| Вид документа | Інструкція з експлуатації |
|---|---|
| Виробник | ABB |
| Код документа | ACS880-01_3AUA0000078093_Instruction_manual |
| Сторінок | 394 |
| Мова документа | англійська |
| Розмір файлу | 45.5 МБ |
О чём документ
Аппаратное руководство (Hardware manual) для настенных частотных преобразователей ABB серии ACS880-01 в корпусах IP21/UL Type 1, IP55/UL Type 12 и IP20 (UL Type Open). Документ охватывает монтаж, электрическое подключение по стандартам IEC и NEC, ввод в эксплуатацию, обслуживание, тормозные резисторы, функцию Safe torque off и технические данные. Пригодится электромонтажникам, наладчикам и инженерам АСУ ТП.
Ключевые характеристики
| Параметр | Значение |
|---|---|
| Серия | ACS880-01 |
| Степени защиты корпуса | IP21 / UL Type 1; IP55 / UL Type 12 (опция +B056); IP20 / UL Type Open (опции +P940, +P944) |
| Габаритные размеры (frame sizes) | R1…R9, R9e |
| Блок управления | ZCU-12 |
| Модули безопасности | FSO safety functions module (+Q973/+Q972), FSPS-21 PROFIsafe, FSCS-21 CIP Safety™ |
| Опции монтажа | +C131 виброгасители, +C135 фланцевый монтаж, +H358 UK gland plate, +P940/+P944 шкафная установка, +C132 морское исполнение |
| Соответствие ЭМС | IEC/EN 61800-3, категории C2/C3/C4 |
| Фильтры | common mode filter, du/dt filter, sine filter |
| Торможение | внешний тормозной резистор (JBR-03, SACE08RE44, SACE15RE13/RE22, SAFUR80F500 и др.) |
| Ограничения питания | не более 5 включений за 10 минут |
Что внутри документа
- Инструкции по безопасности — уровни опасности DANGER/WARNING/CAUTION/NOTICE, общие и электрические меры предосторожности.
- Описание конструкции — главная цепь, компоновка, панели управления, ключ типообозначения и коды опций.
- Механический монтаж — положения установки, свободное пространство, распаковка, кабельные боксы для рам R1…R9e, вертикальный и горизонтальный монтаж.
- Планирование электроустановки — выбор аппаратов защиты, совместимость с двигателем, подбор силовых и управляющих кабелей, заземление, функции безопасности, bypass.
- Электромонтаж IEC и NEC — измерение сопротивления изоляции, подключение силовых и управляющих кабелей по рамам, установка опционных модулей, fieldbus.
- Блок управления ZCU-12 — схема подключений по умолчанию, XSTO (Safe torque off), DIIL, XD2D, данные разъёмов.
- Пуск, поиск неисправностей и обслуживание — интервалы ТО, замена вентиляторов, конденсаторов, блока памяти ZCU-12.
- Технические данные — номиналы, derating по температуре и высоте, предохранители aR/gG (DIN 43653, DIN 43620), автоматические выключатели IEC/UL, размеры, КПД, условия эксплуатации.
- Резисторное торможение — подбор резистора, прокладка кабелей, защита от перегрева, техданные внешних резисторов.
- Safe torque off — соответствие Machinery Directive, схемы подключения, тесты валидации, сертификат TÜV.
Быстрый старт
- Распаковать привод, проверить комплектность; хранить в упаковке до монтажа, защищать от пыли и влаги.
- Смонтировать привод вертикально (или горизонтально согласно разделу) с требуемыми свободными пространствами для охлаждения.
- Измерить сопротивление изоляции привода, питающего кабеля, двигателя и моторного кабеля до подачи напряжения.
- Подключить силовые кабели по процедуре для своей рамы (R1…R3, R4/R5, R6…R9, R9e) — отдельно для IEC или NEC.
- Заземлить экран моторного кабеля на стороне двигателя; выполнить проверку совместимости системы заземления.
- Подключить управляющие кабели к ZCU-12, при необходимости установить опционные модули и модули безопасности.
- Пройти чек-лист монтажа, при необходимости реформировать конденсаторы после длительного хранения, затем выполнить процедуру пуска.
Частые вопросы
- Какие степени защиты доступны у ACS880-01?
- IP21 (UL Type 1) — базовое исполнение; IP55 (UL Type 12) — опция +B056; IP20 (UL Type Open) — опции +P940 и +P944 для шкафной установки.
- Сколько раз можно включать привод под напряжение подряд?
- Не более пяти включений за десять минут — слишком частые включения могут повредить зарядную цепь DC-конденсаторов.
- Нужен ли du/dt-фильтр или синусный фильтр для моего двигателя?
- В документе есть отдельные главы о common mode-, du/dt- и синусных фильтрах, включая таблицы доступности фильтров по типу привода и требования к двигателям ABB и сторонних производителей мощностью до и свыше 100 кВт (134 hp).
- Поддерживает ли привод функцию Safe torque off?
- Да, функция реализована через разъём XSTO блока ZCU-12; глава 16 описывает схемы одно- и двухканального подключения, процедуры валидации и proof-тестов, а также содержит сертификат TÜV.
- Какие предохранители рекомендованы для защиты привода?
- В главе технических данных приведены таблицы быстродействующих aR-предохранителей DIN 43653 (стержневые) и DIN 43620 (ножевые), gG-предохранители DIN 43620, а также автоматические выключатели ABB по IEC и UL (230/480/600 В), с руководством по выбору между gG и aR.
- Можно ли управлять несколькими приводами с одной панели?
- Да, поддерживается panel bus (управление несколькими блоками с одной панели управления), twin panel connection и соединение через модули FDPI-02.
Текст документа
—
ABB INDUSTRIAL DRIVES
ACS880-01 drives
Hardware manual
ACS880-01 drives
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation –
Global (IEC)
7. Electrical installation – North
America (NEC)
10. Start-up
3AUA0000078093 Rev V
EN
Original instructions
EFFECTIVE: 2026-02-26
Table of contents 5
Table of contents
1 Safety instructions
Contents of this chapter.......................................................................................... 17
Safety messages........................................................................................................ 17
General safety in installation, start-up and maintenance................................. 18
Electrical safety in installation, start-up and maintenance.............................. 20
Electrical safety precautions........................................................................... 20
Additional instructions and notes.................................................................. 21
Printed circuit boards........................................................................... 21
Grounding............................................................................................................ 22
General safety in operation..................................................................................... 23
Additional instructions for permanent magnet motor drives......................... 23
Safety in installation, start-up, and maintenance....................................... 23
Safety in operation............................................................................................ 24
2 Introduction to the manual
Contents of this chapter.......................................................................................... 25
Target audience......................................................................................................... 25
Categorization by frame size and option code................................................... 25
Quick installation, commissioning and operation flowchart........................... 26
Terms and abbreviations......................................................................................... 27
Related documents................................................................................................... 29
3 Operation principle and hardware description
Contents of this chapter.......................................................................................... 31
Product overview....................................................................................................... 31
Main circuit.......................................................................................................... 32
Layout................................................................................................................... 33
IP21, UL Type 1......................................................................................... 33
IP55 (option +B056)............................................................................... 34
UL Type 12 (option +B056)................................................................... 35
IP20 (UL Type Open, options +P940 and +P944)............................. 35
Overview of power and control connections................................................ 36
Control panel....................................................................................................... 37
Control panel mounting platform cover........................................... 37
Control panel door mounting kits...................................................... 37
Type designation label............................................................................................. 38
Type designation key................................................................................................ 39
Basic code............................................................................................................ 39
6 Table of contents
Option codes....................................................................................................... 40
4 Mechanical installation
Contents of this chapter.......................................................................................... 45
Safety........................................................................................................................... 45
Mounting positions................................................................................................... 46
Required free space.................................................................................................. 46
Examining the installation site............................................................................... 46
Necessary tools.......................................................................................................... 47
Moving the drive........................................................................................................ 47
Unpacking and examining the delivery................................................................. 47
Examining the delivery...................................................................................... 47
Package of frames R1…R4................................................................................ 48
Package of frames R5 and R6.......................................................................... 50
Frame R5 cable box (IP21, UL Type 1)................................................. 52
Frame R6 cable box (IP21, UL Type 1)................................................. 53
Package of frame R7.......................................................................................... 54
Frame R7 cable box (IP21, UL Type 1)................................................. 56
Package of frames R8 and R9.......................................................................... 57
Frame R8 cable box (IP21, UL Type 1)................................................. 59
Frame R9 cable box (IP21, UL Type 1)................................................. 60
Package of frame R9e........................................................................................ 61
Installing the drive vertically.................................................................................... 63
Vibration dampers (option +C131).................................................................. 63
Flange mounting (option +C135).................................................................... 63
UK gland plate (option +H358)........................................................................ 63
Cabinet installation (options +P940 and +P944)........................................ 63
Frames R1 to R4 (IP21, UL Type 1).................................................................... 64
Frames R5 to R9 (IP21, UL Type 1)................................................................... 65
Frames R1 to R9 (IP55, UL Type 12)................................................................. 67
Frame R9e............................................................................................................ 69
Installing the drive horizontally.............................................................................. 70
5 Guidelines for planning the electrical installation
Contents of this chapter.......................................................................................... 71
Limitation of liability................................................................................................. 71
North America..................................................................................................... 71
Selecting the main supply disconnecting device................................................ 71
Selecting the main contactor.................................................................................. 72
Examining the compatibility of the motor and drive......................................... 72
Protecting the motor insulation and bearings............................................. 72
Requirements tables.......................................................................................... 73
Requirements for ABB motors, Pn < 100 kW (134 hp)..................... 74
Requirements for ABB motors, Pn > 100 kW (134 hp)..................... 75
Table of contents 7
Requirements for non-ABB motors, Pn < 100 kW (134 hp)............. 76
Requirements for non-ABB motors, Pn > 100 kW (134 hp)............. 77
Abbreviations.......................................................................................... 78
Availability of du/dt filter and common mode filter by drive
type........................................................................................................... 78
Additional requirements for explosion-safe (EX) motors............. 78
Additional requirements for ABB motors of types other than M2_,
M3_, M4_, HX_ and AM_......................................................................... 78
Additional requirements for braking applications.......................... 78
Additional requirements for ABB high-output and IP23 motors... 79
Additional requirements for non-ABB high-output and IP23
motors...................................................................................................... 79
Additional data for calculating the rise time and the peak
line-to-line voltage................................................................................. 80
Additional note for sine filters............................................................ 81
Selecting the power cables...................................................................................... 82
General guidelines.............................................................................................. 82
Typical power cable sizes................................................................................. 82
Power cable types.............................................................................................. 83
Preferred power cable types................................................................ 83
Alternate power cable types................................................................ 84
Not allowed power cable types........................................................... 85
Additional guidelines – North America.......................................................... 85
Metal conduit.......................................................................................... 86
Power cable shield............................................................................................. 86
Grounding requirements.......................................................................................... 87
Additional grounding requirements – IEC..................................................... 88
Additional grounding requirements – UL (NEC).......................................... 89
Selecting the control cables.................................................................................... 89
Shielding.............................................................................................................. 89
Signals in separate cables................................................................................ 89
Signals that can be run in the same cable..................................................... 89
Relay cable........................................................................................................... 89
Control panel cable............................................................................................ 90
PC tool cable........................................................................................................ 90
Routing the cables..................................................................................................... 90
General guidelines – IEC.................................................................................... 90
General guidelines – North America............................................................... 91
Continuous motor cable shield/conduit and metal enclosure for
equipment on the motor cable........................................................................ 92
Separate control cable ducts........................................................................... 93
Implementing short-circuit and thermal overload protection......................... 93
Protecting the drive and the input power cable in short-circuits............ 93
Protecting the motor and motor cable in short-circuits............................ 94
Protecting the drive against thermal overload............................................ 94
8 Table of contents
Protecting the input power cable against thermal overload.................... 94
Protecting the motor cables against thermal overload............................. 94
Protecting the motor against thermal overload.......................................... 95
Protecting the motor against overload without thermal model or
temperature sensors......................................................................................... 95
Protecting the drive against ground faults.......................................................... 95
Residual current device compatibility............................................................ 95
Connecting drives to a common DC system........................................................ 96
Implementing the emergency stop function....................................................... 96
Implementing the Safe torque off function......................................................... 96
Implementing the functions provided by the FSO safety functions module. 96
Implementing the functions provided by the FSPS-21 PROFIsafe safety
functions module....................................................................................................... 96
Implementing the functions provided by the FSCS-21 CIP Safety™ functions
module......................................................................................................................... 97
Implementing an ATEX-certified motor thermal protection............................ 97
Implementing the power loss ride-through function........................................ 98
Using power factor compensation capacitors with the drive.......................... 99
Controlling a contactor between drive and motor............................................. 99
Implementing a bypass connection....................................................................... 100
Example bypass connection............................................................................ 100
Switching the motor power supply from drive to direct-on-line.. 102
Switching the motor power supply from direct-on-line to drive.. 102
Protecting the contacts of relay outputs............................................................. 102
Implementing a motor temperature sensor connection................................... 103
Connecting a motor temperature sensor to the drive through an option
module.................................................................................................................. 104
6 Electrical installation – Global (IEC)
Contents of this chapter.......................................................................................... 107
Necessary tools.......................................................................................................... 107
Grounding the motor cable shield at the motor end......................................... 108
Measuring the insulation......................................................................................... 108
Measuring the insulation resistance of the drive........................................ 108
Measuring the insulation resistance of the input power cable................ 108
Measuring the insulation resistance of the motor and motor cable....... 108
Grounding system compatibility check................................................................ 109
Corner-grounded and midpoint-grounded 525…690 V delta systems... 109
Connecting the power cables................................................................................. 110
Connection diagram.......................................................................................... 110
Connection procedure for frames R1…R3..................................................... 111
Connection procedure for frames R4 and R5............................................... 115
Connection procedure for frames R6…R9.................................................... 120
Connection procedure for frame R9e............................................................ 126
Remove the EMC cover plates............................................................. 127
Table of contents 9
Remove the side plates......................................................................... 128
Remove the EMC side plate................................................................. 129
Remove the control cable entry plate................................................ 129
Remove the clamping shelves............................................................. 130
Remove the terminals........................................................................... 131
Connect the power cables.................................................................... 132
Install the control cable entry plate.................................................... 141
Install the EMC plates and side plates............................................... 141
Detaching connectors (frames R8 and R9)................................................... 141
L1, L2 and L3 connectors...................................................................... 141
T1/U, T2/V and T3/W connectors....................................................... 142
Cable lug installation (frames R6…R9).......................................................... 143
Connecting the control cables................................................................................ 144
Connection procedure, frames R1...R9........................................................... 144
Connection procedure, frame R9e.................................................................. 146
Connecting a PC......................................................................................................... 147
Panel bus (control of several units from one control panel)............................. 147
Twin panel connection...................................................................................... 148
Connection with FDPI-02 modules................................................................. 148
Installing option modules........................................................................................ 149
Fieldbus cabling.................................................................................................. 151
Installing FSO safety functions module onto ZCU-12 control unit.......... 154
Installation procedure........................................................................... 154
Installing the FSPS-21 PROFIsafe safety functions module....................... 156
Installing the FSCS-21 CIP Safety™ functions module................................ 156
7 Electrical installation – North America (NEC)
Contents of this chapter.......................................................................................... 157
Safety........................................................................................................................... 157
Necessary tools.......................................................................................................... 157
Measuring the insulation......................................................................................... 157
Grounding system compatibility check................................................................ 158
Connecting the power cables................................................................................. 158
Connection diagram.......................................................................................... 158
Connection procedure for frames R1 to R3................................................... 160
Connection procedure for frames R4 and R5............................................... 164
Connection procedure for frames R6 to R9.................................................. 169
Connection procedure for frame R9e............................................................ 172
Connecting the control cables................................................................................ 178
Connection procedure....................................................................................... 178
Connection procedure for frame R9e................................................ 181
Connecting a PC......................................................................................................... 181
Panel bus (control of several units from one control panel)............................. 182
Installing option modules........................................................................................ 182
10 Table of contents
8 Control unit
Contents of this chapter.......................................................................................... 183
General......................................................................................................................... 183
ZCU-12 layout............................................................................................................. 184
Default control connection diagram of the drive control unit (ZCU).............. 185
Additional information on the connections......................................................... 188
NPN configuration for digital inputs.............................................................. 188
Connecting motor temperature sensors to the drive................................ 188
Power supply for the control unit (XPOW).................................................... 188
Digital interlock (DIIL)....................................................................................... 188
The XD2D connector.......................................................................................... 189
Safe torque off (XSTO)...................................................................................... 189
Safety functions module connection (X12)................................................... 190
Connector data.......................................................................................................... 191
ZCU ground isolation diagram........................................................................ 194
9 Installation checklist
Contents of this chapter.......................................................................................... 197
Checklist...................................................................................................................... 197
10 Start-up
Contents of this chapter.......................................................................................... 201
Reforming the capacitors........................................................................................ 201
Start-up procedure.................................................................................................... 201
11 Fault tracing
Contents of this chapter.......................................................................................... 203
LEDs.............................................................................................................................. 203
Warning and fault messages........................................................................... 203
12 Maintenance
Contents of this chapter.......................................................................................... 205
Maintenance intervals............................................................................................... 205
Description of symbols..................................................................................... 205
Recommended maintenance intervals after start-up................................. 206
Cleaning the exterior................................................................................................ 207
Cleaning the heatsink............................................................................................... 207
Fans.............................................................................................................................. 208
Replacing the main cooling fan of frames R1…R3....................................... 209
Replacing the auxiliary cooling fan of IP55 frames R1…R3........................ 210
Replacing the main cooling fan of frames R4 and R5................................. 212
Replacing the auxiliary cooling fan of frames R4 and R5........................... 213
Table of contents 11
Replacing the main cooling fan of frames R6…R8...................................... 214
Replacing the auxiliary cooling fan of frames R6…R9 (IP21, UL Type 1).. 215
Replacing the second auxiliary cooling fan of frame R9 (IP55, UL
Type 12)................................................................................................................ 217
Replacing the auxiliary cooling fan in the IP55 (UL Type 12) cover, frames
R8 and R9............................................................................................................. 218
Replacing the main cooling fans of frame R9............................................... 220
Replacing the main cooling fan of frames R4…R9 with option +P968.... 220
Replacing the main cooling fans of frame R9e............................................. 221
Replacing the auxiliary cooling fans in the IP55 (UL Type 12) cover, frame
R9 (drive types -453A-4, -490A-3 and -477A-5)............................................. 224
Replacing the internal cooling fan, IP21 (UL Type 1) frame R9e................ 226
Replacing the drive (IP21, UL Type 1, frames R1…R9)......................................... 227
Capacitors................................................................................................................... 228
Reforming the capacitors................................................................................. 229
Control panel.............................................................................................................. 229
Control unit................................................................................................................. 229
Replacing the memory unit of ZCU-12........................................................... 229
Replacing the ZCU-12 control unit battery.................................................... 230
Replacing safety functions modules (FSO-12, option +Q973 and FSO-21,
option +Q972)............................................................................................................. 231
Functional safety components............................................................................... 231
13 Technical data
Contents of this chapter.......................................................................................... 233
Marine type-approved drives (option +C132)...................................................... 233
Drives for SynRM motors......................................................................................... 233
Electrical ratings........................................................................................................ 234
Definitions........................................................................................................... 242
UL Listed drive multiple ratings...................................................................... 242
Deratings............................................................................................................. 243
Surrounding air temperature derating.............................................. 243
Altitude derating.................................................................................... 244
Deratings for special settings in the drive control program........ 245
Fuses (IEC).................................................................................................................. 258
aR fuses DIN 43653 stud-mount..................................................................... 258
aR fuses DIN 43620 blade style....................................................................... 262
gG fuses DIN 43620 blade style....................................................................... 265
Quick guide for selecting between gG and aR fuses.................................. 270
Calculating the short-circuit current of the installation............................ 273
Calculation example.............................................................................. 273
Fuses (UL)................................................................................................................... 275
Circuit breakers (IEC)................................................................................................ 279
ABB miniature and molded case circuit breakers........................................ 280
ABB manual motor starters.............................................................................. 284
12 Table of contents
Circuit breakers (UL)................................................................................................. 285
ABB inverse time circuit breakers................................................................... 285
230 V circuit breakers............................................................................ 286
480 V circuit breakers........................................................................... 287
600 V circuit breakers........................................................................... 288
Dimensions, weights and free space requirements........................................... 290
Package dimensions.......................................................................................... 293
Free space requirements......................................................................................... 294
Losses, cooling data and noise............................................................................... 294
Cooling air flow and heat dissipation for flange mounting (option +C135)... 297
Connector and entry data for the power cables................................................. 301
IEC......................................................................................................................... 301
UL........................................................................................................................... 302
Connector data for the control cables.................................................................. 304
Typical power cables................................................................................................. 304
Electrical power network specification................................................................. 308
Motor connection data............................................................................................. 308
Efficiency..................................................................................................................... 309
Energy efficiency data (ecodesign)....................................................................... 309
Protection classes..................................................................................................... 310
Ambient conditions................................................................................................... 310
Storage conditions.................................................................................................... 312
Colors........................................................................................................................... 312
Materials...................................................................................................................... 312
Drive...................................................................................................................... 312
Package materials for small wall-mounted drives and converter
modules................................................................................................................ 312
Package materials for large wall-mounted drives and converter
modules................................................................................................................ 313
Package materials for options, accessories and spare parts................... 313
Materials of manuals......................................................................................... 313
Disposal....................................................................................................................... 313
Applicable standards................................................................................................ 314
Markings...................................................................................................................... 315
EMC compliance (IEC/EN 61800-3)........................................................................ 316
Definitions........................................................................................................... 316
Category C2......................................................................................................... 317
Category C3......................................................................................................... 318
Category C4......................................................................................................... 318
UL checklist................................................................................................................. 319
Approvals..................................................................................................................... 321
Design lifetime expectancy..................................................................................... 321
Disclaimers.................................................................................................................. 321
Generic disclaimer.............................................................................................. 321
Cyber security disclaimer................................................................................. 321
Table of contents 13
Declarations of conformity...................................................................................... 322
14 Dimension drawings
Contents of this chapter.......................................................................................... 323
Frame R1, IP21 (UL Type 1)........................................................................................ 324
Frame R1, IP55 (UL Type 12)..................................................................................... 325
Frame R2, IP21 (UL Type 1)....................................................................................... 326
Frame R2, IP55 (UL Type 12)..................................................................................... 327
Frame R3, IP21 (UL Type 1)....................................................................................... 328
Frame R3, IP55 (UL Type 12)..................................................................................... 329
Frame R4, IP21 (UL Type 1)....................................................................................... 330
Frame R4, IP55 (UL Type 12).................................................................................... 331
Frame R5, IP21 (UL Type 1)....................................................................................... 332
Frame R5, IP55 (UL Type 12).................................................................................... 333
Frame R6, IP21 (UL Type 1)....................................................................................... 334
Frame R6, IP55 (UL Type 12).................................................................................... 335
Frame R7, IP21 (UL Type 1)....................................................................................... 336
Frame R7, IP55 (UL Type 12)..................................................................................... 337
Frame R8, IP21 (UL Type 1)....................................................................................... 338
Frame R8, IP55 (UL Type 12).................................................................................... 339
Frame R9, IP21 (UL Type 1)....................................................................................... 340
Frame R9, IP55 (UL Type 12).................................................................................... 341
Frame R9, IP55 (UL Type 12)*................................................................................... 342
Frame R9e, IP21.......................................................................................................... 343
Frame R9e, UL Type 1................................................................................................ 344
Frame R9e, IP55.......................................................................................................... 345
Frame R9e, UL Type 12.............................................................................................. 346
15 Resistor braking
Contents of this chapter.......................................................................................... 347
Operation principle and hardware description................................................... 347
Planning the braking system................................................................................... 347
Selecting the brake circuit components........................................................ 347
Selecting a custom resistor............................................................................. 348
Selecting and routing the brake resistor cables.......................................... 349
Minimizing electromagnetic interference......................................... 349
Maximum cable length...................................................................................... 349
EMC compliance of the complete installation.............................................. 349
Placing the brake resistors............................................................................... 349
Protecting the system against thermal overload........................................ 350
Protecting the system in fault situations......................................... 350
Protecting the resistor cable against short-circuits...................... 352
Mechanical installation............................................................................................. 352
14 Table of contents
Electrical installation................................................................................................. 352
Measuring the insulation resistance of the brake resistor circuit........... 352
Connection diagram.......................................................................................... 353
Connection procedure....................................................................................... 353
Start-up........................................................................................................................ 353
Technical data............................................................................................................ 354
Ratings.................................................................................................................. 354
Degree of protection and thermal constant of the resistor..................... 357
Dimensions and weights of external resistors.................................................... 358
JBR-03................................................................................................................... 358
SACE08RE44........................................................................................................ 359
SACE15RE13 and SACE15RE22.......................................................................... 360
SAFUR80F500 and SAFUR90F575................................................................... 360
SAFUR125F500 and SAFUR200F500.............................................................. 361
16 The Safe torque off function
Contents of this chapter.......................................................................................... 363
Description.................................................................................................................. 363
Compliance with the European Machinery Directive and the UK Supply
of Machinery (Safety) Regulations.................................................................. 364
Wiring........................................................................................................................... 365
Activation switch................................................................................................ 365
Cable types and lengths.................................................................................... 365
Grounding of protective shields..................................................................... 366
Single drive (internal power supply)............................................................... 366
Dual-channel connection...................................................................... 366
Single-channel connection................................................................... 367
Multiple drives..................................................................................................... 368
Internal power supply............................................................................ 368
External power supply........................................................................... 369
Operation principle................................................................................................... 370
Start-up including validation test.......................................................................... 371
Competence........................................................................................................ 371
Validation test reports...................................................................................... 371
Validation test procedure................................................................................. 371
Use................................................................................................................................ 373
Maintenance............................................................................................................... 375
Competence........................................................................................................ 376
Perfect proof test procedure........................................................................... 376
Simplified proof test procedure..................................................................... 377
Fault tracing................................................................................................................ 378
Safety data.................................................................................................................. 379
Terms and abbreviations.................................................................................. 383
TÜV certificate.................................................................................................... 385
Table of contents 15
17 Filters
Contents of this chapter.......................................................................................... 387
When is a common mode filter or du/dt filter needed?.................................... 387
Common mode filters............................................................................................... 387
du/dt filters................................................................................................................ 388
du/dt filter types................................................................................................ 388
Description, installation and technical data of the du/dt filters............. 389
Sine filters................................................................................................................... 389
Selecting a sine filter for a drive...................................................................... 389
Definitions........................................................................................................... 392
Derating................................................................................................... 392
Description, installation and technical data..................................... 392
Further information
16
Safety instructions 17
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install,
start-up, operate and do maintenance work on the drive. If you ignore the safety
instructions, injury, death or damage can occur.
Safety messages
These safety messages help to prevent personal injury and damage to the
equipment. The hazard levels comply with standard ANSI Z535.6.
The manual uses these warning symbols:
DANGER Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE Is used to address practices not related to physical injury, but which
can result in equipment damage.
18 Safety instructions
General safety in installation, start-up and maintenance
These instructions are for all persons who do work on the drive.
WARNING Obey these instructions. If you ignore them, injury or death,
or damage to the equipment can occur.
• Keep the drive in its package until you install it. After unpacking, protect the
drive from dust, debris and moisture.
• Use the required personal protective equipment: safety shoes with metal toe
cap, safety glasses, protective gloves and long sleeves, etc. Some parts have
sharp edges.
• Use a lifting device to lift a heavy drive. Use the designated lifting points. Refer
to the dimension drawings.
• Be careful when handling a tall module. The module overturns easily because
it is heavy and has a high center of gravity. Whenever possible, secure the
module with chains. Do not leave an unsupported module unattended especially
on a sloping floor.
• Beware of hot surfaces. Some parts, such as heatsinks of power
semiconductors, and brake resistors, can be hot for a period after operation.
• Before the start-up, vacuum clean the area around the drive to prevent the
drive cooling fan from drawing dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not go into the
drive during installation. Electrically conductive debris inside the drive can
cause damage or malfunction.
• Make sure that there is sufficient cooling. Refer to the technical data.
• Before you connect voltage to the drive, make sure that all covers are in place.
Do not remove the covers when voltage is connected.
• Before you adjust the drive operation limits, make sure that the motor and all
driven equipment can operate throughout the set operation limits.
Safety instructions 19
• 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 break in the power supply. If these functions are activated, the
installation must be clearly marked as defined in IEC/EN/UL 61800-5-1,
subclause 6.5.3, for example, "THIS MACHINE STARTS AUTOMATICALLY".
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors.
• If the drive has connected safety circuits (for example, Safe torque off or
emergency stop), validate them at start-up. Refer to separate instructions for
the safety circuits.
• Beware of hot airflow from the cooling outlets.
• Do not cover the air inlet or air outlet when the drive operates.
Note:
• If you select an external source for the start command and it is on, the drive
starts immediately after a fault reset unless you configure the drive for pulse
start. Refer to the firmware manual.
• If the drive is in remote control mode, you cannot stop or start the drive with
the control panel.
• Only authorized persons are permitted to repair a faulty drive.
20 Safety instructions
Electrical safety in installation, start-up and maintenance
￭ Electrical safety precautions
These electrical safety precautions are for all persons 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 electrical installation or maintenance work. Do these
steps before you do installation or maintenance work.
1. Prepare for the work.
• Make sure that you have a work order.
• Do an on-site risk assessment or job hazard analysis.
• Make sure that you have the correct tools available.
• Make sure that the workers are qualified.
• Select the correct personal protective equipment (PPE).
• Stop the drive and motor(s).
2. Clearly identify the work location and equipment.
3. Disconnect all possible voltage sources. Make sure that connection is not
possible. Lock out and tag out.
• Open the main disconnecting device of the drive
• If there is a permanent magnet motor connected to the drive, disconnect
the motor from the drive with a safety switch or by other means.
• Open the main isolating device of the drive.
• Disconnect all dangerous external voltages from the control circuits.
• After you disconnect power from the drive, wait 5 minutes to let the
intermediate circuit capacitors discharge before you continue.
4. Protect other energized parts in the work location against contact and take
special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a high-quality voltage tester.
• Before and after you measure the installation, verify the operation of the
voltage tester on a known voltage source.
• Make sure that the voltage between the input power terminals of the drive
(L1, L2, L3) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the output power terminals of the
drive (U, V, W) and the grounding (PE) busbar is zero.
Important! Repeat the measurement with the DC voltage setting of the
voltage tester. Measure between each phase and ground. There is a risk
of dangerous DC voltage charging due to leakage capacitances of the
motor circuit. This voltage can remain charged for a long time after the
drive power-off. The measurement discharges the voltage.
Safety instructions 21
• Make sure that the voltage between the drive DC terminals (UDC+ and
UDC-) and the grounding (PE) terminal is zero.
Note: If cables are not connected to the drive DC terminals, measuring the
voltage from the DC terminal screws can give incorrect results.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person that is responsible for the electrical
installation 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 installation or
maintenance work.
• Make sure that the electrical power network, motor/generator, and
environmental conditions agree with the drive data.
• Do not do insulation or voltage withstand tests on the drive.
• If you have a cardiac pacemaker or other electronic medical device, do not go
near the motor, drive, or the drive power cabling when the drive is in operation.
The equipment produces electromagnetic fields that can cause interference
in electronic medical devices. This can cause a health hazard.
Note:
• When the drive is connected to the input power, the motor cable terminals
and the DC bus are at a dangerous voltage.
The brake circuit, including the brake chopper (option +D150) and brake resistor
(if it is installed) are also at a dangerous voltage.
After you disconnect the drive from the input power, these remain at a
dangerous voltage until the intermediate circuit capacitors discharge.
• External wiring can supply dangerous voltages to the relay outputs of the
control units of the drive.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits. The function is not effective against deliberate sabotage or
misuse.
Printed circuit boards
NOTICE Use an antistatic wrist strap when you handle printed circuit boards.
Do not touch the boards unnecessarily. The boards are sensitive to electrostatic
discharge.
22 Safety instructions
￭ Grounding
These instructions are for all persons 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 personnel safety.
• Make sure that the conductivity of the protective earth (PE) conductors is
sufficient and that other requirements are met. Refer to the electrical planning
instructions of the drive. Obey the applicable national and local regulations.
• When you use shielded cables, make a 360° grounding of the cable shields at
the cable entries to reduce electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) busbar of the power supply.
Safety instructions 23
General safety in operation
These instructions are for all persons that operate the drive.
WARNING Obey these instructions. If you ignore them, injury or death,
or damage to the equipment can occur.
• If you have a cardiac pacemaker or other electronic medical device, do not go
near the motor, drive, or the drive power cabling when the drive is in operation.
The equipment produces electromagnetic fields that can cause interference
in electronic medical devices. This can cause a health hazard.
• Give a stop command to the drive before you reset a fault. If you have an
external source for the start command and the start is on, the drive starts
immediately after the fault reset, Показано початок документа. Повний текст — у PDF за посиланням вище.
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