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214

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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