ACS800

Safety Instructions
ACS800 Multidrive and ACS800 Multidrive Modules
 ACS800 Multidrive and
ACS800 Multidrive modules

Safety Instructions

3AFE64760432 REV B
EN
EFFECTIVE: 25.11.2004

 2004 ABB Oy. All Rights Reserved.

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Safety instructions

What this chapter contains

This chapter contains safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, motor or driven equipment. Read the safety
instructions before you work on the unit.
The information is valid for ACS800 Multidrive. It is also valid for ACS800 Multidrive
modules if they are equipped with corresponding auxiliary devices.

Use of warnings and notes

There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment, and advise on how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:

Dangerous voltage warning warns of high voltages which can cause

physical injury or death, or damage to the equipment.

General warning warns about conditions, other than those caused by

electricity, which can result in physical injury or death, or damage to the
equipment.
Electrostatic discharge warning warns of electrostatic discharge which
can damage the equipment.

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Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor.

WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
• Only qualified electricians are allowed to install and maintain the drive!
• Never work on the drive, motor cable or motor when main power is applied. After
disconnecting the input power, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you start working on the drive, motor or motor
cable. Measure the voltage between terminals UDC+ and UDC- with a multimeter
(impedance at least 1 Mohm) to ensure that the drive is discharged before
beginning work.
• Apply temporary grounding before working on the unit.
• Drives equipped with a Diode Supply Unit (supply unit types ACS800-307 and
ACS800-507):
Do not open fuse-switches under load!
Before replacing a fuse in the fuse-switch: 1. Ensure that all motor-side
converters are stopped. 2. Stop the line side-converters and open the main
breaker of the drive. 3. Open the Diode Supply Module switch disconnectors.
4. Disconnect the input fuses from the input power source by pulling the drive
main breaker out and locking it. If the drive is not equipped with the breaker, open
the disconnector of the supply transformer. 5. Wait for five minutes to let the
intermediate circuit capacitors discharge. 6. Ensure by measuring that the fuse is
dead. Measure from both fuse blades.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may carry dangerous
voltage even when the main power of the drive is switched off.
• When joining shipping splits (if any), check the cable connections at the joints
before switching on the supply voltage.
• Live parts inside the cubicle are protected against direct contact. However, pay
special attention when handling metallic shrouds.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the phase order is correct.

Safety instructions
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Note:
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• The drive DC bus carry a dangerous voltage (over 500 V).
• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)
may be present on the relay outputs of the drive system.
• The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.

Safety instructions
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WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
• Use extreme caution when manoeuvring an inverter, supply or filter module that
runs on wheels. The modules are heavy and have a high centre of gravity. They
topple over easily if handled carelessly.

Support the bottom of Do not tilt! Extend the support legs outside the
the module while cabinet!
removing!

Lift the module by the upper part only Mind your fingers! Keep fingers away from the edges Support the bottom of
using the lifting hole(s) at the top! of the front flange of the module! the module while
replacing!

• Beware of the cooling fan blades. The fans may continue to rotate for a while after
the disconnection of the electrical supply.
• Beware of hot surfaces. Some parts inside the drive cabinet, such as heatsinks of
power semiconductors, remain hot for a while after the disconnection of the
electrical supply.

Safety instructions
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• Make sure that dust from drilling does not enter the drive when installing.
Electrically conductive dust inside the unit may cause damage or lead to
malfunction.
• Fastening the cabinet by riveting or welding is not recommended. However, if
welding is necessary, ensure the return wire is properly connected in order not to
damage to the electronic equipment in the cabinet. Also ensure that welding
fumes are not inhaled.
• Ensure sufficient cooling of the unit.

Grounding
These instructions are intended for all who are responsible for the grounding of the
drive.

WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
• Ground the drive, motor and adjoining equipment to ensure personnel safety in all
circumstances, and to reduce electromagnetic emission and pick-up.
• Make sure that grounding conductors are adequately sized as required by safety
regulations.
• In a multiple-drive installation, connect each drive separately to protective earth
(PE).
• Do not install a drive equipped with an EMC filter (option code +E203) to an
ungrounded power system or a high-resistance-grounded (over 30 ohms) power
system.
Note:
• Power cable shields are suitable for equipment grounding conductors only when
adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA DC
(stated by EN 50178, 5.2.11.1), a fixed protective earth connection is required.

Printed circuit boards and fibre optic cables

Ignoring the following instructions can cause damage to the equipment.

WARNING! The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not touch the
boards unnecessarily.

WARNING! Handle the fibre optic cables with care. When unplugging optic cables,
always grab the connector, not the cable itself. Do not touch the ends of the fibres
with bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 25 mm (1 in.).

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Start-up and operation

These warnings are intended for all who commission, plan the operation or operate
the drive.

WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
Drives equipped with a Diode Supply Unit (supply unit types ACS800-307 and
ACS800-507):
• Do not open fuse-switches under load!
Drives equipped with a grounding switch (supply unit option type +F259):
• Do not break the grounding switch by forcing it closed before the main
disconnecting device has been opened. The switch and disconnector are either
mechanically coupled or electrically interlocked and can only be operated in
correct order.
Drives equipped with a Brake Unit (break unit type ACS800-607):
• Make sure that there are inverters connected to the intermediate circuit before
start. As a rule of thumb, the sum capacitance of the inverters connected must be
at least 30% of the sum capacitance of all inverters.
Drives equipped with a Thyristor Supply Unit (supply unit types ACS800-407 and
ACS800-807):
• Make sure that there are inverters connected to the intermediate circuit before
start. As a rule of thumb, the sum capacitance of the inverters connected must be
at least 30% of the sum capacitance of all inverters.
• Never cut-off the supply voltage during regeneration. The supply network forms
an essential part of the thyristor commutation circuit. Circuit cut-off during the
regeneration prevents natural thyristor turn-off, shorting the intermediate circuit
and blowing the fuses.
All drives
• Close the switch fuses of all parallel-connected inverters before start.
• In a humid environment, run the inverter cooling fans for one minute before
starting up and loading the inverter modules. To start the speed-controlled fans,
power the DC bus of the drive i.e. start the supply unit of the drive. To power up
the constant speed fans, switch on the drive auxiliary power supply and close the
fan circuit breakers.
• Do not open the switch fuse of an inverter when the inverter is running.

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WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at speeds
above and below the speed provided by connecting the motor directly to the
power line.
• Do not control the motor with the disconnecting device (means); instead, use the
control panel keys and , or commands via the I/O board of the drive. The
maximum allowed number of charging cycles of the DC capacitors (i.e. power-ups
by applying power) is five in ten minutes.
• Do not use the Prevention of Unexpected Start feature for stopping the drive
when the inverter unit(s) is running. Give a Stop command instead.
Note:
• If an external source for start command is selected and it is ON, the inverter (with
Standard Application Program) will start immediately after fault reset unless the
drive is configured for 3-wire (a pulse) start/stop.
• When the control location is not set to Local (L not shown in the status row of the
display), the stop key on the control panel will not stop the motor. To stop the
motor using the control panel, press the LOC/REM key and then the stop key .

Safety instructions
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Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives. The
warnings are intended for all who work on the drive, motor cable or motor, and all
who commission, plan the operation or operate the drive.

Installation and maintenance work

WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
• Do not open the cabinet doors and work on the drive when the permanent magnet
synchronous motor is rotating. When rotating, the motor feeds power to the
intermediate circuit of the drive and also the supply connections become live
(even when the inverter is stopped!).
Before starting work in the inverter cubicle:
• Stop the motor.
• Isolate the inverter from the intermediate circuit of the drive by opening the
inverter switch fuse or by removing the DC fuses. Alternatively isolate the drive
from the AC power supply by using the main disconnecting device. Lock the
disconnectors to open position.
• Ensure the motor cannot rotate during work.
• Ensure that there is no voltage present on converter power terminals:
Alternative 1) Isolate the converter from the motor. Ensure by measuring that
there is no voltage present on the motor-side converter input or output terminals
(UDC+, UDC- or U2, V2, W2) or motor input terminals (U1, V1, W1).
Alternative 2) Ensure by measuring that there is no voltage present on the motor-
side converter input or output terminals (UDC+, UDC- or U2, V2, W2) or motor
input terminals (U1, V1, W1), and temporarily ground the converter output.
Alternative 3) When possible, apply alternatives 1) and 2), i.e. isolate, measure
and temporary ground.

Start-up and operation

WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
• Do not run the motor above the rated speed. Motor overspeed leads to
overvoltage, which may damage or even explode the capacitors in the
intermediate circuit of the drive.
• Controlling a permanent magnet motor is only allowed using the ACS800
Permanent Magnet Synchronous Motor Drive Application Program, or other
application programs in scalar control mode.

Safety instructions
 3AFE64760432 REV B / EN
EFFECTIVE: 25.11.2004

ABB Oy ABB Inc.

AC Drives Drives and Power Electronics
P.O. Box 184 16250 West Glendale Drive
FIN-00381 HELSINKI New Berlin, WI 53151
FINLAND USA
Telephone +358 10 22 11 Telephone 262 785-3200
Fax +358 10 22 22681 800 243-4384
Internet http://www.abb.com Fax 262 780-5135