ABB ACQ580-34 - Replacing the LCL Filter Module

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11. Pull the drive module carefully out of the cabinet preferably with help from another person.

12. Install the new module in reverse order.

Replacing the LCL filter module

Replace the LCL filter module in the same way as the drive module.

156 Maintenance

Table of Contents

Default Chapter5
- Table of Contents5
- Table of Contents7
1 Safety Instructions15
- Contents of this Chapter15
- Use of Warnings and Notes15
- General Safety in Installation, Start-Up and Maintenance16
- Electrical Safety in Installation, Start-Up and Maintenance18
- General Safety in Operation22
- Additional Instructions for Permanent Magnet Motor Drives22
  - Safety in Installation, Start-Up, Maintenance22
  - Safety in Operation23
2 Introduction to the Manual25
- Contents of this Chapter25
- Applicability25
- Target Audience25
- Purpose of the Manual25
- Categorization by Frame Size and Option Code25
- Quick Installation, Commissioning and Operating Flowchart26
- Terms and Abbreviations27
- Related Documents27
3 Operation Principle and Hardware Description29
- Contents of this Chapter29
- Operation Principle29
- Layout32
- Overview of Power and Control Connections37
- Type Designation Label37
- Type Designation Key38
  - Basic Code38
  - Option Codes39
4 Generic Cabinet Planning Instructions41
- Contents of this Chapter41
- Limitation of Liability41
- Cabinet Construction41
- Cooling and Degrees of Protection43
- EMC Requirements46
- Attaching the Cabinet48
- Cabinet Placement on a Cable Channel48
- Cubicle Heaters49
- Attaching the Control Panel on the Cabinet Door49
5 Guidelines for Planning the Mechanical Installation51
- Contents of this Chapter51
- Installation Positions of the Drive Module51
- Layout Example, Door Closed52
- Layout Example, Door Open (Standard Drive Module Configuration)53
- Layout Example, Door Open (Option +B051)54
- Cooling Solutions55
- Preventing the Recirculation of Hot Air55
  - Bookshelf Mounting (Standard Drive Module Configuration)56
  - Bookshelf Mounting (Option +B051)58
- Required Free Space58
  - Free Space at the Top of the Drive Module59
  - Free Space Around the Drive Module59
- ABB Air Inlet and Outlet Kits59
6 Mechanical Installation61
- Contents of this Chapter61
- Examining the Installation Site61
- Moving and Unpacking61
  - Package Drawings62
- Lifting66
- Attaching the Drive Module and LCL Filter Module to a Mounting Plate or Wall67
- Attaching the Drive Module to the LCL Filter Module67
- Attaching the Drive Module and the LCL Filter Module to the Enclosure Base67
- Grounding the Drive Module and the LCL Filter Module68
- Installing the Drive in Rittal VX25 Enclosure68
- Optional Input Power Cable Connection Terminals and Ground Busbar Assembly (+H370)69
7 Guidelines for Planning the Electrical Installation71
- Contents of this Chapter71
- Limitation of Liability71
- Selecting the Main Supply Disconnecting Device71
  - European Union71
  - North America72
  - Other Regions72
- Selecting the Main Contactor72
- Examining the Compatibility of the Motor and Drive72
  - Protecting the Motor Insulation and Bearings72
  - Requirements Table73
- Selecting the Power Cables78
  - General Guidelines78
  - Typical Power Cable Sizes79
  - Power Cable Types79
  - Additional Guidelines, North America81
    - Metal Conduit82
  - Power Cable Shield82
- Selecting the Control Cables83
  - Shielding83
  - Signals in Separate Cables83
  - Signals that Can be Run in the same Cable83
  - Relay Cable83
  - Control Panel to Drive Cable83
  - PC Tool Cable84
- Routing the Cables84
  - General Guidelines - IEC84
  - General Guidelines - North America85
  - Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable85
  - Separate Control Cable Ducts86
- Implementing Motor and Motor Cable Short-Circuit and Thermal Overload Protection86
- Protecting the Motor and Motor Cable in Short-Circuits86
  - Protecting the Motor Cables against Thermal Overload86
  - Protecting the Motor against Thermal Overload86
  - Protecting the Motor against Overload Without Thermal Model or Temperature Sensors87
- Protecting the Drive and the Input Power Cable in Short-Circuits87
- Protecting the Drive against Thermal Overload87
- Protecting the Input Power Cable against Thermal Overload88
- Implementing a Motor Temperature Sensor Connection88
  - Connecting Motor Temperature Sensor to the Drive Via an Option Module88
- Protecting the Drive against Ground Faults89
  - Residual Current Device Compatibility89
- Implementing the Emergency Stop Function89
- Implementing the Safe Torque off Function89
- Implementing the Undervoltage Control (Power-Loss Ride-Through)90
- Implementing the Functions Provided by the FSO-XX Safety Functions Module90
- Using Power Factor Compensation Capacitors with the Drive90
- Using a Safety Switch between the Drive and the Motor90
- Implementing an ATEX-Certified Motor Thermal Protection91
- Controlling a Contactor between Drive and Motor91
- Implementing a Bypass Connection91
  - Example Bypass Connection92
    - Switching the Motor Power Supply from Drive to Direct-On-Line92
    - Switching the Motor Power Supply from Direct-On-Line to Drive93
- Protecting the Contacts of Relay Outputs93
8 Electrical Installation95
- Contents of this Chapter95
- Safety95
- Grounding the Motor Cable Shield at the Motor End95
- Measuring the Insulation96
- Grounding System Compatibility Check96
- Connecting the Power Cables99
- Connecting the Control Cables to the Integrated Control Unit104
  - Connecting External Power Supply Wires to the Control Units105
- Connecting a Control Panel106
- Connecting a Remote Panel, or Chaining One Panel to Several Drives106
- Connecting a PC107
- Installing Option Modules107
9 Control Unit111
- Contents of this Chapter111
- Layout112
- Default I/O Connection Diagram113
  - Switches114
- Additional Information on I/O Connections114
- Technical Data118
10 External Control Unit (Option +P906)123
- Contents of this Chapter123
- Product Overview123
  - Layout124
  - Cables124
- Unpacking the Delivery125
- Installing the Control Unit125
  - Installation Procedure126
    - Optical Components126
  - Connecting the Control Unit to the Drive Module130
- Maintenance131
- Dimension Drawing132
11 Installation Example in Rittal VX25 Enclosure133
- Contents of this Chapter133
- Limitation of Liability133
- Safety133
- Required Parts134
- Required Tools134
- Overall Flowchart of the Installation Process134
- Installing the Drive Module and LCL Filter Module into an Enclosure135
- Connecting the Motor Cables and Installing the Shrouds (Option +B051)136
- Connecting the Input Cables and Installing the Shrouds (Option +B051)137
- Installing the Air Baffles137
- Installing the Roof and Door (Rittal Parts)138
- Removing the Protective Covering from the Drive Module and LCL Filter Module Air Outlet139
12 Installation Checklist141
- Contents of this Chapter141
- Checklist141
13 Start-Up143
- Contents of this Chapter143
- Start-Up Procedure143
14 Fault Tracing145
- Contents of this Chapter145
- Leds145
  - Drive Leds145
  - Control Panel Leds146
- Warning and Fault Messages146
15 Maintenance147
- Contents of this Chapter147
- Maintenance Intervals147
- Cleaning the Interior of the Cabinet148
- Cleaning the Interior of the Heatsink149
- Cleaning the Interior of the LCL Filter150
- Fans150
- Replacing the Standard Drive Module153
- Replacing the LCL Filter Module156
- Capacitors157
  - Reforming the Capacitors157
- Control Panel157
  - Cleaning the Control Panel157
  - Replacing the Battery157
- Functional Safety Components158
16 Ordering Information159
- Contents of this Chapter159
- Control Panel Options159
- Output (Du/Dt) Filters160
- Cabinet Ventilation160
  - Air Inlet Kits160
  - Air Outlet Kits162
- Cooling Fans163
- Control Panel Mounting Platforms163
- Retrofit Accessory Kits163
17 Technical Data165
- Contents of this Chapter165
- Electrical Ratings165
  - When Is Derating Necessary167
  - Surrounding Air Temperature Derating167
  - Altitude Derating167
- Fuses (IEC)169
- Fuses (UL)170
- Dimensions, Weights and Free Space Requirements171
- Losses, Cooling Data and Noise172
- Terminal and Entry Data for the Power Cables172
- Power Cables173
- Terminal Data for the Control Cables173
- Electrical Power Network Specification174
- Motor Connection Data175
- Control Panel Type176
- Efficiency176
- Energy Efficiency Data (EU Ecodesign)176
- Protection Classes for Module176
- Surrounding Air Conditions176
- Materials177
- Applicable Standards178
- Markings178
- EMC Compliance (IEC/EN 61800-3:2004)179
  - Definitions179
  - Category C3179
  - Category C4180
- UL and CSA Checklist181
- Design Lifetime Expectancy181
- EU Declaration of Conformity (Machinery Directive)181
- Disclaimer182
  - Generic Disclaimer182
  - Cybersecurity Disclaimer182
18 Dimension Drawings183
- Contents of this Chapter183
- Standard Configuration (+E208 and +E210 Included)184
- Drive Module with Option +B051185
- Drive Module with Options +B051, +H370186
- LCL Filter Module187
- Bottom Plate188
- Air Baffles189
  - Material of the Air Baffles189
19 Example Circuit Diagrams191
- Contents of this Chapter191
- Example Circuit Diagram191
20 The Safe Torque off Function193
- Contents of this Chapter193
- Description193
  - Compliance with the European Machinery Directive194
- Wiring195
- Operation Principle200
- Start-Up Including Validation Test201
- Use203
- Maintenance204
  - Competence204
- Fault Tracing205
- Safety Data206
21 CHDI-01 115/230 V Digital Input Extension Module209
- Contents of this Chapter209
- Product Overview209
- Layout and Connection Examples210
- Mechanical Installation211
- Electrical Installation211
  - Wiring211
- Start-Up212
  - Setting the Parameters212
    - Parameter Setting Example for Relay Output212
- Fault and Warning Messages212
- Technical Data212
- Dimension Drawing213
22 CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)215
- Contents of this Chapter215
- Product Overview215
- Layout and Example Connections216
- Mechanical Installation217
- Electrical Installation217
  - Wiring217
- Start-Up218
- Setting the Parameters218
  - Diagnostics219
    - Faults and Warning Messages219
    - Leds219
- Technical Data219
- Dimension Drawing220
23 CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)221
- Contents of this Chapter221
- Product Overview221
- Layout and Example Connections222
- Mechanical Installation222
- Electrical Installation223
  - Necessary Tools and Instructions223
  - Wiring223
- Start-Up223
  - Setting the Parameters223
- Diagnostics224
  - Faults and Warning Messages224
  - Leds224
- Technical Data224
- Dimension Drawing225
24 Filters227
- Contents of this Chapter227
- Du/Dt Filters227
25 Step-By-Step Drawings for an Installation Example of Standard Drive Configuration in Rittal VX25 800 MM Wide Enclosure229
- Handling the Drive Module, Power Cable Connection Diagram229
- Installing the Drive Module and LCL Filter Module into a Rittal VX25 Enclosure231
- Connecting the Motor Cables and Installing the Shrouds236
- Connecting the Input Power Cables and Installing the Shrouds239
- Installing the Air Baffles and Removing the Cardboard Covers240
- Further Information243

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