ACTIVE CUBEOperating InstructionsFrequency inverter 230 V / 400 V0.25 kW ... 132 kW

TABLE OF CONTENTS

1 General information about the documentation ........................................................... 10

1.1 Instruction manuals .................................................................................. 10

1.2 This document........................................................................................... 12

1.3 Warranty and liability ............................................................................... 12

1.4 Obligation ................................................................................................. 13

1.5 Copyright .................................................................................................. 13

1.6 Storage ...................................................................................................... 13

2 General safety instructions and information on use .................................................... 14

2.1 Terminology .............................................................................................. 14

2.2 Designated use ......................................................................................... 15

2.3 Misuse ....................................................................................................... 15 2.3.1 Explosion protection ........................................................................................ 15

2.4 Residual risks ............................................................................................ 16

2.5 Safety and warning signs at frequency inverter ....................................... 16

2.6 Warning information and symbols used in the user manual .................... 17 2.6.1 Hazard classes ................................................................................................ 17 2.6.2 Hazard symbols............................................................................................... 17 2.6.3 Prohibition signs .............................................................................................. 17 2.6.4 Personal safety equipment ............................................................................... 18 2.6.5 Recycling ........................................................................................................ 18 2.6.6 Grounding symbol ........................................................................................... 18 2.6.7 ESD symbol .................................................................................................... 18 2.6.8 Information signs ............................................................................................ 18

2.7 Directives and guidelines to be adhered to by the operator .................... 19

2.8 Operator's general plant documentation .................................................. 19

2.9 Operator's/operating staff's responsibilities ............................................ 19 2.9.1 Selection and qualification of staff .................................................................... 19 2.9.2 General work safety ........................................................................................ 19

2.10 Organizational measures .......................................................................... 20 2.10.1 General .......................................................................................................... 20 2.10.2 Use in combination with third-party products ..................................................... 20 2.10.3 Transport and Storage ..................................................................................... 20 2.10.4 Handling and installation .................................................................................. 20 2.10.5 Electrical connections ...................................................................................... 20

2.10.5.1 The five safety rules ........................................................................................ 21 2.10.6 Safe operation ................................................................................................ 21 2.10.7 Maintenance and service/troubleshooting .......................................................... 22 2.10.8 Final decommissioning ..................................................................................... 22

2.11 Safety Instructions on Function Safe Torque Off (STO) ........................ 23

3 Scope of Supply ............................................................................................................ 25

3.1 ACU 201 (up to 3.0 kW) and 401 (up to 4.0 kW) ...................................... 25

3.2 ACU 201 (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW) .................................. 26

3.3 ACU 401 (18.5 to 30.0 kW) ....................................................................... 27

3.4 ACU 401 (37.0 to 65.0 kW) ....................................................................... 28

3.5 ACU 401 (75.0 to 132.0 kW) ..................................................................... 29

06/13 Operating Instructions ACU 3

4 Technical Data .............................................................................................................. 30

4.1 General technical data .............................................................................. 30

4.2 Technical Data Control Electronic Equipment ....................................... 31

4.3 ACU 201 (0.25 to 1.1 kW, 230 V) .............................................................. 32

4.4 ACU 201 (1.5 to 3.0 kW, 230 V) ................................................................ 33

4.5 ACU 201 (4.0 to 9.2 kW, 230 V) ................................................................ 34

4.6 ACU 401 (0.25 to 1.5 kW, 400 V) .............................................................. 35

4.7 ACU 401 (1.85 to 4.0 kW, 400 V) .............................................................. 36

4.8 ACU 401 (5.5 to 15.0 kW, 400 V) .............................................................. 37

4.9 ACU 401 (18.5 to 30.0 kW, 400 V) ............................................................ 38

4.10 ACU 401 (37.0 to 65.0 kW, 400 V) ............................................................ 39

4.11 ACU 401 (75.0 to 132.0 kW, 400 V) .......................................................... 40

4.12 Operation diagrams .................................................................................. 41

5 Mechanical Installation ................................................................................................ 42

5.1 ACU 201 (up to 3.0 kW) and 401 (up to 4.0 KW) ..................................... 43

5.2 ACU 201 (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW) .................................. 44

5.3 ACU 401 (18.5 to 30.0 kW) ....................................................................... 45

5.4 ACU 401 (37.0 to 65.0 kW) ....................................................................... 46

5.5 ACU 401 (75.0 to 132.0 kW) ..................................................................... 47

6 Electrical Installation ................................................................................................... 48

6.1 EMC Information ....................................................................................... 50

6.2 Block diagram ........................................................................................... 52

6.3 Optional Components ............................................................................... 53

6.4 Connection of Unit .................................................................................... 54 6.4.1 Dimensioning of conductor cross-section ........................................................... 54

6.4.1.1 Typical cross-sections ...................................................................................... 54 6.4.2 Mains Connection ............................................................................................ 56 6.4.3 Motor Connection ............................................................................................ 56

6.4.3.1 Length of motor cables, without filter ................................................................ 57 6.4.3.2 Motor cable length, with output filter dU/dt ....................................................... 57 6.4.3.3 Motor cable length, with sinus filter .................................................................. 57 6.4.3.4 Group drive .................................................................................................... 58 6.4.3.5 Speed sensor connection ................................................................................. 58

6.4.4 Connection of a Brake Resistor ......................................................................... 59

6.5 Connection of types .................................................................................. 60 6.5.1 ACU 201 (up to 3.0 kW) and 401 (up to 4.0 kW) ................................................ 60 6.5.2 ACU 201 (4.0 to 9.2 kW) and 401 (5.5 to 15.0 kW) ............................................ 62 6.5.3 ACU 401 (18.5 to 30.0 kW) .............................................................................. 64 6.5.4 ACU 401 (37.0 to 65.0 kW) .............................................................................. 66 6.5.5 ACU 401 (75.0 to 132.0 kW) ............................................................................ 68

6.6 Control Terminals....................