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46 Planning the electrical installation

Table of Contents

Default Chapter2
- List of Related Manuals2
- Table of Contents5
Safety17
- What this Chapter Contains17
- Use of Warnings17
- Safety in Installation and Maintenance18
  - Electrical Safety18
  - General Safety19
- Safe Start-Up and Operation20
Introduction to the Manual21
- What this Chapter Contains21
- Applicability21
- Target Audience21
- Purpose of the Manual21
- Contents of this Manual22
- Related Documents23
- Categorization by Frame Size23
- Quick Installation and Commissioning Flowchart24
Operation Principle and Hardware Description25
- What this Chapter Contains25
- Operation Principle25
  - Product Overview26
    - Layout26
    - Power Connections and Control Interfaces27
- Type Designation Label28
- Type Designation Key29
Mechanical Installation31
- What this Chapter Contains31
- Checking the Installation Site31
  - Requirements for the Installation Site31
- Required Tools32
- Unpacking33
- Checking the Delivery33
- Installing34
Planning the Electrical Installation37
- What this Chapter Contains37
- Implementing the AC Power Line Connection37
- Selecting the Supply Disconnecting Device (Disconnecting Means)37
  - European Union38
  - Other Regions38
- Checking the Compatibility of the Motor and Drive38
- Selecting the Power Cables38
- Selecting the Control Cables40
- Routing the Cables41
  - Control Cable Ducts42
- Protecting the Drive, Input Power Cable, Motor and Motor Cable in Short Circuit Situations and against Thermal Overload43
- Implementing the Safe Torque off (STO) Function44
- Using Residual Current Devices (RCD) with the Drive44
- Using a Safety Switch between the Drive and the Motor44
- Implementing a Bypass Connection44
- Protecting the Contacts of Relay Outputs45
Electrical Installation47
- What this Chapter Contains47
- Checking the Insulation of the Assembly47
- Checking the Compatibility with IT (Ungrounded) and Corner-Grounded TN Systems48
- Connecting the Power Cables49
  - Connection Diagram49
  - Connection Procedure50
- Connecting the Control Cables51
Installation Checklist57
- Checking the Installation57
Start-Up, Control with I/O and ID Run59
- What this Chapter Contains59
- How to Start up the Drive59
- How to Control the Drive through the I/O Interface68
- How to Perform the ID Run69
  - ID Run Procedure69
Control Panels73
- What this Chapter Contains73
- About Control Panels73
- Applicability73
- Basic Control Panel75
- Assistant Control Panel87
Application Macros109
- What this Chapter Contains109
- Overview of Macros109
- Summary of the I/O Connections of the Application Macros111
- ABB Standard Macro112
  - Default I/O Connections112
- 3-Wire Macro113
  - Default I/O Connections113
- Alternate Macro114
  - Default I/O Connections114
- Motor Potentiometer Macro115
  - Default I/O Connections115
- Hand/Auto Macro116
  - Default I/O Connections116
- PID Control Macro117
  - Default I/O Connections117
- Torque Control Macro118
  - Default I/O Connections118
- User Macros119
Program Features121
- What this Chapter Contains121
- Start-Up Assistant121
  - Introduction121
  - Default Order of the Tasks122
  - List of the Tasks and the Relevant Drive Parameters123
  - Contents of the Assistant Displays124
- Local Control Vs. External Control125
  - Local Control125
  - External Control126
  - Settings126
  - Diagnostics126
  - Block Diagram: Start, Stop, Direction Source for EXT1127
  - Block Diagram: Reference Source for EXT1127
- Reference Types and Processing128
  - Settings128
  - Diagnostics128
- Reference Trimming129
  - Settings129
  - Example130
- Programmable Analog Inputs130
  - Settings130
  - Diagnostics131
- Programmable Analog Output131
  - Settings131
- Programmable Digital Inputs132
  - Settings132
  - Diagnostics132
- Programmable Relay Output133
  - Settings133
  - Diagnostics133
- Frequency Input133
- Transistor Output134
  - Settings134
  - Diagnostics134
- Actual Signals134
  - Diagnostics135
- Motor Identification135
  - Settings135
- Power Loss Ride-Through136
  - Settings136
- DC Magnetizing136
- Maintenance Trigger137
  - Settings137
- DC Hold137
- Speed Compensated Stop137
- Flux Braking138
  - Settings139
- Flux Optimization139
- Acceleration and Deceleration Ramps139
- Critical Speeds140
  - Settings140
- Constant Speeds140
- Custom U/F Ratio141
  - Settings141
  - Diagnostics141
- Speed Controller Tuning142
  - Settings142
  - Diagnostics143
  - Speed Control Performance Figures143
  - Torque Control Performance Figures143
- Scalar Control144
  - Settings144
- IR Compensation for a Scalar Controlled Drive144
- Programmable Protection Functions144
  - Ai<Min144
  - Panel Loss145
  - External Fault145
  - Stall Protection145
  - Motor Thermal Protection145
  - Underload Protection146
  - Earth Fault Protection146
  - Incorrect Wiring146
  - Input Phase Loss147
- Pre-Programmed Faults147
  - Overcurrent147
  - DC Overvoltage147
  - DC Undervoltage147
  - Drive Temperature147
  - Short Circuit147
  - Internal Fault147
- Operation Limits147
  - Settings147
- Power Limit148
- Automatic Resets148
  - Settings148
  - Diagnostics148
- Supervisions148
- Parameter Lock149
  - Settings149
- PID Control149
  - Process Controller PID1149
  - External/Trim Controller PID2149
  - Block Diagrams150
  - Settings152
  - Diagnostics152
- Sleep Function for the Process PID (PID1) Control153
  - Example154
  - Settings154
  - Diagnostics154
- Motor Temperature Measurement through the Standard I/O155
  - Settings156
  - Diagnostics156
- Control of a Mechanical Brake157
  - Example157
  - Operation Time Scheme158
  - State Shifts159
  - Settings160
- Jogging161
  - Settings162
  - Diagnostics162
- Timed Functions163
  - Example164
  - Settings165
- Timer165
  - Diagnostics165
- Counter165
  - Diagnostics166
- Sequence Programming166
  - Settings166
  - Diagnostics167
  - State Shifts168
  - Example 1169
  - Example 2170
- Safe Torque off (STO) Function174
Actual Signals and Parameters175
- What this Chapter Contains175
- Terms and Abbreviations175
- Fieldbus Addresses175
- Fieldbus Equivalent176
- Default Values with Different Macros176
- Actual Signals178
Fieldbus Control with Embedded Fieldbus301
- What this Chapter Contains301
- System Overview301
- Setting up Communication through the Embedded Modbus303
- Drive Control Parameters304
- Fieldbus Control Interface307
- Fieldbus References308
- Modbus Mapping312
- Communication Profiles315
  - ABB Drives Communication Profile315
  - DCU Communication Profile320
Fieldbus Control with Fieldbus Adapter325
- What this Chapter Contains325
- System Overview325
- Setting up Communication through a Fieldbus Adapter Module327
- Drive Control Parameters328
- Fieldbus Control Interface330
- Communication Profile331
- Fieldbus References332
Fault Tracing335
- What this Chapter Contains335
- Safety335
- Alarm and Fault Indications335
- How to Reset335
- Fault History336
- Alarm Messages Generated by the Drive337
- Alarms Generated by the Basic Control Panel341
- Fault Messages Generated by the Drive344
- Embedded Fieldbus Faults352
Maintenance and Hardware Diagnostics353
- What this Chapter Contains353
- Maintenance Intervals353
- Cooling Fan354
  - Replacing the Cooling Fan (Frame Sizes R1354
- Capacitors355
  - Reforming the Capacitors355
- Power Connections355
- Control Panel356
  - Cleaning the Control Panel356
  - Changing the Battery in the Assistant Control Panel356
- Leds356
Technical Data357
- What this Chapter Contains357
- Ratings358
  - Definitions359
  - Sizing359
  - Derating359
- Power Cable Sizes and Fuses361
- Dimensions, Weights and Free Space Requirements363
  - Dimensions and Weights363
  - Free Space Requirements363
- Losses, Cooling Data and Noise364
  - Losses and Cooling Data364
  - Noise365
- Terminal and Lead-Through Data for the Power Cables366
- Terminal and Lead-Through Data for the Control Cables366
- Electric Power Network Specification367
- Motor Connection Data367
- Control Connection Data369
- Brake Resistor Connection370
- Common DC Connection370
- Efficiency370
- Degrees of Protection370
- Ambient Conditions371
- Materials372
- Applicable Standards372
- CE Marking373
  - Compliance with the European EMC Directive373
- Compliance with en 61800-3:2004373
  - Definitions373
  - Category C1373
  - Category C2374
  - Category C3374
- UL Marking375
  - UL Checklist375
- C-Tick Marking376
- TÜV NORD Safety Approved Mark376
- Rohs Marking376
- Compliance with the Machinery Directive376
- Patent Protection in the USA377
Dimension Drawings379
- Frame Sizes R0 and R1, IP20 (Cabinet Installation) / UL Open380
- Frame Sizes R0 and R1, IP20 / NEMA 1381
- Frame Size R2, IP20 (Cabinet Installation) / UL Open382
- Frame Size R2, IP20 / NEMA 1383
- Frame Size R3, IP20 (Cabinet Installation) / UL Open384
- Frame Size R3, IP20 / NEMA 1385
- Frame Size R4, IP20 (Cabinet Installation) / UL Open386
- Frame Size R4, IP20 / NEMA 1387
Appendix: Resistor Braking389
- What this Chapter Contains389
- Planning the Braking System389
- Electrical Installation392
- Start-Up392
Appendix: Extension Modules393
- What this Chapter Contains393
- Extension Modules393
- MTAC-01 Pulse Encoder Interface Module396
- MREL-01 Output Relay Module396
- MPOW-01 Auxiliary Power Module397
Appendix: Safe Torque off (STO)399
- What this Appendix Contains399
- Basics399
- Program Features, Settings and Diagnostics400
  - Operation of the STO Function and Its Diagnostics Function400
- STO Status Indications401
  - STO Function Activation and Indication Delays402
- Installation402
- Start-Up and Commissioning403
- Technical Data403
  - STO Components403
    - Data Related to Safety Standards404
Further Information405
- Product and Service Inquiries405

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