Product Related Information

Overview

Health and safety risks arising from the Lexium 62 Drive System have been reduced. However, residual risks remain, since the Lexium 62 Drive System works with electrical voltage and currents as well as movement.

If activities involve residual risks, a safety message is made at the appropriate points. This includes potential hazards that may arise, their possible consequences, and describes preventive measures to avoid the hazards.

Electrical Parts

DANGER
	ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires. Place a "Do Not Turn On" or equivalent hazard label on all power switches and lock them in the non-energized position. Wait 15 minutes to allow the residual energy of the DC bus capacitors to discharge. Measure the voltage on the DC bus with a properly rated voltage sensing device and verify that the voltage is less than 42.4 Vdc. Do not assume that the DC bus is voltage-free when the DC bus LED is off. Block the motor shaft to prevent rotation prior to performing any type of work on the drive system. Do not create a short-circuit across the DC bus terminals or the DC bus capacitors. Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a proper ground connection exists before applying power to the unit. Use only the specified voltage when operating this equipment and any associated products. Failure to follow these instructions will result in death or serious injury.

DANGER

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires.
Place a "Do Not Turn On" or equivalent hazard label on all power switches and lock them in the non-energized position.
Wait 15 minutes to allow the residual energy of the DC bus capacitors to discharge.
Measure the voltage on the DC bus with a properly rated voltage sensing device and verify that the voltage is less than 42.4 Vdc.
Do not assume that the DC bus is voltage-free when the DC bus LED is off.
Block the motor shaft to prevent rotation prior to performing any type of work on the drive system.
Do not create a short-circuit across the DC bus terminals or the DC bus capacitors.
Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a proper ground connection exists before applying power to the unit.
Use only the specified voltage when operating this equipment and any associated products.

Failure to follow these instructions will result in death or serious injury.

DANGER
	ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Operate electrical components only with a connected protective ground (earth) cable. After the installation, verify the secure connection of the protective ground (earth) cable to all electrical devices to ensure that connection complies with the connection diagram. Before enabling the device, safely cover the live components to prevent contact. Do not touch the electrical connection points of the components when the module is energized. Provide protection against indirect contact. Connect and disconnect cables and terminals only after you have verified that the power has been removed from the system. Insulate the unused conductors on both ends of the motor cable. Failure to follow these instructions will result in death or serious injury.

DANGER

ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Operate electrical components only with a connected protective ground (earth) cable.
After the installation, verify the secure connection of the protective ground (earth) cable to all electrical devices to ensure that connection complies with the connection diagram.
Before enabling the device, safely cover the live components to prevent contact.
Do not touch the electrical connection points of the components when the module is energized.
Provide protection against indirect contact.
Connect and disconnect cables and terminals only after you have verified that the power has been removed from the system.
Insulate the unused conductors on both ends of the motor cable.

Failure to follow these instructions will result in death or serious injury.

DANGER
	ELECTRIC SHOCK CAUSED BY HIGH LEAKAGE (TOUCH) VOLTAGE Attach the terminal covers on the extremities of the Bus Bar Module combination. Apply power to the device only if the terminal covers have been attached to the extremities of the Bus Bar Module combination. Failure to follow these instructions will result in death or serious injury.

DANGER
	ELECTRIC SHOCK CAUSED BY HIGH LEAKAGE (TOUCH) VOLTAGE Before working on the product, make sure that it is de-energized. After disconnection, do not touch connector CN6 mains connection on the Lexium 62 Power Supply module as it still carries hazardous voltages for approximately one second. Only operate the Lexium 62 components in a control cabinet that cannot be opened without the help of tools. Failure to follow these instructions will result in death or serious injury.

DANGER

ELECTRIC SHOCK CAUSED BY HIGH LEAKAGE (TOUCH) VOLTAGE

Before working on the product, make sure that it is de-energized.
After disconnection, do not touch connector CN6 mains connection on the Lexium 62 Power Supply module as it still carries hazardous voltages for approximately one second.
Only operate the Lexium 62 components in a control cabinet that cannot be opened without the help of tools.

Failure to follow these instructions will result in death or serious injury.

Assembly and Handling

This product has a leakage current greater than 3.5 mA. If the protective ground connection is interrupted, a hazardous touch current may flow if the housing is touched.

DANGER
	INSUFFICIENT GROUNDING Use a protective ground copper conductor with at least 10 mm² (AWG 6) or two protective ground copper conductors with the same or larger cross section of the conductors supplying the power terminals. Verify compliance with all local and national electrical code requirements as well as all other applicable regulations with respect to grounding of all equipment. Failure to follow these instructions will result in death or serious injury.

DANGER

INSUFFICIENT GROUNDING

Use a protective ground copper conductor with at least 10 mm² (AWG 6) or two protective ground copper conductors with the same or larger cross section of the conductors supplying the power terminals.
Verify compliance with all local and national electrical code requirements as well as all other applicable regulations with respect to grounding of all equipment.

Failure to follow these instructions will result in death or serious injury.

WARNING
	CRUSHING, SHEARING, CUTTING AND HITTING DURING HANDLING Observe the general construction and safety regulations for handling and assembly. Use appropriate mounting and transport equipment and use appropriate tools. Prevent clamping and crushing by taking appropriate precautions. Cover edges and angles to protect against cutting damage. Wear appropriate protective clothing (for example, protective goggles, protective boots, protective gloves). Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

CRUSHING, SHEARING, CUTTING AND HITTING DURING HANDLING

Observe the general construction and safety regulations for handling and assembly.
Use appropriate mounting and transport equipment and use appropriate tools.
Prevent clamping and crushing by taking appropriate precautions.
Cover edges and angles to protect against cutting damage.
Wear appropriate protective clothing (for example, protective goggles, protective boots, protective gloves).

Failure to follow these instructions can result in death, serious injury, or equipment damage.

Hot Surfaces

The metal surfaces of the product may exceed 65 °C (149 °F) (for bare metal) during operation.

WARNING
	HOT SURFACES Avoid unprotected contact with hot surfaces. Do not allow flammable or heat-sensitive parts in the immediate vicinity of hot surfaces. Verify that the heat dissipation is sufficient by performing a test run under maximum load conditions. Failure to follow these instructions can result in death, serious injury, or equipment damage.

Magnetic and Electromagnetic Fields

Conductors and motors can generate strong local electrical and magnetic fields. This can cause interference in sensitive devices.

WARNING
	ELECTROMAGNETIC FIELDS Keep persons with electronic medical implants, such as pacemakers, away from the motor and the conductors. Do not place electromagnetically sensitive devices in the vicinity of the motor or of the conductors. Failure to follow these instructions can result in death, serious injury, or equipment damage.

Hazardous Movements

There can be different sources of hazardous movements:

No, or incorrect, homing of the drive
Wiring or cabling errors
Errors in the application program
Component errors
Error in the measured value and signal transmitter

NOTE: Provide for personal safety by primary equipment monitoring or measures. Do not rely only on the internal monitoring of the drive components. Adapt the monitoring or other arrangements and measures to the specific conditions of the installation in accordance with a risk and error analysis.

DANGER
	UNAVAILABLE OR INADEQUATE PROTECTION DEVICE(S) Prevent entry to a zone of operation with, for example, protective fencing, mesh guards, protective coverings, or light barriers. Dimension the protective devices properly and do not remove them. Do not make any modifications that can degrade, incapacitate, or in any way invalidate protection devices. Before accessing the drives or entering the zone of operation, bring the drives and the motors they control to a stop. Protect existing workstations and operating terminals against unauthorized operation. Position EMERGENCY STOP switches so that they are easily accessible and can be reached quickly. Validate the functionality of EMERGENCY STOP equipment before start-up and during maintenance periods. Prevent unintentional start-up by disconnecting the power connection of the drive using the EMERGENCY STOP circuit or using an appropriate lock-out tag-out sequence. Validate the system and installation before the initial start-up. Avoid operating high-frequency, remote control, and radio devices close to the system electronics and their feed lines, and perform, if necessary, an EMC validation of the system. Failure to follow these instructions will result in death or serious injury.

DANGER

UNAVAILABLE OR INADEQUATE PROTECTION DEVICE(S)

Prevent entry to a zone of operation with, for example, protective fencing, mesh guards, protective coverings, or light barriers.
Dimension the protective devices properly and do not remove them.
Do not make any modifications that can degrade, incapacitate, or in any way invalidate protection devices.
Before accessing the drives or entering the zone of operation, bring the drives and the motors they control to a stop.
Protect existing workstations and operating terminals against unauthorized operation.
Position EMERGENCY STOP switches so that they are easily accessible and can be reached quickly.
Validate the functionality of EMERGENCY STOP equipment before start-up and during maintenance periods.
Prevent unintentional start-up by disconnecting the power connection of the drive using the EMERGENCY STOP circuit or using an appropriate lock-out tag-out sequence.
Validate the system and installation before the initial start-up.
Avoid operating high-frequency, remote control, and radio devices close to the system electronics and their feed lines, and perform, if necessary, an EMC validation of the system.

Failure to follow these instructions will result in death or serious injury.

Drive systems may perform unanticipated movements because of incorrect wiring, incorrect settings, incorrect data or other errors.

WARNING
	UNINTENDED MOVEMENT OR MACHINE OPERATION Carefully install the wiring in accordance with the EMC requirements. Do not operate the product with undetermined settings and data. Perform comprehensive commissioning tests that include verification of configuration settings and data that determine position and movement. Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

UNINTENDED MOVEMENT OR MACHINE OPERATION

Carefully install the wiring in accordance with the EMC requirements.
Do not operate the product with undetermined settings and data.
Perform comprehensive commissioning tests that include verification of configuration settings and data that determine position and movement.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

PELV Circuits

All signal and control voltages must be designed as PELV (Protective Extra Low Voltage) circuits. In particular, this implies protective measures against direct and indirect contact with hazardous voltage by:

Ensuring that the voltage with respect to PE (Protective earth ground) remains below 30 Vdc.
Ensuring separation between PELV circuits and other circuits implemented in the cabinet.

Connect GND / 0 V to PE at least at one point in the control cabinet.

Separate high and low voltage wiring and respect the standard IEC 61800-5-1, Adjustable speed electrical power drive systems - safety requirements.

DANGER
	ELECTRIC SHOCK DUE TO INADEQUATE PROTECTIVE SEPARATION Only connect devices, electrical components, or lines to the signal voltage connectors of these products that feature a sufficient, protective separation from the connected circuits in accordance with the standards (IEC 61800-5-1: Adjustable speed electrical power drive systems - safety requirements). Failure to follow these instructions will result in death or serious injury.

DANGER

ELECTRIC SHOCK DUE TO INADEQUATE PROTECTIVE SEPARATION

Only connect devices, electrical components, or lines to the signal voltage connectors of these products that feature a sufficient, protective separation from the connected circuits in accordance with the standards (IEC 61800-5-1: Adjustable speed electrical power drive systems - safety requirements).

Failure to follow these instructions will result in death or serious injury.