Mechanical Installation
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Handling Requirements
- Module weight: 18.28 kg (40.3 lb) – use lifting equipment for alignment¹
- Chassis material: Aluminum alloy (5052-H32/5754-H22) with conductive iridite finish¹
- Mounting torque: 1.5 Nm ±0.3 Nm for DIN rail (TS35 compliant)¹⁴
- Lateral shift tolerance: ≤0.2mm during positioning⁴
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Environmental Constraints
- Operating temperature: -25°C to +55°C (derate power >40°C)¹³
- Relative humidity: 5-95% non-condensing³
- Altitude limit: ≤2000m ASL³
- Vibration resistance: 5-500Hz @ 1.5G acceleration⁴
Electrical Safety
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1. ESD Protection:
• Mandatory grounded wrist strap handling³
• Anti-static packaging until installation⁴
2. Power Isolation:
• Verify voltage cutoff (<0.5V residual) before wiring⁴
• Separate from HV cables by ≥200mm³
3. Shielding:
- Use CY-type shielded cables for control signals⁴
- Ground shield at controller end only¹
Critical Prohibitions
DO NOT:
- Apply torque >15 Nm on terminal blocks (risk of housing deformation)¹³
- Energize without pneumatic pre-charge (IGCT burnout risk)⁴
- Bypass force-guided relay monitoring circuits²³
- Operate without 3µm filtration (ISO 8573-1 Class 3.4.2)¹⁴
REQUIRED INTERLOCKS:
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--[ ]--|GU_STATUS=OK|--(K1)--
K1 contacts enable main power bus
(SIL 3 compliant per IEC 61508)³
Post-Installation Verification
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Diagnostic Sequence
- Apply 6 bar test pressure → check leaks with bubble solution⁴
- Measure input impedance: 45Ω ±5% (Pin1-Pin2)¹
- Validate feedback signal: 12.5mA @ mid-stroke (Pin4-Pin2)¹⁴
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Commissioning Protocol
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Thermal_Scan = PASS ; IR camera <85°C
Vibration_FFT = PASS ; <4µm RMS @ 100Hz
Isolation_Test = PASS ; >100MΩ @ 500VDC
5SHY4045L0006 3BHB030310R0001 3BHE039203R0101 GVC736CE101 ABB pdf
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