DEMAG ACS880-DEMAG 04 User manual

010420 enUS 211 323 44 719 IS 922
Hardware Manual
ACS880-DEMAG 04 Drives
(200 to 710 kW, 300 to 700 hp)

220217 Rev G
Hersteller / Manufacturer: DE: www.demagcranes.de/dedrive-
pro-880-produktdokumentation
EN: www.demagcranes.com/en/
dedrive-pro-880-frequency-
inverter-product-documentation
Demag Cranes & Components GmbH
Postfach 67 · 58286 Wetter (Deutschland)
Telefon: [phone]
Telefax: [phone]
www.demagcranes.com
Liste ergänzender Handbücher / List of related manuals
Frequenzumrichter-Handbücher und Anleitungen
Drive manuals and guides
ACS 880
Baugröße
size
mehr-
sprachig
multilingual
Code
(English)
Code
(Deutsch)
Kurzanleitung Montage
Brief assembly instructions R1-R3 211 317 44
R4-R5 211 318 44
R6-R9 211 319 44
R10-R11 211 320 44
Kurzanleitung Inbetriebnahme
Brief instructions putting into operation R1-R11 211 321 44
Bedienungsanleitung Hardware
Operation instructions hardware R1-R9 211 322 44 EN 211 322 44 DE
R10-R11 211 323 44 EN 211 323 44 DE
Bedienungsanleitung Software (Firmware-Handbuch)
Operation instructions software (firmware manual) R1-R11 211 324 44 EN 211 324 44 DE
Datenträger Dedrive Pro ACS880
Data medium Dedrive Pro ACS880 R1-R11 213 752 44
Technische Daten Frequenzumrichter-Zubehör
Technical data for frequency inverter accessories R1-R11 203 815 44
Frequenzumrichter-Hardware-Handbücher und Anleitungen
Drive hardware manuals and guides
Code (Englisch) Code (Deutsch)
ACS880-01 +P940/+P944 drives for cabinet installation supplement3AUA0000145446
ACS880-01 assembly drawings
for cable entry boxes of IP21 frames R5 to R9 3AUA0000119627
ACS880-01 +H358 gland plate installation guide 3AD50000034735
ACS-AP-x assistant control panels user’s manual 3AUA0000085685 3AXD50000028267
Vibration dampers for ACS880-01 drives
(frames R4 and R5, option +C131) installation guide 3AXD50000010497
Vibration dampers for ACS880-01 drives
(frames R6 to R9, option +C131) installation guide 3AXD50000013389
ACS880-01/04 +C132 marine type-approved drives supplement 3AXD50000010521
ACS880-01 +N7502 drives for SynRM motors (0.8 to 200 kW)
supplement 3AXD50000029482
Flange mounting kit installation supplement 3AXD50000019100
Flange mounting kit quick installation guide for ACS880-01 frames
R1 to R3 3AXD50000026158
Flange mounting kit quick installation guide for ACS880-01 frames
R4 to R5 3AXD50000026159
Flange mounting kit quick installation guide for ACS880-01 and
ACS580-01 frames R6 to R9 3AXD50000019099
Common mode filter kit for ACS880-01 drives
(frame R6, option +E208) installation guide 3AXD50000015178
Common mode filter kit for ACS880-01 drives
(frame R7, option +E208) installation guide 3AXD50000015179
Common mode filter kit for ACS880-01 drives
(frame R8, option +E208) installation guide 3AXD50000015180
Common mode filter kit for ACS880-01 drives
(frame R9, option +E208) installation guide 3AXD50000015201
ACS880-01 drives and ACS880-04 drive modules
common DC systems application guide 3AUA0000127818

Hardware manual
ACS880-04 drive modules
(200 to 710 kW, 300 to 700 hp)
1. Safety instructions
6. Installation instructions
Table of contents
10. Start-up

5
Table of contents
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . 18
Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . 21
Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2. Introduction to the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Quick installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . 25
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3. Operation principle and hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Standard drive module configuration with option +E208 . . . . . . . . . . . . . . . . . . . . . . 31
Drive module for flat mounting (option +C173) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drive module with full power cabling panels (option +H381) . . . . . . . . . . . . . . . . . . . 34
Drive module without full-size output cable connection terminals (option +0H371) and
IP20 shrouds (option +0B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drive module configuration with power cable connection terminals on the right-hand side
of the drive module (option +H391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
External control connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
External control unit connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4. Guidelines for planning the cabinet installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation positions of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Basic requirements for the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Planning the layout of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Layout example, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6
Layout example, door open (standard drive module configuration) . . . . . . . . . . . . . 47
Layout example, door open (option +H391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Layout example, door open (option +0B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Arranging the grounding inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Selecting the busbar material and preparation of the joints . . . . . . . . . . . . . . . . . . . . . . 50
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Planning the fastening of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Planning the cabinet placement on a cable channel . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Planning the electromagnetic compatibility (EMC) of the cabinet . . . . . . . . . . . . . . . . . 51
Planning the cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Bookshelf mounting (standard drive module configuration) . . . . . . . . . . . . . . . . . . . 55
Bookshelf mounting (option +0B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Bookshelf mounting (option +H381) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Flat mounting (option +C173) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Flat mounting (option +C173+0B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Required free space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Free space at the top of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Free space around the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Other installation positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Drive module on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Planning the placement of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Planning the use of cubicle heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Air inlet and outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5. Guidelines for planning the electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Selecting the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Additional requirements for explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . 67
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and
AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Additional requirements for the braking applications . . . . . . . . . . . . . . . . . . . . . . 67
Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . 67
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . 67
Additional data for calculating the rise time and the peak line-to-line voltage . . . 68
Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Additional note for common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Power cable types for restricted use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

7
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Continuous motor cable shield or enclosure for equipment in the motor cable . . . . . 74
Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . 75
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . 75
Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . 76
Protecting the drive and the input power and motor cables against thermal overload . .
77
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connecting drive modules to a common DC system . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . 78
Implementing safety functions provided by the FSO-xx safety functions module (options
+Q972 and +Q973) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Implementing the Power loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . 79
Implementing a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . 79
Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . 81
Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . 82
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Drive I/O, I/O extension and encoder interface modules . . . . . . . . . . . . . . . . . . . . . . 83
Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6. Installation instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Package drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installing the motor cable at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Brake resistor and resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

8
Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . 93
Installation alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Standard drive module configuration (bookshelf mounting) . . . . . . . . . . . . . . . . . . . 94
Drive module configuration for flat mounting (option +C173) . . . . . . . . . . . . . . . . . . 94
Optional input power cable connection terminals and ground busbar assembly (+H370)
94
Drive module with full cabling panels (option +H381) . . . . . . . . . . . . . . . . . . . . . . . . 95
Drive module without full-size output cable connection terminals (option +0H371) and
IP20 shrouds (option +0B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Drive module configuration with power cable connection terminals on the right-hand side
of the drive module (option +H391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Drive module without pedestal (option +0H354) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Attaching the drive module to a mounting plate or wall . . . . . . . . . . . . . . . . . . . . . . . 96
Attaching the drive module to a mounting plate or wall (option +H391) . . . . . . . . . . 96
Alternatives for grounding the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Installing the bottom grille for IP20 degree of protection . . . . . . . . . . . . . . . . . . . . . . 98
Installing the EMC filter (option +E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Removing the control panel holder from the external control unit . . . . . . . . . . . . . . . . 101
Fastening the control cable clamp plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Connecting the external control unit to the drive module . . . . . . . . . . . . . . . . . . . . . . . 103
Routing the control unit cables into the drive module . . . . . . . . . . . . . . . . . . . . . . . 103
Connections to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Connections to the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Mounting the external control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Mounting the external control unit to wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Mounting the external control unit vertically on a DIN rail . . . . . . . . . . . . . . . . . . . . 106
Mounting the control unit horizontally on a DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . 106
Connecting the control cables to the terminals of the control unit . . . . . . . . . . . . . . . . 107
Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
External power supply for the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . 110
DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Installing the control panel holder back onto the external control unit . . . . . . . . . . 112
Connecting the control cables to the internal control unit (option +P905) . . . . . . . . 113
Connecting the control cables to the internal control unit (options +P905 and +0B051)
114
Connecting a control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Controlling several drives from one control panel through panel bus . . . . . . . . . . . . . 116
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Installing the FSO safety functions module (options +Q972 and +Q973) . . . . . . . . 117
Case 1: FSO safety functions module on Slot 2 . . . . . . . . . . . . . . . . . . . . . . . . . 118
Case 2: FSO safety functions module above the control unit . . . . . . . . . . . . . . . 119
Installing I/O extension, fieldbus adapter and pulse encoder interface modules . . 120
Wiring the optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

9
7. Installation example of the standard drive module configuration
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Overall flowchart of the installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Installing the drive module into a cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Connecting the power cables and installing the shrouds . . . . . . . . . . . . . . . . . . . . . . . 123
Installing the roof and door (Rittal parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Installing the roof and door (ABB air filters and roof) . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Removing the protective covering from the drive module air outlet . . . . . . . . . . . . . 127
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Input power cable lead-through from top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Attaching the drive module to a mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8. Installation example with full cabling panels (option +H381)
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Overall flowchart of the installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Installing the mechanical accessories into the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 131
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Installing the drive module into the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Assembly drawing of installing the drive module to the cabinet (frame R10) . . . 138
Assembly drawing of installing the drive module to the cabinet (frame R11) . . . 139
Assembly drawing of installing the roof and door . . . . . . . . . . . . . . . . . . . . . . . . 140
Removing the protective covering from the drive module air outlet . . . . . . . . . . . . . 141
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Installations with input and motor cables of size 4 × 240 mm2 per phase . . . . . . . . 141
Installing the rubber grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Modular design of Rittal TS8 cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11. Fault tracing
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
LEDs with options +J410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

10
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
12. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . 153
Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . 154
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Cleaning the interior of the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Replacing the circuit board compartment cooling fan . . . . . . . . . . . . . . . . . . . . . . . 156
Replacing the main cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Replacing the standard drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Replacing the drive module with option +H381 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Replacing the control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
13. Ordering information
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
ACS-AP-W control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Output (du/dt) filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Cabinet ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Air inlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Air outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
EMC filter ARFI-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
FSO accessories kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Retrofit accessory kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
14. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Marine type-approved drives (option +C132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
When is derating needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . . . 178
Ex motor, sine filter, low noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

11
Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Units with optional cabling panels (+H381) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Units without full-size output cable connection terminals (+0H371) and with a common
mode filter (+E208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
DC connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Control unit connection data (ZCU-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Control panel type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . 192
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Compliance with the European RoHS Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Compliance with EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
EAC (Eurasian Conformity) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
15. Dimension drawings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
R10 – Standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
R10 with options +E208+H370+J414+P905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
R10 with options +0B051+C173+E208+H356+0H354+0H371 . . . . . . . . . . . . . . . . . . . 200
R10 with options +0B051+E208+H356+0H371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
R10 with options +E208+H356+H381+J414+P905 . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
R10 – Cabling panels (+H381) installed into a Rittal TS 8 cabinet . . . . . . . . . . . . . . . . 203
Frame R10 with options +E208+H370+H391+0J400 . . . . . . . . . . . . . . . . . . . . . . . . . . 204
R11 – Standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
R11 with options +E208+H370+J414+P905 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
R11 with options +0B051+E208+H356+0H371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
R11 with options +E208+H356+H381+J414+P905 . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
R11 with options +0B051+C173+E208+H356+0H354+0H371 . . . . . . . . . . . . . . . . . . . 209
Frame R11 – Cabling panels (+H381) installed into a Rittal TS 8 cabinet . . . . . . . . . . 210
Bottom plate for option +H381 in Rittal TS 8 400 mm wide cabinet installation . . . . . . 211

12
Frame R11 with options +E208+H370+H391+0J400 . . . . . . . . . . . . . . . . . . . . . . . . . 212
Air baffles for the standard drive module and option +C173 . . . . . . . . . . . . . . . . . . . . 213
Air baffles for option +H381 in Rittal TS 8 400 mm wide cabinet installation . . . . . . . . 214
External control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
16. Example circuit diagram
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
17. Safe torque off function
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 220
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
18. Resistor braking
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Selecting the default brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Selecting a custom resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Selecting and routing the external brake resistor cables . . . . . . . . . . . . . . . . . . . . 232
Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . 234
Mechanical installation of external brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

13
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
You can find the technical data of the brake resistors in the manual „Technical data
Drives Accessories“. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
SAFUR resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Terminals and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
19. du/dt and sine filters
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . 238
Sine filters (on request only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
When is a sine filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Description, installation and technical data of the sine filters . . . . . . . . . . . . . . . . . . 239
20. Step-by-step drawings for an installation example of standard drive configuration
with option +E208 in Rittal TS 8 600 mm wide cabinet
21. Step-by-step drawings for installing full cabling panels (option +H381) in a Rittal
TS 8 400 mm wide cabinet
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
22. Step-by-step drawings for a flat installation example in Rittal TS 8 600 mm wide
cabinet
23. Step-by-step drawings for option +H391 installation example in Rittal TS 8 600
mm wide cabinet

14

Safety instructions 15
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install and
operate the drive and do maintenance on the drive. If you ignore the safety instructions,
injury, death or damage can occur.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death, or damage to the
equipment. They also tell you how to prevent the danger. Notes draw attention to a
particular condition or fact, or give information on a subject.
The manual uses these warning symbols:
Electricity warning tells about hazards from electricity which can cause injury
or death, or damage to the equipment.
General warning tells about conditions, other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
Electrostatic sensitive devices warning tells you about the risk of
electrostatic discharge which can cause damage to the equipment.

16 Safety instructions
General safety in installation, start-up and maintenance
These instructions are for all personnel that install the drive module and do maintenance
work on it.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
•Use protective gloves when working on the drive module.
•Handle the drive module carefully:
•Use safety shoes with a metal toe cap to prevent foot injury.
•Lift the drive module only by the lifting lugs.
•Make sure that the module does not topple over when you move it on the floor:
Open the support legs by pressing each leg a little down (1, 2) and turning it aside.
Whenever possible secure the module also with chains.
•Do not tilt the drive module (A). It is heavy and its center of gravity is high. The
module overturns from a sideways tilt of 5 degrees. Do not leave the module
unattended on a sloping floor.
•Do not use the module installation ramp with plinth heights which exceed the
maximum height marked on the ramp. (The maximum plinth height is 50 mm
[1.97 in] when the telescopic ramp is fully retracted and 150 mm [5.91 in] when
the ramp is fully extended.)
•Attach the module installation ramp carefully.
1
2
3
3AUA0000086323
A

Safety instructions 17
•To prevent the drive module from falling, attach its top lifting lugs with chains to the
cabinet frame before you push the module into the cabinet and pull it from the
cabinet. Work carefully preferably with help from another person as shown below.
Keep a constant pressure with one foot on the base of the module to prevent the
module from falling on its back
•Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,
remain hot for a while after disconnection of the electrical supply.
•Make sure that debris from borings and grindings 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.
•Before you connect voltage to the drive, make sure that the cabinet doors are closed.
Keep the doors closed during the operation. Obey the panel builder’s instructions.
•Before you adjust the drive operation limits, make sure that the motor and all driven
equipment can operate throughout the set operation limits.
•Before you activate the automatic fault reset or automatic restart functions of the drive
control program, make sure that no dangerous situations can occur. These functions
reset the drive automatically and continue operation after a fault or supply break. If
these functions are activated, the installation must be clearly marked as defined in
IEC/EN 61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS
AUTOMATICALLY".
•The maximum number of drive power-ups is five in ten minutes. Too frequent power-
ups can damage the charging circuit of the DC capacitors.
•Make sure that any safety circuits (for example, emergency stop and Safe torque off)
are validated in start-up. See chapter Start-up for reference of the validation
instructions.
Note:
•If you select an external source for start command and it is on, the drive will start
immediately after fault reset unless you configure the drive for pulse start. See the
firmware manual.
•When the control location is not set to Local, the stop key on the control panel will not
stop the drive.
3AUA0000088632

18 Safety instructions
Electrical safety in installation, start-up and maintenance
Precautions before electrical work
These warnings are for all personnel that do work on the drive, motor cable or motor.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur. If you are not a qualified electrician, do not
do installation or maintenance work. Go through these steps before you begin any
installation or maintenance work.
1. Clearly identify the work location.
2. Disconnect all possible voltage sources.
•Open the main disconnector of the drive.
•Open the disconnector of the supply transformer as the main disconnector of the
drive does not remove the voltage from the input busbars of the drive.
•Make sure that reconnection is not possible. Lock the disconnectors to open
position and attach a warning notice to them.
•Disconnect any external power sources from the control circuits before you do
work on the control cables.
•After you disconnect the drive, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you continue.
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.
•Use a multimeter with an impedance of at least 1 Mohm.
•Make sure that the voltage between the drive module input power terminals
(L1/U1, L2/V1, L3/W1) and the grounding (PE) busbar is close to 0 V.
•Make sure that the voltage between the drive module UDC+ and UDC- terminals
and the grounding (PE) busbar is close to 0 V.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation 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 electrician, do not do installation or maintenance work.
•Do not install a drive with EMC filter option +E200 or +E202 on an ungrounded power
system or a high resistance-grounded (over 30 ohms) power system.
•Do not connect the drive to a voltage higher than what is on the type designation label.
If you do, the brake chopper starts to operate which causes the overheating of the
brake resistor (if present). Overvoltage can also cause the motor to rush to its
maximum speed.
•We do not recommend that you secure the cabinet by arc welding.
•Do not do insulation or voltage withstand tests on the drive or drive modules.
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.
•The DC bus and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a
dangerous voltage.
•External wiring can supply dangerous voltages to the terminals of relay outputs
(XRO1, XRO2 and XRO3).
•The Safe torque off function does not remove the voltage from the main and auxiliary
circuits. The function is not effective against deliberate sabotage or misuse.
WARNING! Use a grounding wrist band when you handle the printed circuit
boards. Do not touch the boards unnecessarily. The boards contain components
sensitive to electrostatic discharge.
WARNING! Obey these instructions. If you ignore them, equipment malfunction
and damage to the fiber optic cables can occur.
•Handle the fiber optic cables with care.
•When you unplug the cables, always hold the connector, not the cable itself.
•Do not touch the ends of the fibers with bare hands as the ends are extremely
sensitive to dirt.
•Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is
35 mm (1.4 in).

20 Safety instructions
Grounding
These instructions are for all personnel who are responsible for the grounding of the drive.
WARNING! Obey these instructions. If you ignore them, injury or death, or
equipment malfunction can occur, and electromagnetic interference can increase.
•If you are not a qualified electrician, do not do grounding work.
•Always ground the drive, the motor and adjoining equipment. This is necessary for the
personnel safety. Proper grounding also reduces electromagnetic emission and
interference.
•Make sure that the conductivity of the grounding conductors is sufficient. See section
Selecting the power cables on page 69. Obey the local regulations.
•Connect the power cable shields to protective earth (PE) of the drive to make sure of
personnel safety.
•Make a 360° grounding of the power and control cable shields at the cable entries to
suppress electromagnetic disturbances.
•In a multiple-drive installation, connect each drive separately to the protective earth
(PE) busbar of the switch board or the transformer.
Note:
•You can use power cable shields as grounding conductors only when their conductivity
is sufficient.
•As the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you
must use a fixed protective earth connection. See standard EN 61800-5-1, 4.3.5.5.2.