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ABB ACH400 Series, User Manual

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ABB ACH400 Series User Manual Download Page 32

Chapter 3 – Installation Instructions

ACH 400 with Electronic Bypass User’s Manual

3-13

Electrical Installation

Cable Entries

Most ACH 400 Electronic Bypass drives are configured for wiring access 
from the bottom only. Types ACH 401612032 and ACH 401614032 are 
configured for wiring access from the top only. At least three separate 
conduits are required, one for input power, one for output power to the motor 
and one for control signals.

Terminal Sizes

Power and motor cable terminal sizes are shown in the Table 3-2 for 
connections to an input circuit breaker or disconnect switch, a motor terminal 
block and ground lugs. The table also lists torque that should be applied when 
tightening the terminals.

Table 3-2

Wire Size Capacities and Tightening Torques for Power Terminals

ACH 400 Type Code and Nominal Hp

Wire Size Range(AWG) and Tightening Torque (in/lbs.)

240 V Units

480 V Units

Input

Circuit

Breaker

Input

Disconnect Switch

Motor Terminal Block

Ground

Lug

Hp

Type Code

ACH 40x-

Hp

Type Code

ACH 40x-

3

x0043

#14 - #8:
22 in/lbs.

#6 - #3:
4 in/lbs. 

#18 - #8:

7 in/lbs.

#20 - #6:

11 - 13 in/lbs.

#14 - #10:

35 in/lbs.

#8:

40 in/lbs.

#6 - #4:

45 in/lbs.

#2:

50 in/lbs.

5

x0053

3

x0042

7.5

x0063

5

x0052

10

x0093

7.5

x0062

15

x0113

10

x0112

20

x0163

#14 - #4:
18 in/lbs.

#14 - #10:

35 in/lbs.

#8:

40 in/lbs.

#6 - #2/0:

120 in/lbs.

AWG

#14 - #10:

35 in/lbs.

#8:

40 in/lbs.

#6 - #4:

45 in/lbs.

#2 - #1/0:

50 in/lbs.

15

x0112

25

x0203

30

x0253

20

x0162

40

x0303

25

x0202

50

x0413

#8 - #1/0:

55 in/lbs.

60

60603x

#2 - #4/0:

120 in/lbs.

#14 - #1/0:

35 in/lbs.

30

x0302x

75

60703x

#2 - 300MCM:

375 in/lbs.

40

x0412x

100

61003x

50

60601x

25 kAIC CB:

#4 to 300 MCM:

275 in/lbs.

65 kAIC CB:

#6 to 350 MCM:

275 in/lbs.

60

60701x

125

612032

#6 - 350kcmil,

275 in/lbs.

#6 - 300kcmil,

275 in/lbs.

#6 - 350kcmil,

275 in/lbs.

300MCM 3BRL

375 in/lbs.

150

614032

#4 - 400kcmil,

375 in/lbs.

125

612035

25 kAIC CB:

#4 to 300 MCM:

275 in/lbs.

65 kAIC CB:

#6 to 350 MCM:

275 in/lbs.

Not Applicable

Bus bar connection:

Two holes, 10mm (3/8”) 

diameter, 1” spacing

NEMA two hole lugs can 

be used.

350 in/lbs.

Bus bar connection

See description at 

left

150

614035

200

62103x

Qty (2) 3/0 to 250 

MCM:

275 in/lbs.

250

62603x

Qty (2) 250 MCM 

to 500 MCM:

275 in/lbs.

300

63203x

400

64003x

Summary of Contents for ACH400 Series

Page 1: ...ACH 400 Users Manual ACH 400 with Electronic Bypass ...

Page 2: ......

Page 3: ...ACH 400 with Electronic Bypass User s Manual ACH400 US 08EB 3AUA489002B4233 R0101 Rev D EFFECTIVE 4 20 01 SUPERSEDES 5 15 00 2001 ABB Inc All Rights Reserved ...

Page 4: ...ions or conditions which will damage machinery or cause additional motor operation down time if you do not take suggested steps to correct or address such situations or conditions Note Notes provide you with additional and useful information Although less urgent than cautions and warnings notes are important and should not be ignored Warning Symbols For your own safety please pay special attention...

Page 5: ...injury Only a qualified electrician should carry out the electrical installation The DC bus capacitors contain dangerous DC voltage levels 1 35 x VIN After disconnecting the supply wait at least five minutes after the display readout on the control panel has disappeared before taking any measurements Dangerous external control voltages may be present on the relay outputs of the Electronic Bypass c...

Page 6: ...Input Power 2 2 Bypass Contactors 2 4 Motor Overload Protection 2 4 Operator Control 2 4 Electronic Bypass Options 2 4 Detailed Description of Operation 2 5 Bypass Control Keypad 2 5 Operating Modes 2 6 Bypass Control Board Inputs and Outputs 2 7 ACH 400 Drive Inputs and Outputs 2 8 Chapter 3 Installation Instructions 3 1 Pre Installation Planning 3 1 Environment 3 1 Heat Dissipation Requirements ...

Page 7: ...ng 3 15 Output Wiring 3 16 Control Wiring 3 17 Chapter 4 Start up Procedure 4 1 Safety Precautions 4 1 Installation Inspection 4 1 Electronic Bypass Jumper Switch and Pot Settings 4 2 DIP Switch Settings 4 2 User Override Jumper 4 2 Relay Output Jumpers 4 3 Overload Trip Current Adjustment Potentiometer 4 3 Macros and Parameter Settings 4 4 Keypad Control Tests 4 4 Motor Disconnected from the ACH ...

Page 8: ...tion and the available features and functions and provides a detailed description of operation Chapter 3 Installation Instructions covers Electronic Bypass pre installation planning initial inspection mounting and electrical wiring Chapter 4 Start up Procedure includes safety precautions configuration settings installation inspection and initial start up tests Intended Audience The audience for th...

Page 9: ...shall the manufacturer ever be liable for consequential and incidental damages The period of manufacturer s warranty is 12 months after installation and not more than 18 months from the date of delivery Extended warranty may be available with certified start up Contact your local distributor for details Your local ABB Drives company or distributor may have a different warranty period which is spec...

Page 10: ...ss hardware components and input output connections General Information About the ACH 400 Control Identification The ACH 400 with Electronic Bypass is a packaging arrangement that provides space for mounting factory installed options as designated by the type code characters following a plus sign after the ACH 400 base unit type code Locate the Control Nameplate on the Electronic Bypass and use Fi...

Page 11: ...eaker Door Interlocked Disconnect Switch The door interlocked disconnect switch is not fused The branch circuit that provides power to the ACH 400 with Electronic Bypass must include appropriate motor branch circuit protective devices to provide short circuit and ground fault protection for the motor in the bypass mode Door Interlocked Circuit Breaker The door interlocked circuit breaker is an opt...

Page 12: ...Input Fuse Ratings Semiconductor Protection Type Codes HP Type Codes HP Amps 660 V Bussmann Type ACH401x0043x 3 R1 10 KTK R 10 ACH401x0053x 5 15 KTK R 15 ACH401x0042x 3 15 KTK R 15 ACH401x0063x 7 5 15 KTK R 15 ACH401x0052x 5 25 KTK R 25 ACH401x0093x 10 R2 20 KTK R 20 ACH401x0062x 7 5 30 KTK R 30 ACH401x0113x 15 30 KTK R 30 ACH401x0163x 20 R3 40 JJS 40 ACH401x0203x 25 50 JJS 50 ACH401x0112x 10 15 6...

Page 13: ...cuit are commanding the motor to run the motor will start as soon as the overload protection is reset Use caution when resetting the overload protection to make sure it is safe to start the motor Operator Control The ACS PAN B Control Panel is a keypad with an LCD unit that provides status indication and operator control for the ACH 400 drive In normal operation with the Electronic Bypass the ACH ...

Page 14: ... Bypass Fault LED The Bypass Fault LED indicates the status of the bypass overload protection The LED is red when the overload has tripped or the bypass control board has faulted Drive Run LED The Drive Run LED is illuminated green when the ACH 400 drive is running Drive Fault LED The Drive Fault LED is illuminated red when the motor or drive protection functions have shut down the ACH 400 Drive S...

Page 15: ...e motor and controls its speed The source of the drive s start stop and speed commands is determined by the Auto or Hand mode selection of the drive s keypad Commands come from the control terminals when the Auto mode has been selected or from the drive keypad when the Hand mode has been selected Bypass mode In the Bypass mode the motor is powered by AC line power through the bypass contactor The ...

Page 16: ...t across the line as soon as power is applied If the bypass is in the Drive mode with the drive in the Auto mode the motor will start on the drive as soon as power is applied Automatic Transfer option When the Automatic Transfer option is selected the motor is automatically transferred to line power if the drive trips out on a protective trip If automatic restart has been enabled in the drive the ...

Page 17: ...n Chapter 4 on page 4 2 The Bypass Run relay is energized when the motor is running on bypass power The N O contact of this relay is connected in parallel with the N O contact of the Inverter Run relay to provide an output that is closed when the motor is running whether powered by the ACH 400 drive or the bypass The Bypass Run contacts can be disconnected from the Inverter Run contacts and used s...

Page 18: ...electing constant speeds or providing Speed Increase and Speed Decrease inputs The functions of these inputs is determined by the ACH 400 macro selection Refer to the ACH 400 User s Manual for additional information The ACH 400 Auto Mode External Reference input is an analog input that sets the operating speed when the ACH 400 HVAC macro is selected and the drive is in the Auto mode When the HVAC ...

Page 19: ...Chapter 2 Overview of ACH 400 with Electronic Bypass 2 10 ACH 400 with Electronic Bypass User s Manual ...

Page 20: ...s can be met The following topics should be considered in pre installation planning Environment Heat Dissipation Requirements Mounting Area Wiring Requirements Environment The ACH 400 with Electronic Bypass must be installed in a heated indoor controlled environment that is relatively free of moisture and conductive contaminants such as condensation carbon dust and the like The maximum ambient tem...

Page 21: ... The ACH 400 can be started again when the temperature of the heatsink has fallen below the trip level 240 Volt Models 480 Volt Models Heat Dissipation Drive Only Drive with Line Reactors Type Codes HP Type Codes HP Watts BTU Hr Watts BTU Hr ACH40160042x 3 80 95 ACH401x0043x 3 100 340 115 390 ACH40160052x 5 120 140 ACH401x0053x 5 130 440 145 490 ACH40160062x 7 5 ACH401x0063x 7 5 180 610 195 670 AC...

Page 22: ...for less than 100 amps or 75 C if rated 100 amps or more At least three separate conduits are required one for input power one for output power to the motor and one for control signals The External Speed Reference signal must be wired using a shielded twisted pair cable Refer to Electrical Installation on page 3 13 for detailed wiring information Initial Inspection Procedure As you unpack the ACH ...

Page 23: ... unit Before mounting the unit verify that the environmental conditions conform to the specifications listed in Pre Installation Planning in this chapter To ensure safe installation check that the surface of the mounting location is flat Attach the Electronic Bypass enclosure at the mounting notches and tighten the bolts Dimensions and Weights The dimensions and weights of the ACH 400 Electronic B...

Page 24: ...e IP21 NEMA 1 R1 Dimensions Reference in mm W W1 H H1 D Mass lb kg R2 R3 R4 5 28 134 5 28 134 8 66 220 8 66 220 3 96 101 3 96 101 6 34 161 6 34 161 43 67 1114 47 80 1214 54 93 1395 58 47 1485 41 68 1059 45 62 1159 52 47 1133 56 01 1423 10 28 261 10 20 259 1176 299 11 76 299 34 16 41 19 108 49 127 58 W1 W D H H1 OFF ON ...

Page 25: ... W W1 H H1 D Mass lb kg R2 R3 R4 8 43 214 8 43 214 10 09 256 10 09 256 3 96 101 3 96 101 6 34 161 6 34 161 48 63 1235 52 51 1334 59 71 1517 63 65 1617 45 97 1168 50 37 1279 57 29 1455 61 19 1554 10 20 259 10 20 259 11 76 299 12 45 316 36 17 44 20 112 51 131 60 D W1 W H H1 OH_65J5 OH_65J5 OH_65J6 OH_65J6 OH_65J8 OH_65J8 DISC SW HDL DISC SW HDL 65J F 65J F OFF ON ...

Page 26: ...Chapter 3 Installation Instructions ACH 400 with Electronic Bypass User s Manual 3 7 ACH 400 Side By Side NEMA Type 1 12 Size R1 R4 ...

Page 27: ...Chapter 3 Installation Instructions 3 8 ACH 400 with Electronic Bypass User s Manual NEMA Type 1 12 Size R5 R6 ...

Page 28: ...Chapter 3 Installation Instructions ACH 400 with Electronic Bypass User s Manual 3 9 ACH 401 NEMA Type 1 Size R7 ...

Page 29: ...Chapter 3 Installation Instructions 3 10 ACH 400 with Electronic Bypass User s Manual ACH 402 NEMA Type 12 Size R7 Conduit Connection Cutout Area ...

Page 30: ...on the frequency converter before working on the frequency converter Wait at least 5 min after disconnecting Wait at least 5 min after disconnecting Consult the installation Start Up Manual Consult the installation Start Up Manual supply before continuing to work supply before continuing to work WARNING 3AUA294001A28 ATTENTION ATTENTION ATTENTION ATTENTION ATTENTION CAUTION CAUTION CAUTION CAUTION...

Page 31: ...he frequency converter before working on the frequency converter Wait at least 5 min after disconnecting Wait at least 5 min after disconnecting Consult the installation Start Up Manual Consult the installation Start Up Manual supply before continuing to work supply before continuing to work WARNING 3AUA294001A28 3AUA294001A28 ATTENTION ATTENTION ATTENTION ATTENTION ATTENTION CAUTION CAUTION CAUTI...

Page 32: ... Ground Lug Hp Type Code ACH 40x Hp Type Code ACH 40x 3 x0043 14 8 22 in lbs 6 3 4 in lbs 18 8 7 in lbs 20 6 11 13 in lbs 14 10 35 in lbs 8 40 in lbs 6 4 45 in lbs 2 50 in lbs 5 x0053 3 x0042 7 5 x0063 5 x0052 10 x0093 7 5 x0062 15 x0113 10 x0112 20 x0163 14 4 18 in lbs 14 10 35 in lbs 8 40 in lbs 6 2 0 120 in lbs AWG 14 10 35 in lbs 8 40 in lbs 6 4 45 in lbs 2 1 0 50 in lbs 15 x0112 25 x0203 30 x...

Page 33: ...o the ACH 400 User s Manual for control connections to the drive Figure 3 1 Wiring Connection Points ACH 400 Disconnect Switch or Circuit Breaker Ground Lug Output Terminals behind cover Input Power Cable Motor Cable Motor Cable Input Power Cable Current Transformers Input and Output Connections For Frames R1 and R2 Electronic Bypass Control Board Terminals Ground Lug Output Terminals behind cover...

Page 34: ... make any voltage tolerance tests Hi Pot or Megger on any part of the unit Disconnect motor wires before taking any measurements in the motor or motor wires Make sure that power factor correction capacitors are not connected between the drive and the motor Connection Points For Frames R1 through R4 Connect the input power to the terminals at the bottom of the disconnect switch or circuit breaker a...

Page 35: ... incoming line power Failure to disconnect line power could result in death or serious injury Connection Points For frames R1 through R4 Connect the output power to the terminals at the bottom of the bypass section as shown in Figure 3 1 Connect the equipment grounding conductor to the ground lug near the motor cable terminal block connection point For frames R5 through R9 Connect the motor cables...

Page 36: ...the Keypad Control Test Motor Disconnected Refer to Keypad Control Tests Chapter 4 Start up Procedure in this manual Motor Cable Length The rapid rate of voltage changes causes capacitive coupling between motor wiring and the grounded metallic conduit This phenomenon can cause substantially higher measured current than actual motor current which may result in nuisance overcurrent trips or ground f...

Page 37: ... the ACH 400 User s Manual for information about control connections on Terminal Block X1 When making connections to Terminal Block X1 be careful not to disturb the factory installed wiring between ACH 400 terminal block X1 and Electronic Bypass control board terminal X2 Figure 3 4 Basic Control Connections for HVAC Hand Auto Macro X1 Terminals on the ACH 400 Control Board Auto Speed Reference 1 T...

Page 38: ...2 13 Closing this contact will start the motor when the drive or bypass is in the Auto mode Caution There are pre wired connections on bypass terminals X2 10 and X2 13 Do not disturb these connections when adding external wiring connections to these terminals Run Enable Interlock Input Contacts Run Enable interlocks such as Freeze Fire and Smoke protection are normally closed dry contacts connecte...

Page 39: ...d protection is reset Form C contacts of a Mode relay are pre wired connections on bypass terminals X2 26 NC X2 27 NO and X2 28 COM Do NOT disturb these connections The Mode relay is energized when the bypass is in the Drive mode and deenergized when the bypass is in the Bypass mode Relay contact ratings Maximum Voltage 30 VDC 125 VAC Maximum Switching Current 8 A at 24 VDC 0 4 A at 125 VAC Maximu...

Page 40: ... Disconnect and lock out power to the drive before servicing the drive Failure to disconnect power may cause death or serious injury Installation Inspection Inspect the mechanical and electrical installation of the ACH 400 with Electronic Bypass for compliance with your local electrical installation regulations and codes Note Do not connect the motor wires before proceeding with the Keypad Control...

Page 41: ...sition as shown in Figure 4 1 Power must first be applied to the system before placing the jumper in the User Override position When the jumper is in the User Override position the Drive contactor is energized and the Bypass contactor is deenergized The contactors are not controlled by the Electronic Bypass keypad when the bypass is in the User Override mode Switch Switch Setting Configurations Ov...

Page 42: ...for potentiometer settings for 0 to 100 Table 4 2 Overload Trip Current Potentiometer Settings Table 4 3 Overload Trip Current DIP Switch Code Selection Potentiometer Setting Trip Currents for the Various Potentiometer Settings A B C D E F G H 10 1 2 2 5 3 8 7 5 10 4 15 5 20 0 47 7 20 2 4 5 0 7 6 15 0 20 8 31 0 40 0 95 4 30 3 6 7 5 11 4 22 5 31 2 46 5 60 0 143 1 40 4 8 10 0 15 2 30 0 41 6 62 0 80 ...

Page 43: ...ower to the Electronic Bypass unit by turning on the branch circuit disconnect device and the bypass disconnect switch or circuit breaker 4 The ACH 400 Control Panel display should be illuminated On the bypass keypad the Ready LED and Enable LED should be illuminated If the Enable LED is not illuminated check to see that closed contacts or a jumper connect terminal X2 2 on the bypass control board...

Page 44: ...Check for zero volts at Terminals UC and UC Meter must be rated for 1000 VDC If the drive does not operate according to these steps refer to the ACH 400 User s Manual Motor Connected to the Electronic Bypass After successfully testing the drive with the motor disconnected continue testing the drive as follows 1 Disconnect and lock out power to the Electronic Bypass unit 2 Connect the motor to the ...

Page 45: ...e the output current in all three phases The current should be balanced and should not exceed the motor or drive rating 8 Press the OFF key on the ACH 400 control panel The motor should stop CAUTION Check the motor rotation direction in bypass Press the OFF key and then the Bypass Select key on the bypass keypad Press the Hand key and then quickly press the OFF key to bump the motor If the motor t...

Page 46: ...n checking bypass 4 6 Direction of rotation checking drive 4 6 Disconnect switch 2 2 E Electronic Bypass definition 2 2 features 2 2 functions 2 2 illustration 2 2 Electrostatic Discharge ESD warning v Environment 3 1 F Fault bypass failure 2 7 Fuses drive input fuse rating table 2 3 drive input fuses 2 2 G General information 2 1 H Heat sink 3 2 I Identification control type code 2 1 Input Power ...

Page 47: ... trip current adjustment 4 3 Override user 2 7 P Parameter settings 4 4 Potentiometer adjustment overload trip current 4 3 R Relay contact outputs 2 8 3 20 4 3 Relay contact ratings 3 20 Rotation direction checking drive 4 6 Rotation direction checking bypass 4 6 S Safety Instructions 4 6 installation wiring 3 15 Motor starting upon application of power 4 5 start up 4 1 voltage tolerance tests Hi ...

Page 48: ... 4 20 01 SUPERSEDES 5 15 00 ABB Inc Drives Power Electronics 16250 W Glendale Drive New Berlin WI 53151 USA Telephone 262 785 8378 800 243 4384 Fax 262 780 5135 All specifications and instructions are subject to change without notice from the manufacturer ...

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