ABB ACS880-37 Hardware Manual

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ABB INDUSTRIAL DRIVES

ACS880-37 drives (45…400 kW, 60…450 hp)

Hardware manual

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ACS880-37 drives (45…400 kW, 60…450 hp)

Hardware manual

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation

10. Start-up

3AXD50000035159 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

of the drive with brake options +D150 and +D151 . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cabinet layout of R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cabinet layout of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Connection overview of R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Connection overview of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

External control cable connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Connection terminals of R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Connection terminals of R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Door switches and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Main disconnecting device (Q1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Other devices on the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Descriptions of cabinet options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

IP22 (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

IP42 (option +B054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

IP54 (option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Channeled air inlet through bottom (option +C128) . . . . . . . . . . . . . . . . . . . . . . . . . 54

Channeled air outlet (option +C130) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Marine construction (option +C121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

UL listed (option +C129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Plinth height (options +C164 and +C179) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Seismic design (option +C180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Resistor braking (options +D150 and +D151) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Empty cubicles (options +C196, +C197, +C198, +C199, +C200, +C201) . . . . . . . . 56

EMC filters (option + E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

du/dt filter (option +E205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Sine filter (option +E206) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Common mode filter (option +E208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Cabinet heater with external supply (option +G300) . . . . . . . . . . . . . . . . . . . . . . . . . 56

Cabinet lighting (option +G301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Terminals for external interruptible control voltage (option +G307) . . . . . . . . . . . . . 57

Output for motor space heater (option +G313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Ready/Run/Fault lights (options +G327…G329) . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Halogen-free materials and wiring (option G330) . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

V-meter with selector switch (option +G334) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

A-meter in one phase (option +G335) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Additional wire markings (options +G340 and +G342) . . . . . . . . . . . . . . . . . . . . . . . 58

Standard wire markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Bottom cable entry/exit (options +H350 and +H352) . . . . . . . . . . . . . . . . . . . . . . . . 58

Top cable entry/exit (options +H351 and +H353) . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Cable conduit entry (option +H358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Additional terminal block X504 (option +L504) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Thermal protection with PTC relays (options +L505, +2L505. +L513, +2L513) . . . . 59

+L505, +2L505, +L513, +2L513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

+L536, +L537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

More information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Pt100 relays (options +2L506, +3L506, +5L506, +8L506, +L514) . . . . . . . . . . . . . . 60

Starter for auxiliary motor fan (options +M600…+M605) . . . . . . . . . . . . . . . . . . . . . 61

What the option contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Moving and unpacking the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Moving the drive in its packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Moving the crate with a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Removing the transport package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Moving the unpacked drive cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Lifting the cabinet with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Moving the cabinet on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Moving the cabinet on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Final placement of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Installing the IP54 roof (option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Attaching the cabinet to the floor and wall or roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Attaching methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Alternative 1 – Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Alternative 2 – Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 77

Attaching the cabinet to the floor and wall or roof (marine units) . . . . . . . . . . . . . . . . . . 78

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Air inlet through the bottom (option +C128) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Air outlet duct on the cabinet roof (option +C130) . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Calculating the required static pressure difference . . . . . . . . . . . . . . . . . . . . . . . . 80

Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5. Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Additional requirements for explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . . 86

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

HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Additional requirements for the regenerative and low harmonic drives . . . . . . . . . 87

Additional requirements for braking applications . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . 87

Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . 87

Additional data for calculating the rise time and the peak line-to-line voltage . . . . 89

Additional note for sine filters (option +E206) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Typical cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . 97

Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . 97

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . 97

R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 97

Protecting the drive and the power cables against thermal overload . . . . . . . . . . . . 98

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Implementing a ground fault detection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . 99

Implementing the Prevention of unexpected start-up function . . . . . . . . . . . . . . . . . . . . 99

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

+Q972 or +Q973) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Supplying power for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . 101

Implementing a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . 101

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . 103

Connection of motor temperature sensor to the drive via an option module . . . . . . 103

Connection of motor temperature sensor to the drive via a relay . . . . . . . . . . . . . . 104

6. Electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

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

grounded delta and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

EMC filter (options +E200 or +E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Corner-grounded and midpoint-grounded 690 V delta systems . . . . . . . . . . . . . . . 107

Attaching the device stickers to the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Checking the settings of auxiliary voltage transformers . . . . . . . . . . . . . . . . . . . . . . . 107

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Grounding the outer shields of the control cables at the cabinet entry . . . . . . . . 109

Routing the control cables inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Connecting to the drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Connecting an auxiliary voltage supply (UPS, option +G307) . . . . . . . . . . . . . . 117

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

+Q964, +Q978, +Q979) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Wiring the starter for auxiliary motor fan (options +M600…+M605) . . . . . . . . . . 117

Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513, +2L513) . . 118

Wiring the Pt100 relays (option +nL506) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Wiring the Pt100 relays (option +nL514) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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

+G313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Wiring ground fault monitoring for IT ungrounded systems (option +Q954) . . . . 122

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Connection diagram of frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Connection diagram of frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Layout of power cable connection terminals and cable entries . . . . . . . . . . . . . . . . 126

Frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Layout of power cable connection terminals (option +C129) . . . . . . . . . . . . . . . . 128

External resistor cable connection terminals and cable entries . . . . . . . . . . . . . . 129

Connection procedure (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Connection procedure (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . 133

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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

interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Installation of safety functions modules (frame R8) . . . . . . . . . . . . . . . . . . . . . . . . . 136

Installation of safety functions modules (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . 137

Case 1: FSO-xx safety functions module on Slot 2 . . . . . . . . . . . . . . . . . . . . . . . 137

Case 2: FSO-xx safety functions module next to the control unit . . . . . . . . . . . . 139

7. Control unit of frame R8

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Default I/O connection diagram of frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 144

AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . . . 145

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

FSO-xx safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . 147

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

8. Control unit of frame R11

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Default I/O connection diagram of frame R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 154

AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . . . 155

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

FSO-xx safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . 157

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

9. Installation checklist

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

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

10. Start-up

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

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Checks/Settings with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Powering up the auxiliary circuit of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Setting up the line-side converter parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Setting up the motor-side converter parameters, and performing the first start . 165 Activating the Run enable signal of the line-side converter (with options +Q951,

+Q952 and +Q978) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

11. Fault tracing

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

12. Maintenance

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . 170

Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . 170

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Cleaning the door air inlets (IP22 and IP42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Cleaning the door air inlets (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Cleaning the outlet (roof) filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Replacing the outlet (roof) filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Retightening the power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Replacing the cabinet “door fan” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Replacing the internal cabinet cooling fans (frame R8) . . . . . . . . . . . . . . . . . . . . . 175

Replacing the drive module main fan (frame R8) . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Replacing the drive module main fans (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . 178

Replacing the LCL filter module fan (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Replacing the auxiliary cooling fan of the drive module (frame R8) . . . . . . . . . . . . 181

Replacing the auxiliary cooling fans of the drive module (frame R11) . . . . . . . . . . 182

Frame R8: Replacing the IP54 (UL Type 12) roof fan and brake chopper (option

+D150) cubicle fan G101.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Frame R11 with options +B055 and +C128: Replacing the roof fan . . . . . . . . . . . . 185

Frame R11 with option +B055: Replacing the roof fan . . . . . . . . . . . . . . . . . . . . . . . 186

Replacing the brake chopper (option +D150) cubicle fan . . . . . . . . . . . . . . . . . . . . . 187

Replacing the sine filter cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Replacing the drive module (frame R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Replacing the drive and LCL filter modules (frame R11) . . . . . . . . . . . . . . . . . . . . . . . 197

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Replacing the drive module (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Replacing the LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Replacing fuses (frame R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Replacing fuses (frame R11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Replacing the control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Replacing the memory unit of the motor-side converter control unit (frame R8) . . . 214

Replacing the memory unit of the motor-side converter control unit (frame R11) . . 215

Replacing the memory unit of the line-side converter control unit (frame R11) . . . . 216

13. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Marine type-approved drives (option +C132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

UL (NEC) ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . 221

Ex motor, sine filter, low noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Dimensions and weights of sine filter cabinet (option +E206) . . . . . . . . . . . . . . . . . 226

Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Cooling data, noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Sine output filter data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Terminal and exit data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Terminal data for the drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Control unit connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Auxiliary circuit power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . 235

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 235

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Compliance with EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

The KC (Korea Certification) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

EAC (Eurasian Conformity) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

EIP (Electronic Information Products) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

14. Dimensions

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

R8: IP22 (UL Type 1), option +B054 (IP42 [UL Type 1 Filtered]) . . . . . . . . . . . . . . . . 244

R8 (IP54, UL Type 12, option +B055): option +C129 . . . . . . . . . . . . . . . . . . . . . . . . . 245

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

+D151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

R8 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option+E206 . . . 247

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

R11: option+B055 (IP54 [UL Type 12]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

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

+H350, +H352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

R11 option +B055 (IP54 [UL Type 12]): option +C128 . . . . . . . . . . . . . . . . . . . . . . . . 251

R11 option +B055 (IP54 [UL Type 12]): option +C129 . . . . . . . . . . . . . . . . . . . . . . . . 252

R11 option +B055 (IP54 [UL Type 12]): options +C129, +H350, +H352 . . . . . . . . . . . 253

R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +D150 . . 254 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +D150,

+D151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +E206) . 256

Location and size of power cable connection terminals . . . . . . . . . . . . . . . . . . . . . . . 257

R8 input and motor cable terminal dimensions – bottom entry and exit . . . . . . . . . 257

R8 input and motor cable terminal dimensions – top entry and exit . . . . . . . . . . . . . 258

R8 input and motor cable terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

R11 input and motor cable terminal dimensions – bottom entry and exit . . . . . . . . . 260

R11 input and motor cable terminal dimensions – top entry and exit . . . . . . . . . . . . 261

R11 input cable terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

R11 motor cable terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Terminals for connecting external resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Sine filter (+E206) cubicle, 400 mm: motor cable terminals . . . . . . . . . . . . . . . . . . . 263

Sine filter (+E206) cubicle, 600 mm: motor cable terminals . . . . . . . . . . . . . . . . . . . 263

Sine filter (+E206) cubicle, 1000 mm: motor cable terminals . . . . . . . . . . . . . . . . . . 264

15. The Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 266

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

16. Resistor braking

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Selecting the default braking circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Planning a braking system with the factory-installed brake chopper and custom brake

resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Verifying the capacity of the braking equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Custom resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Calculating the allowed maximum braking power for a custom braking cycle . . . 279

Selecting and routing the cables of a custom resistor . . . . . . . . . . . . . . . . . . . . . . . 280

Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Placing custom brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Thermal protection of the resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . 281

Mechanical installation of custom brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Electrical installation of custom brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Factory-installed brake chopper and resistor types . . . . . . . . . . . . . . . . . . . . . . . . 283

Ratings for the factory-installed brake choppers and resistors . . . . . . . . . . . . . . . . 283

Calculating the maximum braking power for a custom duty cycle . . . . . . . . . . . 284

Ratings for factory-installed brake choppers and custom brake resistors . . . . . . . . 284

Terminals and cable entry data of factory-installed chopper/resistor cubicles . . . . 285

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 67).

• 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 265). 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. If you do, the brake chopper (option +D150) starts to operate which causes overheating of the brake resistor (option +D151, 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. If you have to, obey

the instructions on page 80.

• 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, brake chopper and brake resistors (if any) are 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 90). 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.

Resistor braking describes selection, protection, wiring and start-up of optional brake

choppers (+D150) and resistors (+D151). The chapter also contains technical data.

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 62).

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 62). The option selections are listed in section Type designation key (page 63).

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 232)

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 96)

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

Guidelines for planning the electrical installation (page 83)

Technical data (page 217)

Mechanical installation (page 67)

If the drive has been nonoperational for more than one year, the DC link capacitors need to be reformed (page 208)

Checking the insulation of the assembly (page 105)

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 161)

Start the drive up. Start-up (page 163)

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 106)

Electrical installation (page 105)

manual

+ 258 hidden pages

ABB ACS880-37 Hardware Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Safety instructions

Contents of this chapter

Use of warnings and notes

General safety in installation, start-up and maintenance

Electrical safety in installation, start-up and maintenance

 Electrical safety precautions

 Additional instructions and notes

 Additional instruction for DC connection

 Grounding

Additional instructions for permanent magnet motor drives

 Safety in installation, start-up and maintenance

Introduction to the manual

Contents of this chapter

Target audience

Contents of the manual

Related documents

Categorization by frame size and option code

Quick installation, commissioning and operation flowchart