351 and +H353) ......................................
56Cable conduit entry (option +H358) ......................................................
56Common motor terminal cubicle (option +H359) ......................................
56Common output terminals (option +H366) .............................................
57Connectivity for wired remote monitoring (option +K496) ..........................
57Connectivity for wireless remote monitoring (option +K497) ......................
57Additional terminal block X504 (option +L504) ........................................
57
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513,
+L536, +L537) ..................................................................................
58+L505, +2L505, +L513, +2L513 ..........................................................
58+L536, +L537 ................................................................................
58Thermal protection with Pt100 relays (options +nL506, +nL514) ..................
59Starter for auxiliary motor fan (options +M600…M610) .............................
59What the option contains ................................................................
59Description .................................................................................
60Type designation label ..........................................................................
61Type designation key ............................................................................
61Option codes ...................................................................................
4 Mechanical installation
67Contents of this chapter ........................................................................
68Examining the installation site ................................................................
6 Table of contents

68Necessary tools ...................................................................................
68Examining the delivery ..........................................................................
69Moving and unpacking the drive ..............................................................
69Moving the drive in its packaging .........................................................
69Lifting the crate with a forklift .........................................................
70Lifting the crate with a crane ...........................................................
71Moving the crate with a forklift ........................................................
71Removing the transport package .........................................................
72Moving the unpacked drive cabinet .......................................................
72Lifting the cabinet with a crane ........................................................
72Moving the cabinet on rollers ...........................................................
73Moving the cabinet on its back .........................................................
73Moving the cabinet to its final position ..............................................
74Attaching the cabinet to the floor and wall or roof .......................................
74General rules ...................................................................................
75Attaching the cabinet (non-marine units) ...............................................
75Alternative 1 – Clamping .................................................................
76Alternative 2 – Using the holes inside the cabinet ..................................
76Alternative 3 – Cabinets with plinth options +C164 and +C179 ..................
77Attaching the cabinet (marine units) .....................................................
78Joining cabinet sections together ............................................................
82Miscellaneous .....................................................................................
82Cable ductin thefloor belowthe cabinet ................................................
82Arc welding .....................................................................................
82Air inlet through the bottom of the cabinet (option +C128) .........................
83Air outlet duct on the cabinet roof (option +C130) ....................................
84Calculating the required static pressure difference ...............................
84Lifting lugs and bars .............................................................................
84Certificate of conformity ....................................................................
85Declarations of conformity .................................................................
5 Guidelines for planning the electrical installation
89Contents of this chapter ........................................................................
89Limitation of liability .............................................................................
89North America .................................................................................
90Selecting the supply transformer .............................................................
90Basic guidelines ...............................................................................
90Additional notes ...............................................................................
90A drive with a 12-pulse diode supply unit .............................................
92Selecting the supply disconnecting device .................................................
92Selecting the main contactor or breaker ....................................................
92Examining the compatibility of the motor and drive .....................................
92Protecting the motor insulation and bearings .........................................
93Requirements tables .........................................................................
93Requirements for ABB motors, P
n< 100 kW (134 hp) ..............................
94Requirements for ABB motors, P
n> 100 kW (134 hp) ..............................
95Requirements for non-ABB motors, P
n< 100 kW (134 hp) ........................
96Requirements for non-ABB motors, P
n> 100 kW (134 hp) ........................
96Abbreviations ..............................................................................
96Availability of d u /d t filter and common mode filter by drive type ..............
97Additional requirements for explosion-safe (EX) motors .........................
Table of contents 7

97
Additional requirements for ABB motors of types other than M3_, HX_, AM_
andAX_ ......................................................................................
97Additional requirements for braking applications .................................
97Additional requirements for ABB high-output and IP23 motors ................
97Additional requirements for non-ABB high-output and IP23 motors ..........
98Additional data for calculating the rise time and the peak line-to-line voltage .
99Additional note for sine filters ..........................................................
100Selecting the power cables .....................................................................
100Power cable selection procedure and applicability check ............................
100General guidelines ............................................................................
100Typical power cable sizes ...................................................................
101Power cable types .............................................................................
101Preferred power cable types ............................................................
101Alternate power cable types ............................................................
102Not allowed power cable types .........................................................
102Power cable shield ............................................................................
103Grounding requirements ........................................................................
104Additional grounding requirements – IEC ...............................................
104Additional grounding requirements – UL (NEC) ........................................
104Selecting the control cables ....................................................................
104Shielding ........................................................................................
105Signals in separate cables ...................................................................
105Signals that can be run in the same cable ...............................................
105Relay cable ......................................................................................
105Control panel to drive cable ................................................................
105PC tool cable ...................................................................................
105Routing the cables ...............................................................................
105General guidelines – IEC .....................................................................
106
Continuous motor cable shield/conduit and metal enclosure for equipment on
the motorcable ................................................................................
106Separate control cable ducts ...............................................................
107
Protecting the drive, input power cable, motor and motor cable in short circuit
situations and against thermal overload ....................................................
107Protecting the input cabling and the drive upon a short-circuit ....................
107Protecting the motor and motor cable in short-circuits .............................
107Protecting the drive and the power cables against thermal overload .............
107Protecting the motor against thermal overload .......................................
108
Protecting the motor against overload without thermal model or temperature
sensors ..........................................................................................
108Protecting the drive against ground faults .................................................
108Residual current device compatibility ....................................................
108Implementing the emergency stop function ...............................................
109Implementing theSafe torque offfunction .................................................
109Implementing the Prevention of unexpected start-up function ........................
109Implementing an ATEX-certified motor thermal protection ............................
110Implementing the functions provided by the FSO safety functions module ........
110Implementing the power loss ride-through function .....................................
110Implementing a bypass connection ..........................................................
111Supplying power for the auxiliary circuits ...................................................
111Using power factor compensation capacitors with the drive ..........................
111Using a safety switch between the drive and the motor .................................
112Implementing the control of a contactor between drive and motor ..................
8 Table of contents

112Protecting thecontacts of relayoutputs ....................................................
113Implementing a motor temperature sensor connection .................................
114
Connecting a motor temperature sensor to the drive through an option mod-
ule ................................................................................................
6 Electrical installation
115Contents of this chapter ........................................................................
115Warnings ...........................................................................................
115Measuring theinsulation ........................................................................
115Measuring the insulation resistance of the drive ......................................
116Measuring the insulation resistance of the motor and motor cable ...............
116Measuring the insulation resistance of the input power cable ......................
116Compatibility check - IT (ungrounded) earthing system .................................
116Attaching the device stickers to the cabinet door ........................................
117Checking the settings of transformers T21, T101 and T111 ..............................
117T21 and T101 tap settings (400…500 V units) ..........................................
118T21 and T101 tap settings (690 V units) ..................................................
119T111 tap settings ..............................................................................
120Connecting the control cables .................................................................
120Control cable connection procedure ......................................................
120Grounding the outer shields of the control cables 360° at the cabinet entry .
122Routing the control cables inside the cabinet .......................................
122Connecting control cabling .............................................................
123
Connecting the motor cables (units without common motor terminal cubicle or
sine output filter) .................................................................................
124Motor connection diagram (without option +H366) ..................................
124Motor connection diagram (with option +H366) .......................................
125Procedure .......................................................................................
125Removing an inverter module ...........................................................
125Removing the fan carriage of an inverter module ..................................
128Connecting the motor cables ...........................................................
130Installing the fan carriage of an inverter module ...................................
130Installing an inverter module ............................................................
130
Connecting the motor cables (units with common motor terminal cubicle or sine
output filter) .......................................................................................
130Output busbars ................................................................................
130Connection diagram ..........................................................................
130Procedure .......................................................................................
131Connecting an external brake resistor assembly ..........................................
132Connecting the input power cables ..........................................................
132Connection diagram, 6-pulse units .......................................................
132Connection diagram, 12-pulse units ......................................................
133Layout of the input cable connection terminals and cable entries .................
133Connection procedure .......................................................................
135Use of fasteners in cable lug connections ..................................................
135Connecting a PC ..................................................................................
136Panel bus (control of several units from one control panel) .............................
139Installing option modules .......................................................................
139
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder
interface modules .............................................................................
139Installation of an FSO safety functions module onto BCU ...........................
141Wiring of option modules ...................................................................
Table of contents 9

7 Control units of the drive
143Contents of this chapter ........................................................................
143General ..............................................................................................
144BCU layout .........................................................................................
146Default I/O diagram of the supply control unit (BCU-x2) ................................
149Default I/O diagram of the inverter control unit (BCU) ..................................
153UCU-22…24 layout ...............................................................................
156Default I/O diagram of the supply control unit (UCU-22…24) ..........................
159Default I/O diagram of the inverter control unit (UCU-22…24) ........................
163Additional informationon the connections .................................................
163Power supply for the control unit (XPOW) ...............................................
163DIIL input ........................................................................................
163The XD2D connector ..........................................................................
164Safe torque off (XSTO, XSTO OUT) ........................................................
164FSO safety functions module connection (X12, with BCU only) .....................
164SDHC memory card slot .....................................................................
164MicroSDHC memory card slot ..............................................................
165Connector data ...................................................................................
168BCU ground isolation diagram .............................................................
169UCU-22…24 ground isolation diagram ...................................................
8 Installation checklist
171Contents of this chapter ........................................................................
171Checklist ............................................................................................
9 Start-up
173Contents of this chapter ........................................................................
173Start-up procedure ...............................................................................
176Switching off the drive ..........................................................................
10 Fault tracing
177Contents of this chapter ........................................................................
177Control unit LEDs (BCU-x2) .....................................................................
178Control unit LEDs (UCU-22…24) ...............................................................
178Control panel and panel platform/holder LEDs ............................................
178Warning and fault messages ...................................................................
11 Maintenance
179Contents of this chapter ........................................................................
179Handling fiber optic cables .....................................................................
180Maintenance intervals ...........................................................................
180Description of symbols ......................................................................
181Recommended maintenance intervals after start-up .................................
183Cabinet .............................................................................................
183Cleaning the interior of the cabinet .......................................................
183Cleaning the exterior of the drive .........................................................
184Cleaning the door air inlets (IP22 and IP42) .............................................
185Replacing the inlet door filters (IP54) .....................................................
185Cleaning theroof outlet filters(IP54) .....................................................
185Replacing the roof outlet filters (IP54) ...................................................
10 Table of contents

186Fans .................................................................................................
186Replacing a supply module (D7T) cooling fan ...........................................
187Replacing a supply module (D8T) or inverter module (R8i) cooling fan ...........
188Replacing the circuit board compartment fan ..........................................
190Replacing the cooling fan in the auxiliary control cubicle ............................
190Replacing the cooling fan in the incoming cubicle .....................................
191Replacing the roof fan (IP54/UL type 12) ................................................
192Replacing the common motor terminal cubicle fan ...................................
192Fan attached to the cabinet door ......................................................
192Roof fan (with options +C128 and +H353) ...........................................
193Floor fan (with options +C128 and +H353) ...........................................
193
Replacing the brake chopper and resistor cubicle fans (options +D150 and
+D151) ...........................................................................................
194Supply and inverter modules ...................................................................
194Replacing a frame D7T supply module ...................................................
197Replacing a frame D8T supply module ...................................................
202Removing an inverter module ..............................................................
207Installing an inverter module ...............................................................
209Cleaning the heatsink ........................................................................
209Activating the reduced run of the supply unit ..........................................
209Starting reduced run operation ........................................................
210Resuming normal operation ............................................................
210Activating the reduced run function of the inverter unit .............................
212Returning the module ....................................................................
212Capacitors ......................................................................................
212Reforming thecapacitors ................................................................
213Fuses ................................................................................................
213Checking and replacing the DC fuses of a D7T supply module ......................
214Checking and replacing the DC fuses of a D8T supply module .....................
216Control panel ......................................................................................
217Control units .......................................................................................
217BCU control unit types .......................................................................
217Replacing the memory unit (BCU) .........................................................
217Replacing the BCU control unit battery ..................................................
218UCU control unit types .......................................................................
218Replacing the memory unit (UCU-22…24) ...............................................
219Replacing the UCU control unit battery ..................................................
220Replacing the microSDHC memory card (UCU-22…24) ...............................
221Functional safety components ................................................................
12 Technical data
223Contents of this chapter ........................................................................
223Ratings ..............................................................................................
225Definitions ......................................................................................
225Derating .........................................................................................
225Surrounding air temperature derating ...............................................
225Altitude derating ..........................................................................
226Switching frequency derating ..........................................................
226Output frequency derating ..............................................................
227Frame sizesand powermodule types ........................................................
228Fuses ................................................................................................
228AC fuses .........................................................................................
Table of contents 11

230DC fuses .........................................................................................
231Supply module internal DC fuses ..........................................................
231Fuses on CVAR varistor board ..............................................................
231Brake chopper DC fuses .....................................................................
232Dimensions and weights ........................................................................
232Free space requirements .......................................................................
232Losses, cooling data and noise ................................................................
234Sine output filter data ...........................................................................
235Typical power cable sizes .......................................................................
236Terminal and cable entry data for the power cables ......................................
236Terminal data for the motor cables .......................................................
237Terminal data for the supply and inverter control units .................................
237Terminal data for block X504 ..................................................................
237Electrical power network specification ......................................................
238Motor connection data ..........................................................................
238Efficiency ...........................................................................................
238Energy efficiency data (ecodesign) ...........................................................
238Protection classes ................................................................................
239Ambient conditions ..............................................................................
240Transportation ....................................................................................
240Storage conditions ...............................................................................
241Colors ...............................................................................................
241Materials ............................................................................................
241Drive .............................................................................................
241Packaging of drive ............................................................................
241Packaging of options ........................................................................
241Manuals .........................................................................................
242Disposal ............................................................................................
242Applicable standards ............................................................................
243Markings ............................................................................................
244EMC compliance (IEC/EN 61800-3) ...........................................................
244Definitions ......................................................................................
244Category C2 ....................................................................................
245Category C3 ....................................................................................
245Category C4 ....................................................................................
247UL and CSA checklist .............................................................................
248Tightening torques ...............................................................................
248Electrical connections ........................................................................
248Mechanical connections .....................................................................
248Insulation supports ...........................................................................
248Cable lugs .......................................................................................
249Disclaimers .........................................................................................
249Generic disclaimer ............................................................................
249Cyber security disclaimer ...................................................................
13 Dimensions
251Cabinet line-up dimensions ....................................................................
252Dimension tables ..............................................................................
260Weights .........................................................................................
261Dimension drawing examples ..............................................................
261Frame 2×D7T + 2×R8i, 12-pulse (+A004) ..............................................
262Frame 1×D8T + 2×R8i (IP22) .............................................................
12 Table of contents

263Frame 1×D8T + 2×R8i, IP54 (+B055) ...................................................
264Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 1/2 ....
265Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 2/2 ....
266Frame 1×D8T + 2×R8i with brake choppers and resistors (+D150 +D151), 1/2 .
267Frame 1×D8T + 2×R8i with brake choppers and resistors (+D150 +D151), 2/2 .
268Frame 1×D8T + 2×R8i with sine output filter (+E206), 1/2 ........................
269Frame 1×D8T + 2×R8i with sine output filter (+E206), 2/2 ........................
270Frame 2×D8T + 2×R8i, 12-pulse (+A004) with grounding switch (+F259) .....
271Frame 2×D8T + 3×R8i, 1/2 ...............................................................
272Frame 2×D8T + 3×R8i, 2/2 ...............................................................
273Frame 2×D8T + 3×R8i with common motor terminal cubicle (+H359), 1/2 ....
274Frame 2×D8T + 3×R8i with common motor terminal cubicle (+H359), 2/2 ....
275Frame 2×D8T + 3×R8i with top entry / top exit (+H351/+H353), 1/2 ...........
276Frame 2×D8T + 3×R8i with top entry/top exit, 2/2 .................................
277Frame 3×D8T + 4×R8i, 1/2 ...............................................................
278Frame 3×D8T + 4×R8i, 2/2 ...............................................................
279Frame 3×D8T + 4×R8i with common motor terminal cubicle (+H359), 1/2 ....
280Frame 3×D8T + 4×R8i with common motor terminal cubicle (+H359), 2/2 ...
281Frame 3×D8T + 4×R8i with top entry / top exit (+H351/+H353), 1/2 ...........
282Frame 3×D8T + 4×R8i with top entry / top exit (+H351/+H353), 2/2 ...........
283Frame 4×D8T + 5×R8i (6-pulse) with top entry/exit, UL Listed (+C129), 1/2 ..
284Frame 4×D8T + 5×R8i (6-pulse) with top entry/exit, UL Listed (+C129), 2/2 ..
285Dimensions of empty cubicles (options +C199, +C200, +C201) .....................
285IP22/IP42 ....................................................................................
286IP54 ...........................................................................................
287Location and size of input terminals .........................................................
287400 mm, bottom cable entry ...............................................................
287400 mm, top cable entry ....................................................................
288
600 mm, without main breaker, bottom cable entry (including 12-pulse units
with grounding switch) ......................................................................
288
600 mm, without main breaker, top cable entry (including 12-pulse units with
grounding switch) ............................................................................
289600 mm, 12-pulse units without grounding switch, bottom cable entry .........
289600 mm, 12-pulse units without grounding switch, top cable entry ...............
290600 mm, with main breaker, bottom cable entry ......................................
290600 mm,with main breaker,top cableentry ............................................
2911000 mm (UL/CSA), top cable entry ......................................................
2921000 mm (UL/CSA), bottom cable entry .................................................
292Location and size of output terminals .......................................................
292Units without common motor terminal cubicle ........................................
293Inverter module cubicle with two R8i modules, bottom cable exit .............
294Inverter module cubicle with two R8i modules, top cable exit ...................
295Inverter module cubicle with three R8i modules, bottom cable exit ...........
296Inverter module cubicle with three R8i modules, top cable exit .................
297Brake chopper cubicle ....................................................................
298Sine filter cubicle, 1000 mm, bottom cable exit ....................................
299Sine filter cubicle, 1000 mm, top cable exit ..........................................
300Units with common motor terminal cubicle (+H359) ..................................
300Cubicle width 300 mm, bottom cable exit ...........................................
301Cubicle width300 mm, topcable exit .................................................
302Cubicle width 400 mm, bottom cable exit ...........................................
303Cubicle width 400 mm, top cable exit ................................................
Table of contents 13

304Cubicle width 600 mm, bottom cable exit ...........................................
305Cubicle width 600 mm, top cable exit ................................................
14 The Safe torque off function
307Contents of this chapter ........................................................................
307Description .........................................................................................
308
Compliance with the European Machinery Directive and the UK Supply of Ma-
chinery (Safety) Regulations ................................................................
309Wiring ...............................................................................................
309Activation switch ..............................................................................
309Cable types and lengths .....................................................................
309Grounding of protective shields ...........................................................
310Dual-channel connection with internal power supply (BCU-x2) .....................
311Dual-channel connection with internal power supply (UCU-22…24) ...............
312Single-channel connection of activation switch (BCU-x2) ............................
312Single-channel connection of activation switch (UCU-22…24) .....................
313Multiple drives .................................................................................
313Internal power supply (example, drives with ZCU-xx and BCU-x2) ..............
314Internal power supply (example, drives with UCU-22…24) .......................
315External power supply (example, drives with ZCU-xx and BCU-x2) .............
316External power supply (example, drives with UCU-22…24) ......................
317Operation principle ..............................................................................
318Start-up including validation test .............................................................
318Competence ....................................................................................
318Validation test reports .......................................................................
318Validation test procedure ...................................................................
320Use ...................................................................................................
322Maintenance .......................................................................................
322Competence ....................................................................................
323Perfect proof test procedure ...............................................................
323Simplified proof test procedure ...........................................................
324Fault tracing .......................................................................................
325Safety data .........................................................................................
327Terms and abbreviations ....................................................................
328TÜV certificate .................................................................................
329Declarations of conformity .................................................................
15 Resistor braking
333Contents of this chapter ........................................................................
333Operation principle ..............................................................................
334Factory-installed brake choppers and resistors ...........................................
335Technical data .....................................................................................
335Ratings of chopper/resistor combinations .............................................
335Definitions ......................................................................................
336SAFUR resistor data ..........................................................................
336
Terminals and cable lead-through data of factory-installed chopper/resistor
cubicles ..........................................................................................
337Planning the braking system ...................................................................
337Verifying the load capacity of the braking equipment ................................
337Custom resistor ............................................................................
337Calculating the maximum braking power for a custom duty cycle .............
14 Table of contents

338Selecting and routing the cables of a custom resistor ...............................
338Minimizing electromagnetic interference ............................................
339Maximum cable length ...................................................................
339Selecting the installation location for the brake resistors ...........................
339Protecting the brake system against thermal overload ..............................
339Thermal protection of the resistors ...................................................
339Protecting the resistor cable against short-circuits ..................................
339Mechanical installation of custom brake resistors ........................................
340Electrical installation of custom brake resistors ..........................................
340Connection diagram ..........................................................................
340Connection procedure .......................................................................
341Brake system start-up ...........................................................................
342Maintenance .......................................................................................
342Replacing the brake resistor cabinet fan ................................................
Further information
Table of contents 15

16

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 17

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.
• Obey the local laws and regulations applicable to lifting, such as requirements for
planning the lifting, 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 falling 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.
• 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.
18 Safety instructions
3

max.
• Do not move the module on its wheels for long distances. It can cause damage to
the wheels. Also, there is a risk of the module falling over.
• 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 dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not go into the
drive during installation. Electrically conductive debris inside the drive can 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).
Safety instructions 19

• 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/UL 61800-5-1, subclause 6.5.3, for example, "THIS
MACHINE STARTS AUTOMATICALLY".
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors.
• 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.
20 Safety instructions
3