ABB ACS880-17 Hardware Manual

—

ABB INDUSTRIAL DRIVES

ACS880-17 dri

ves

(45…400 kW, 60…450 hp)

Hardware manual

—

ACS880-17 drives (45…400 kW, 60…450 hp)

Hardware manual

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation

10. Start-up

3AXD50000035158 Rev D

EFFECTIVE: 2019-01-28

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 . . . . . . . . . . . . . . . . . . . . . . . 19

Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Additional instruction for DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . 26

Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Quick installation, commissioning and operation flowchart . . . . . . . . . . . . . . . . . . . . . . . 30

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Single-line diagram of R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Single-line diagram of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cabinet layout of R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cabinet layout of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Connection overview of R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Connection overview of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

External control cable connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Connection terminals of R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Connection terminals of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Door switches and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Main disconnecting device (Q1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Other devices on the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Descriptions of cabinet options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

IP22 (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

IP42 (option +B054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

IP54 (option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Channeled air inlet through bottom (option +C128) . . . . . . . . . . . . . . . . . . . . . . . . . 50

Channeled air outlet (option +C130) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Marine construction (option +C121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

UL listed (option +C129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Plinth height (options +C164 and +C179) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Seismic design (option +C180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Empty cubicles (options +C196, +C197, +C198, +C199, +C200, +C201) . . . . . . . . 52

EMC filters (option + E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

du/dt filter (option +E205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Sine filter (option +E206) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Common mode filter (option +E208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Cabinet heater with external supply (option +G300) . . . . . . . . . . . . . . . . . . . . . . . . . 52

Cabinet lighting (option +G301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Terminals for external interruptible control voltage (option +G307) . . . . . . . . . . . . . 53

Output for motor space heater (option +G313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Ready/Run/Fault lights (options +G327…G329) . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Halogen-free materials and wiring (option G330) . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

V-meter with selector switch (option +G334) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

A-meter in one phase (option +G335) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Additional wire markings (options +G340 and +G342) . . . . . . . . . . . . . . . . . . . . . . . 54

Standard wire markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Bottom cable entry/exit (options +H350 and +H352) . . . . . . . . . . . . . . . . . . . . . . . . 54

Top cable entry/exit (options +H351 and +H353) . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Cable conduit entry (option +H358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Additional terminal block X504 (option +L504) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Thermal protection with PTC relays (options +L505, +2L505. +L513, +2L513) . . . . 55

+L505, +2L505, +L513, +2L513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

+L536, +L537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

More information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Pt100 relays (options +2L506, +3L506, +5L506, +8L506, +L514) . . . . . . . . . . . . . . 56

Starter for auxiliary motor fan (options +M600…+M605) . . . . . . . . . . . . . . . . . . . . . 57

What the option contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Moving and unpacking the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Moving the drive in its packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Moving the crate with a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Removing the transport package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Moving the unpacked drive cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Lifting the cabinet with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Moving the cabinet on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Moving the cabinet on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Final placement of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Installing the IP54 roof (option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Attaching the cabinet to the floor and wall or roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Attaching methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Alternative 1 – Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Alternative 2 – Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 73

Attaching the cabinet to the floor and wall or roof (marine units) . . . . . . . . . . . . . . . . . . 74

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Air inlet through the bottom (option +C128) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Air outlet duct on the cabinet roof (option +C130) . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Calculating the required static pressure difference . . . . . . . . . . . . . . . . . . . . . . . . 76

Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

5. Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Additional requirements for explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . . 82

Additional requirements for ABB motors of types other than M2_, M3_, M4_,

HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Additional requirements for the regenerative and low harmonic drives . . . . . . . . . 83

Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . 83

Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . 83

Additional data for calculating the rise time and the peak line-to-line voltage . . . . 85

Additional note for sine filters (option +E206) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Typical cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . 93

Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . 93

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . 93

R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 93

Protecting the drive and the power cables against thermal overload . . . . . . . . . . . . 94

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Implementing a ground fault detection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . 95

Implementing the Prevention of unexpected start-up function . . . . . . . . . . . . . . . . . . . . 95

Implementing the functions provided by the FSO-xx safety functions module (option

+Q972 or +Q973) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Supplying power for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . 97

Implementing a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . 97

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . 99

Connection of motor temperature sensor to the drive via an option module . . . . . . . 99

Connection of motor temperature sensor to the drive via a relay . . . . . . . . . . . . . . 100

6. Electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Checking the compatibility with IT (ungrounded), corner-grounded delta, midpoint-

grounded delta and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

EMC filter (options +E200 or +E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Corner-grounded and midpoint-grounded 690 V delta systems . . . . . . . . . . . . . . . 103

Attaching the device stickers to the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Checking the settings of auxiliary voltage transformers . . . . . . . . . . . . . . . . . . . . . . . 103

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Grounding the outer shields of the control cables at the cabinet entry . . . . . . . . 105

Routing the control cables inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Connecting to the drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Connecting an auxiliary voltage supply (UPS, option +G307) . . . . . . . . . . . . . . 113

Connecting emergency stop push buttons (options +Q951, +Q952, +Q963,

+Q964, +Q978, +Q979) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Wiring the starter for auxiliary motor fan (options +M600…+M605) . . . . . . . . . . 113

Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513, +2L513) . . 114

Wiring the Pt100 relays (option +nL506) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Wiring the Pt100 relays (option +nL514) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Powering the heating and lighting equipment (options +G300, +G301 and

+G313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Wiring ground fault monitoring for IT ungrounded systems (option +Q954) . . . . 118

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Connection diagram of frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Connection diagram of frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Layout of power cable connection terminals and cable entries . . . . . . . . . . . . . . . . 121

Frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Layout of power cable connection terminals (option +C129) . . . . . . . . . . . . . . . . 123

Connection procedure (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Connection procedure (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . 128

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Mechanical installation of I/O extension, fieldbus adapter and pulse encoder

interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Installation of safety functions modules (frame R8) . . . . . . . . . . . . . . . . . . . . . . . . . 131

Installation of safety functions modules (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . 132

Case 1: FSO-xx safety functions module on Slot 2 . . . . . . . . . . . . . . . . . . . . . . . 132

Case 2: FSO-xx safety functions module next to the control unit . . . . . . . . . . . . 134

7. Control unit of frame R8

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Default I/O connection diagram of frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 138

AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . . . 139

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

FSO-xx safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . 141

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

8. Control unit of frame R11

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Default I/O connection diagram of frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 148

AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . . . 149

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

FSO-xx safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . 151

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

9. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

10. Start-up

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Checks/Settings with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Powering up the auxiliary circuit of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Setting up the line-side converter parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Setting up the motor-side converter parameters, and performing the first start . 159 Activating the Run enable signal of the line-side converter (with options +Q951,

+Q952 and +Q978) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

11. Fault tracing

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

12. Maintenance

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . 164

Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . 164

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Cleaning the door air inlets (IP22 and IP42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Cleaning the door air inlets (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Cleaning the outlet (roof) filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Replacing the outlet (roof) filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Retightening the power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Replacing the cabinet “door fan” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Replacing the internal cabinet cooling fans (frame R8) . . . . . . . . . . . . . . . . . . . . . 169

Replacing the drive module main fan (frame R8) . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Replacing the drive module main fans (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . 172

Replacing the LCL filter module fan (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Replacing the auxiliary cooling fan of the drive module (frame R8) . . . . . . . . . . . . 175

Replacing the auxiliary cooling fans of the drive module (frame R11) . . . . . . . . . . 176

Frame R8: Replacing the IP54 (UL Type 12) roof fan . . . . . . . . . . . . . . . . . . . . . . . 178

Frame R11 with options +B055 and +C128: Replacing the roof fan . . . . . . . . . . . . 179

Frame R11 with option +B055: Replacing the roof fan . . . . . . . . . . . . . . . . . . . . . . 180

Replacing the sine filter cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Replacing the drive module (frame R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Replacing the drive and LCL filter modules (frame R11) . . . . . . . . . . . . . . . . . . . . . . . 190

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Replacing the drive module (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Replacing the LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Replacing fuses (frame R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Replacing fuses (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Replacing the control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Replacing the memory unit of the motor-side converter control unit (frame R8) . . . 207

Replacing the memory unit of the motor-side converter control unit (frame R11) . . 208

Replacing the memory unit of the line-side converter control unit (frame R11) . . . . 209

13. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Marine type-approved drives (option +C132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

UL (NEC) ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . 215

Ex motor, sine filter, low noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Dimensions and weights of sine filter cabinet (option +E206) . . . . . . . . . . . . . . . . . 220

Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Cooling data, noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Sine output filter data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Terminal and exit data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Terminal data for the drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Control unit connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Auxiliary circuit power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . 229

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 229

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Compliance with EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

The KC (Korea Certification) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

EAC (Eurasian Conformity) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

EIP (Electronic Information Products) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

14. Dimensions

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

R8: IP22 (UL Type 1), option +B054 (IP42 [UL Type 1 Filtered]) . . . . . . . . . . . . . . . . 238

R8 (IP54, UL Type 12, option +B055): option +C129 . . . . . . . . . . . . . . . . . . . . . . . . . 239

R8 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +D150,

+D151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

R8 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option+E206 . . . 241

R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054) . . . . . . . . . . . . . 242

R11: option+B055 (IP54 [UL Type 12]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +C129,

+H350, +H352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

R11 option +B055 (IP54 [UL Type 12]): option +C128 . . . . . . . . . . . . . . . . . . . . . . . . 245

R11 option +B055 (IP54 [UL Type 12]): option +C129 . . . . . . . . . . . . . . . . . . . . . . . . 246

R11 option +B055 (IP54 [UL Type 12]): options +C129, +H350, +H352 . . . . . . . . . . . 247

R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +D150 . . 248 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +D150,

+D151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +E206) . 250

Location and size of power cable connection terminals . . . . . . . . . . . . . . . . . . . . . . . 251

R8 input and motor cable terminal dimensions – bottom entry and exit . . . . . . . . . 251

R8 input and motor cable terminal dimensions – top entry and exit . . . . . . . . . . . . 252

R8 input and motor cable terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

R11 input and motor cable terminal dimensions – bottom entry and exit . . . . . . . . 254

R11 input and motor cable terminal dimensions – top entry and exit . . . . . . . . . . . 255

R11 input cable terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

R11 motor cable terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Terminals for connecting external resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Sine filter (+E206) cubicle, 400 mm: motor cable terminals . . . . . . . . . . . . . . . . . . . 257

Sine filter (+E206) cubicle, 600 mm: motor cable terminals . . . . . . . . . . . . . . . . . . . 257

Sine filter (+E206) cubicle, 1000 mm: motor cable terminals . . . . . . . . . . . . . . . . . . 258

15. The Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 260

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Further information

Safety instructions

Safety instructions 15

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 and do maintenance work on it.

WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

• Secure the cabinet to the floor to prevent it from toppling over when you pull out drive

and LCL filter modules. The modules are heavy and have a high center of gravity.

• Wear protective gloves and long sleeves. Some parts have sharp edges.

• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,

remain hot for a while after disconnection of the electrical supply.

• Beware of hot air exiting from the air outlets.

• Keep the drive in its package or protect it otherwise from dust and metal shavings from

drilling and grinding until you install it. Protect also the installed drive against dust and metal shavings. Electrically conductive debris inside the drive can cause damage or malfunction.

• Vacuum clean the area below the drive before the start-up to prevent the drive cooling

fan from drawing the dust inside the drive.

• Do not cover the air inlet and outlet when the drive is running.

• Make sure that there is sufficient cooling. See section Examining the installation site

(page 63).

• Keep the cabinet doors closed when the drive is powered. With the doors open, a risk

of a potentially fatal electric shock, arc flash or high-energy arc blast exists. If you cannot avoid working on a powered drive, obey the local laws and regulations on live working (including – but not limited to – electric shock and arc protection).

• Before you connect voltage to the drive, make sure that the cabinet doors are closed.

Keep the doors closed during operation.

• 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

Safety instructions 17

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 at start-up. See chapter The Safe torque off function (page 259). For other safety functions, see their separate instructions.

• Handle the drive and LCL filter modules carefully:

• Use safety shoes with a metal toe cap to avoid foot injury.

• Lift the module with a lifting device only. Use the designated lifting points.

• Frame R11:

• Do not tilt the module. It is heavy and its center of gravity is high.

• Make sure that the module does not topple over when you move it on the floor: Do not leave the module unattended on a sloping floor. Extend the support legs: Press each leg a little down and turn it aside. Whenever possible secure the module also with chains.

• 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.)

• Secure the module installation ramp carefully.

18 Safety instructions

• 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. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.

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.

• When the control location is not set to Local, the stop key on the control panel will not

stop the drive.

• Only authorized persons are allowed to repair a malfunctioning drive.

Safety instructions 19

Electrical safety in installation, start-up and maintenance

 Electrical safety precautions

These warnings are for all personnel who do work on the drive, motor cable or motor.

WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Go through these steps

before you begin any installation or maintenance work.

1. Keep the cabinet doors closed when the drive is powered. With the doors open, a risk of electric shock and/or arcing exists.

2. Clearly identify the work location.

3. Disconnect all possible voltage sources.

• Open the main disconnecting device (Q1) of the drive. Open the disconnector of

the supply transformer as the main disconnecting device of the drive does not remove the voltage from the input busbars or V-meter (option +G334) 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.

4. Protect any other energized parts in the work location against contact.

5. Take special precautions when close to bare conductors.

20 Safety instructions

L1, L2, L3

Frame R8

L1, L2, L3

Frame R11

6. Measure that the installation is de-energized.

WARNING! If the measurement requires removal or disassembly of shrouding or other cabinet structures, obey the local laws and regulations applicable to live working (including – but not limited to – electric shock and arc protection).

• Use a multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive input power terminals (L1, L2, L3)

and the grounding (PE) busbar is close to 0 V. The measuring holes in the shroud of the standard drive are shown below.

Safety instructions 21

AC busbars

• Frame R11: Make sure that the voltage of the drive AC busbars between the drive

module and the LCL filter and the grounding (PE) busbar are close to 0 V. The measuring holes in the shroud of the standard drive are shown below.

22 Safety instructions

Frame R8

DC+

DC-

DC- and DC+

Frame R11

DC+

DC-

• Make sure that the voltage between the DC busbars is close to 0 V. You can

measure the voltage through the holes in the shroud.

Safety instructions 23

• For frame R8, you can measure the voltage at the drive module input (a) and

output (b) terminals through the holes in the shroud.

7. Install temporary grounding as required by the local regulations. Connect the AC and DC busbars to PE with a temporary grounding tool.

8. Ask the person in control of the electrical installation work for a permit to work.

 Additional instructions and notes

WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

• If you are not a qualified electrical professional, do not do electrical installation or

maintenance work.

• Do not install a drive with an EMC filter (option +E202) on an IT (ungrounded) power

system or a high resistance-grounded (over 30 ohms) power system without disconnecting the filter and/or the varistor screws.

• Do not connect the drive to a voltage higher than what is specified on the type

designation label.

• We do not recommend that you secure the cabinet by arc welding. If you have to, obey

the instructions on page 76.

• Do not do insulation or voltage withstand tests on the drive or its 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 is at a dangerous voltage.

• External wiring can supply dangerous voltages to the relay outputs of the control units

of the drive.

24 Safety instructions

• 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 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”).

 Additional instruction for DC connection

WARNING! Do not connect the drive DC link to a common DC system. The drive will get damaged.

 Grounding

These instructions are for all personnel who are responsible for the grounding of the drive.

WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase.

• If you are not a qualified electrical professional, do not do grounding work.

• 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 (page 86). 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.

Safety instructions 25

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 (PE) connection. See standard EN 61800-5-1,

4.3.5.5.2.

26 Safety instructions

Additional instructions for permanent magnet motor drives

 Safety in installation, start-up and maintenance

These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid.

WARNING! Obey these instructions. If you ignore them, injury or death and damage to the equipment can occur.

• Do not do work on the drive when the permanent magnet motor is rotating. A rotating

permanent magnet motor energizes the drive including its input power terminals.

Before installation, start-up and maintenance work on the drive:

• Stop the motor.

• Disconnect the motor from the drive with a safety switch or by other means.

• If you cannot disconnect the motor, make sure that the motor cannot rotate during

work. Make sure that no other system, like hydraulic crawling drives, can rotate the motor directly or through any mechanical connection like felt, nip, rope, etc.

• 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 output terminals (U2, V2, W2) and

the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive input power terminals (L1, L2, L3)

and the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the plus and minus busbars of the drive DC

link and the grounding (PE) busbar is close to 0 V.

• Install temporary grounding to the drive output terminals (U2, V2, W2). Connect the

output terminals together as well as to the PE.

• Make sure that the operator cannot run the motor over the rated speed. Motor

overspeed causes overvoltage which can damage the capacitors in the intermediate circuit of the drive.

Introduction to the manual 27

Introduction to the manual

Contents of this chapter

This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.

Target audience

This manual is intended for people who plan the installation, install, start up, use and service the drive. Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

The manual is written for readers worldwide. Both SI and imperial units are shown.

Contents of the manual

This manual contains the instructions and information for the basic drive configuration. The chapters of the manual are briefly described below.

Safety instructions gives safety instructions for the installation, start-up, operation and

maintenance of the drive.

Introduction to the manual gives and introduction to this manual. Operation principle and hardware description describes the operation principle and

construction of the drive.

Mechanical installation describes how to install the drive mechanically. Guidelines for planning the electrical installation contains instructions for the motor and

cable selection, protections and cable routing.

28 Introduction to the manual

Electrical installation gives instructions on wiring the drive. Control unit of frame R11 contains the default I/O connection diagrams, descriptions of the

terminals and technical data for the control unit of the drive.

Installation checklist contains a list for checking the mechanical and electrical installation

of the drive.

Start-up describes the start-up procedure of the drive. Fault tracing describes the fault tracing possibilities of the drive. Maintenance contains preventive maintenance instructions. Technical data contains the technical specifications of the drive, for example, the ratings,

sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings.

Dimensions contains example dimension drawings of the drive. The Safe torque off function describes the Safe torque off function of the drive and gives

instructions on its implementation.

Categorization by frame size and option code

Some instructions, technical data and dimension drawings which concern only certain frame sizes are marked with the symbol of the frame size, for example R11. The frame size is marked on the type designation label (see page 58).

The instructions, technical data and dimension drawings which only concern certain optional selections are marked with option codes (such as +E205). The options included in the drive can be identified from the option codes visible on the type designation label (see page 58). The option selections are listed in section Type designation key (page 59).

30 Introduction to the manual

Quick installation, commissioning and operation flowchart

Task See

Plan the electrical installation and acquire the accessories needed (cables, fuses, etc.).

Check the ratings, required cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data.

Check the installation site. Ambient conditions (page 226)

Unpack and check the drive (only intact units may be started up). Make sure that all necessary optional modules and equipment are

present and correct. Mount the drive.

Route the cables. Routing the cables (page 92)

Check the insulation of the supply cable, the motor and the motor cable.

Guidelines for planning the electrical installation (page 79)

Technical data (page 211)

Mechanical installation (page 63)

If the drive has been nonoperational for more than one year, the DC link capacitors need to be reformed (page 201)

Checking the insulation of the assembly (page 101)

If the drive is about to be connected to an IT (ungrounded) system, check that the drive is not

Connect the power cables. Connect the control cables.

Check the installation. Installation checklist (page 155)

Start the drive up. Start-up (page 157)

Operate the drive: start, stop, speed control etc. Quick start-up guide, firmware

equipped with EMC filter (option +E202).

Checking the compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded delta and TT systems (page 102)

Electrical installation (page 101)

manual

+ 242 hidden pages