Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Contents of this chapter
- General safety in installation, start-up and maintenance
- Electrical safety in installation, start-up and maintenance
- Grounding
- Additional instructions for permanent magnet motor drives
- Categorization by frame size and option code
- Quick installation, commissioning and operation flowchart
- Terms and abbreviations
- Overview circuit diagram of the drive
- pulse connection (option +A004)
- Cabinet line-up and layout examples
- Frame 2×D7T + 2×R8i (12-pulse connection, option +A004)
- Frame 2×D8T + 3×R8i
- Frame 3×D8T + 4×R8i (with main breaker, option +F255)
- Auxiliary control cubicle (ACU) layout
- Overview of power and control connections
- Door switches and lights
- Main disconnecting device (Q1.1)
- Control by PC tools
- IP42 (option +B054)
- Plinth height (options +C164 and +C179)
- Cabinet lighting (option +G301)
- A-meter in one phase (option +G335)
- Top cable entry/exit (options +H351 and +H353)
- Additional terminal block X504 (option +L504)
- L536, +L537
- Starter for auxiliary motor fan (options +M602...M610)
- Type designation label
- Necessary tools
- Moving and unpacking the drive
- Lifting the crate with a crane
- Moving the crate with a forklift
- Moving the unpacked drive cabinet
- Moving the cabinet on rollers
- Final placement of the cabinet
- Fastening methods
- Alternative 2 – Using the holes inside the cabinet
- Joining shipping splits together
- Miscellaneous
- Air outlet duct on the cabinet roof (option +C130)
- Calculating the required static pressure difference
- Examining the compatibility of the motor and drive
- Availability of du/dt filter and common mode filter by drive type
- Additional requirements for non-ABB high-output and IP23 motors
- Additional data for calculating the rise time and the peak line-to-line voltage
- Selecting the power cables
- Alternative power cable types
- Power cable types for limited use
- Additional US requirements
- Signals in separate cables
- Separate control cable ducts
- Protecting the motor and motor cable in short-circuits
- Implementing the emergency stop function
- Implementing the Power-loss ride-through
- Supplying power for the auxiliary circuits
- Connecting a motor temperature sensor to the drive I/O
- Drive I/O, I/O extension and encoder interface modules
- Custom brake resistor assembly
- T21 and T101 tap settings (400...500 V units)
- T111 tap settings
- Connecting the control cables
- Grounding the outer shields of the control cables at the cabinet lead-through
- Routing the control cables inside the cabinet
- Connecting to the inverter control unit (A41)
- Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307)
- Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513 and +2L513)
- Wiring the Pt100 relays (option +nL506)
- Powering the heating and lighting equipment (options +G300, +G301 and G313)
- Wiring ground fault monitoring for IT ungrounded systems (option +Q954)
- Connecting the motor cables (units without common motor terminal cubicle or sine output filter)
- Motor connection diagram (with option +H366)
- Procedure
- Removing and reinstalling the fan carriage of an inverter module
- Connecting the motor cables
- Re-installing the fan carriage of an inverter module
- Connection diagram
- Connecting an external brake resistor assembly
- Connection diagram, 12-pulse units
- Connecting a PC
- Panel bus (Control of several units from one control panel)
- Installing option modules
- Wiring of optional modules
- What this chapter contains
- Control unit layout and connections
- Default I/O diagram of the supply control unit (A51)
- Default I/O diagram of the inverter control unit (A41)
- External power supply for the control unit (XPOW)
- DIIL input
- Safe torque off (XSTO, XSTO OUT)
- Ground isolation diagram
- Cabinet
- Cleaning the outlet (roof) filters (IP54)
- Fans
- Replacing a roof fan (IP54/UL type 12)
- Replacing a supply module (D7T) cooling fan
- Replacing a supply module (D8T) or inverter module (R8i) cooling fan
- Replacing the circuit board compartment fan
- Supply and inverter modules
- Replacing a frame D8T supply module
- Cleaning the heatsink
- Activating the reduced run of the inverter unit
- Returning the module
- Fuses
- Replacing the supply module DC fuses (D7T and D8T)
- Control panel
- Control units
- Definitions
- Altitude derating
- Frame sizes and power module types
- DC fuses
- Supply module internal DC fuses
- Brake chopper DC fuses
- Sine output filter data
- Input cable sizes
- Output cable sizes
- Terminal and lead-through data for the power cables
- Motor connection data
- Materials
- Applicable standards
- CE marking
- Declaration of Conformity (According to Machinery Directive)
- Compliance with EN 61800-3:2004
- Category C4
- UL and CSA markings
- Mechanical connections
- Disclaimers
- Cabinet line-up dimensions
- Dimension tables
- Weights
- Dimension drawing examples
- Frame 1×D8T + 2×R8i (IP22)
- Frame 1×D8T + 2×R8i, IP54 (+B055)
- Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 1/2
- Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 2/2
- Frame 1×D8T + 2×R8i with brake choppers and resistors (+D150 +D151), 1/2
- Frame 1×D8T + 2×R8i with brake choppers and resistors (+D150 +D151), 2/2
- Frame 1×D8T + 2×R8i with sine output filter (+E206), 1/2
- Frame 1×D8T + 2×R8i with sine output filter (+E206), 2/2
- Frame 2×D8T + 2×R8i, 12-pulse (+A004) with grounding switch (+F259)
- Frame 2×D8T + 3×R8i, 1/2
- Frame 2×D8T + 3×R8i, 2/2
- Frame 2×D8T + 3×R8i with common motor terminal cubicle (+H359), 1/2
- Frame 2×D8T + 3×R8i with common motor terminal cubicle (+H359), 2/2
- Frame 2×D8T + 3×R8i with top entry / top exit (+H351/+H353), 1/2
- Frame 2×D8T + 3×R8i with top entry/top exit, 2/2
- Frame 3×D8T + 4×R8i, 1/2
- Frame 3×D8T + 4×R8i, 2/2
- Frame 3×D8T + 4×R8i with common motor terminal cubicle (+H359), 1/2
- Frame 3×D8T + 4×R8i with common motor terminal cubicle (+H359), 2/2
- Frame 3×D8T + 4×R8i with top entry / top exit (+H351/+H353), 1/2
- Frame 3×D8T + 4×R8i with top entry / top exit (+H351/+H353), 2/2
- Frame 4×D8T + 5×R8i (6-pulse) with top entry/exit, UL Listed (+C129), 1/2
- Frame 4×D8T + 5×R8i (6-pulse) with top entry/exit, UL Listed (+C129), 2/2
- Dimensions of empty cubicles (options +C199, +C200, +C201)
- IP54
- Location and size of input terminals
- mm, without main breaker, bottom cable entry (including 12-pulse units with grounding switch)
- mm, 12-pulse units without grounding switch, bottom cable entry
- mm, with main breaker, bottom cable entry
- mm (UL/CSA), top cable entry
- mm (UL/CSA), bottom cable entry
- Location and size of output terminals
- Inverter module cubicle with three R8i modules, bottom cable exit (no +H353)
- Brake chopper cubicle
- Sine filter (+E206) cubicle, 1000 mm, top cable exit (+H353)
- Units with common motor terminal cubicle (option +H359)
- Cubicle width 300 mm, top cable exit
- Cubicle width 400 mm, bottom cable exit
- Cubicle width 600 mm, bottom cable exit
- Compliance with the European Machinery Directive
- Grounding of protective shields
- Multiple inverter units (internal power supply)
- Multiple inverter units (external power supply)
- Start-up including acceptance test
- Maintenance
- Competence
- Abbreviations
- Factory-installed brake choppers and resistors
- SAFUR resistor data
- Custom resistor
- Selecting and routing the cables of a custom resistor
- Thermal protection of the resistors
- Brake system start up
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Supply and inverter modules￭ Replacing a frame D7T supply moduleWARNING!Only qualified electricians are allowed to do this work. Read the complete safetyinstructions of the drive. Ignoring the instructions can cause physical injury ordeath, or damage to the equipment.WARNING!Use extreme caution when maneuvering the supply module. It is heavy and havea high center of gravity. Ignoring the following instructions can cause physicalinjury, or damage to the equipment.• Wear appropriate safety equipment.• Be careful when removing bolts and washers on top of the module not to drop anythinginside the module.• Use a lifting device:• Attach the lifting device securely to the module lifting eyes before removing themodule fastening bolts. Keep the lifting device attached to the module until youhave lifted the module onto a pallet and made sure that the module is supportedand cannot topple over.• Lift a replacement module only with a lifting device. Keep the lifting device attachedto the module during the work until you are tighten the module fastening bolts.• Do not tilt the module. Do not leave the module unattended on a floor.• When you push the replacement module into the cabinet, keep your fingers away fromthe edge of the module edges to avoid pinching them between the module and thecabinet.Obey these instructions for replacing the module. Refer to the drawings below.1. Stop the drive and do the steps in section Electrical safety precautions (page 19) beforeyou start the work.2. Open the cubicle door.3. Remove the shroud.4. Unplug the plug connector on top of the module (a), and the plug connector and fiberoptic connector in front of the module (b).5. Remove the lower support bracket of the module.6. Remove the fastening bolts of the DC busbars (a) and the DC busbars carefully. Donot drop anything inside the module. Remove the fastening bolts of the AC busbars (b).7. Remove the cooling fan plug connector (a) and the cooling fan (b). See also sectionabout the cooling fan replacement.8. Remove the side fastening screws of the module on the top (a) and bottom (b).9. Attach a lifting device to the lifting eyes of the module (a).10. Remove the upper support brackets of the module (a).11. Pull the module out of the cabinet carefully. Keep the weight on the lifting deviceconstantly.12. Lift the module down onto a pallet.13. Keep the lifting chain attached to the module and attach the module safely to the pallet.160 Maintenance
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