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ACH550 Installation, Operation and Maintenance Manual

ACH550 E-Clipse Bypass

ACH550 Drive

E-Clipse Bypass Control Board

Terminals (X2)

Input Ground Lug

Input Power Terminals

Motor Terminals

Output Ground Lug

Service Switch (optional)

ACH550 Drive

Cable Guides

E-Clipse Bypass Control Board

Terminals (X2)

Disconnect Switch

or Circuit Breaker

Input Ground Lug

Input Power Terminals

Motor Terminals

Output Ground Lug

Service Switch (optional)

User Power

Summary of Contents for ACH550-UH HVAC

Page 1: ...ACH550 Installation Operation and Maintenance Manual I O M ACH550 UH HVAC Drives 1 550 HP ACH550 BCR BDR VCR VDR E Clipse Bypass Drives 1 400 HP ACH550 PCR PDR Packaged Drives with Disconnect 1 550 HP...

Page 2: ...es on the terminals of the relay outputs WARNING When the control terminals of two or more drives are connected in parallel the auxiliary voltage for these control connections must be taken from a sin...

Page 3: ...ass page 39 PCR PDR Packaged Drives with Disconnect page 79 ACH550 UH Installation Study these installation instructions carefully before proceeding Failure to observe the warnings and instructions ma...

Page 4: ...the shipping pallet WARNING Use the lifting lugs bars at the top of the unit to lift R7 R8 drives 4 Use a hoist to lift the drive Do not place drive in final position until mounting site is prepared...

Page 5: ...the mounting location 1 Mark the position of the mounting holes Note Frame sizes R3 and R4 have four holes along the top Use only two If possible use the two outside holes to allow room to remove the...

Page 6: ...hood is present Remove screws 2 holding the hood in place 2 If hood is present Slide hood up and off of the cover 3 Loosen the captive screws around the edge of the cover 4 Remove the cover R7 R8 Cabi...

Page 7: ...h sides at the top 4 Re install the rubber plugs 5 Non English speaking locations Add a warning sticker in the appropriate language over the existing warning on the top of the module R7 R8 1 Use a hoi...

Page 8: ...ault LED Red Optional Module 1 X1 Communications Optional Module 2 GND Power Output to Motor Power Input EM1 X1 Analog Inputs and Outputs X1 Digital Inputs X1 Relay Outputs and 10 V Ref Voltage Output...

Page 9: ...e drive on IT systems and corner grounded TN systems see section Disconnecting the internal EMC filter on page 10 GND Power Input PE U1 V1 W1 X0011 F1 F2 Power Input PE U1 V1 W1 F1 F2 X0013 Power Outp...

Page 10: ...stem types see Floating networks on page 12 and Unsymmetrically grounded networks on page 11 The locations of screws EM1 and EM3 are shown in the diagram on page 8 The locations of screws F1 and F2 ar...

Page 11: ...not connect drive terminals in series Unsymmetrically grounded networks WARNING Do not attempt to install or remove EM1 or EM3 screws while power is applied to the drive s input terminals Unsymmetrica...

Page 12: ...2 screws see page 9 Where EMC requirements exist check for excessive emission propagated to neighboring low voltage networks In some cases the natural suppression in transformers and cables is suffici...

Page 13: ...r to Power terminal considerations R6 Frame size on page 16 8 Route the control cables through the conduit not the same conduit as either input power or motor wiring 9 Use available secure points and...

Page 14: ...to the drive terminals Note For R5 frame size the minimum power cable size is 25 mm2 4 AWG For R6 frame size refer to Power terminal considerations R6 Frame size on page 16 7 Route the control cables...

Page 15: ...e separate install liquid tight conduit connectors not supplied 5 Connect input power and motor cables to the bus terminals 6 Connect grounds to ground bar 7 Use available secure points and tie strap...

Page 16: ...le provides specifications for the drive s control terminals Control terminal descriptions The following full page diagram provides a general description of the control terminals on the drive Note Ter...

Page 17: ...ircuit common connected internally to chassis gnd through 1 M 10 24V Auxiliary voltage output 24 VDC 250 mA reference to GND short circuit protected 11 GND Auxiliary voltage output common connected in...

Page 18: ...1 F2 The drive is properly grounded The input power voltage matches the drive nominal input voltage range The input power connections at U1 V1 and W1 are connected and tightened as specified The input...

Page 19: ...situations However review the following situations Perform the associated procedures as appropriate Spin motor When first installed and started the control panel displays a welcome screen with the fo...

Page 20: ...owing from the motor ratings plate Voltage Nominal motor current Nominal frequency Nominal speed Nominal power 2 Edit parameters 9905 9909 to the correct values Assistant Control Panel The Start Up As...

Page 21: ...tatus information Select MENU and use UP DOWN buttons to select other modes The modes are Standard Display Mode Shows drive status information and operates the drive Parameters Mode Edits parameter va...

Page 22: ...eference To modify the reference only possible if the display in the upper right corner is in reverse video press the UP or DOWN buttons the reference changes immediately The reference can be modified...

Page 23: ...cation macro HVAC Default 1 Select MENU to enter the main menu 2 Select the Parameters mode with the UP DOWN buttons and select ENTER to select the Parameters mode 3 Select the appropriate parameter g...

Page 24: ...C 257 F Check for and correct Fan failure Obstructions in the air flow Dirt or dust coating on the heat sink Excessive ambient temperature Excessive motor load 4 SHORT CIRC Fault current Check for an...

Page 25: ...s while the drive is running and while the drive is not running Detection is more sensitive when the drive is not running and can produce false positives Possible corrections Check for correct faults...

Page 26: ...orrect Parameter settings for 2001 and 2002 Adequacy of motor braking torque Applicability of torque control Brake chopper and resistor 25 RESERVED Not used as of the publication of this manual 26 DRI...

Page 27: ...ger than the time defined by 3703 USER LOAD C TIME 101 SERF CORRUPT Error internal to the drive Contact your local ABB sales representative and report the error number 102 RESERVED 103 SERF MACRO 104...

Page 28: ...er is set for fieldbus control e g 1001 EXT1 COMMANDS 10 COMM but 9802 COMM PROT SEL 0 1008 PAR PFAWOSCALAR Parameter values are inconsistent 9904 MOTOR CTRL MODE must be 3 SCALAR SPEED when 8123 PFA...

Page 29: ...time parameters 2203 DECELER TIME 1 and 2206 DECELER TIME 2 Interaction with external input filter 2003 UNDERVOLTAGE Under voltage controller is active Check for and correct Undervoltage on mains 2004...

Page 30: ...3005 3009 Check the temperature sensors and Group 35 parameters 2011 UNDERLOAD Motor load is lower than expected This alarm warns that a Motor Underload fault trip may be near Check Motor and drive r...

Page 31: ...OP Emergency stop activated 2024 ENCODER ERROR The drive is not detecting a valid encoder signal Check for and correct Encoder presence and proper connection reverse wired loose connection or short ci...

Page 32: ...the dust entering adjoining equipment perform the cleaning in another room 4 Replace the cooling fan 5 Restore power Maintenance Application Interval Instruction Check replace R7 R8 enclosure inlet a...

Page 33: ...IG instructions Frame Sizes R1 R4 To replace the fan 1 Remove power from drive 2 Remove drive cover 3 For Frame Size R1 R2 Press together the retaining clips on the fan cover sides and lift R3 R4 Pres...

Page 34: ...an in reverse order noting that The fan air flow is up refer to arrow on fan The fan wire harness is toward the front The notched housing barb is located in the right rear corner The fan cable connect...

Page 35: ...fan and capacitor with the replacement part for ABB in the reverse order of the above Ensure the fan is centered on the velocity stack and rotates freely Enclosure air filter replacement UL Type 12 e...

Page 36: ...ing pulled out of the filter frame Install the center bracket first Install the 2nd bracket overlapping the center bracket by 1 2 to the left Install the 3nd bracket overlapping the center bracket by...

Page 37: ...squeezing the open end of the U towards the middle of the square until the retainer top open end of U clears the filter frame Save the retainers for reinstallation 3 Remove and inspect the filter 4 I...

Page 38: ...a capacitor failure Capacitor failure is usually followed by a input power fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements for frame size R5 R6 and R8 are avail...

Page 39: ...icing the drive Failure to disconnect power may cause serious injury or death 1 Install wiring bypass WARNING Do not connect or disconnect input or output power wiring or control wires when power is a...

Page 40: ...ng access from the bottom only The following figure shows the Vertical E Clipse Bypass wiring connection points BP0054 ACH550 E Clipse Bypass Control Board Terminals X2 Disconnect Switch or Circuit Br...

Page 41: ...pass units are configured for wiring access from the top The following figure shows the Standard E Clipse Bypass wall mounted wiring connection points ACH550 Motor Input Power Output Ground Terminals...

Page 42: ...erminals X2 Input Ground Lug Input Power Terminals Motor Terminals Output Ground Lug Service Switch optional B2 ACH550 Drive Cable Guides E Clipse Bypass Control Board Terminals X2 Disconnect Switch o...

Page 43: ...se Bypass units are configured for wiring access from the top The following figure shows the Standard E Clipse Bypass floor mounted wiring connection points B4 ACH550 Drive E Clipse Bypass Control Boa...

Page 44: ...put connections Connect input power to the terminals of the disconnect switch or circuit breaker Connect the equipment grounding conductor to the ground lug at the top of the enclosure The figure belo...

Page 45: ...hese 3R enclosures on an open rack system requires the use of the supplied 3R enclosure back plates to maintain 3R integrity Standard Configuration B3 Input Ground Standard Configuration B1 B2 Power C...

Page 46: ...l block location and terminal data are defined in the ACH550 UH User s Manual X2 terminal block location is illustrated in the figures starting with Connection diagrams Vertical E Clipse Bypass on pag...

Page 47: ...trol connections made on the E Clipse Bypass control board Use wire ties to permanently affix control communications wiring to the hooked wire race tie points provided maintaining a minimum 6 mm 1 4 s...

Page 48: ...ACH550 VxR 031A 2 R2 2 50 in lbs 2 50 in lbs 2 50 in lbs 15 ACH550 VxR 046A 2 R3 4 18 in lbs 2 0 120 in lbs 20 ACH550 VxR 059A 2 R3 25 ACH550 VxR 075A 2 R4 1 50 in lbs 1 55 in lbs 380 480 Volt 1 1 5...

Page 49: ...10 ACH550 VxR 011A 6 R2 15 ACH550 VxR 017A 6 R2 20 ACH550 VxR 022A 6 R3 4 62 in lbs 2 50 in lbs 2 50 in lbs 25 ACH550 VxR 027A 6 R3 30 ACH550 VxR 032A 6 R4 1 62 in lbs 4 18 in lbs 2 0 120 in lbs 40 A...

Page 50: ...50 BxR 017A 2 R1 7 5 ACH550 BxR 024A 2 R2 10 ACH550 BxR 031A 2 R2 1 50 in lbs 1 50 in lbs 3 50 in lbs 3 50 in lbs 2 50 in lbs 2 50 in lbs 15 ACH550 BxR 046A 2 R3 4 18 in lbs 4 18 in lbs 2 0 120 in lbs...

Page 51: ...lbs 1 0 70 in lbs 1 0 70 in lbs 1 53 in lbs 1 53 in lbs 2 x 3 0 250 in lbs 100 ACH550 BxR 125A 4 R5 300 MCM 275 in lbs 300 MCM 275 in lbs 250 MCM 300 in lbs 250 MCM 300 in lbs 125 ACH550 BxR 157A 4 R...

Page 52: ...3 30 ACH550 BxR 032A 6 R4 4 18 in lbs 4 18 in lbs 2 0 120 in lbs 2 0 120 in lbs 40 ACH550 BxR 041A 6 R4 50 ACH550 BxR 052A 6 R4 1 55 in lbs 1 55 in lbs 60 ACH550 BxR 062A 6 R4 1 75 in lbs 1 75 in lbs...

Page 53: ...fault Parameters Changed Relative to E Clipse HVAC Default Smoke Control Override1 is a fixed input Closing Digital Input 6 will place the E Clipse Bypass in Smoke Control mode which may reassign the...

Page 54: ...between the ACH550 and the E Clipse Bypass are configured at the factory and require no adjustment Drive Link recovery procedure If the ACH550 Drive communication settings are unintentionally changed...

Page 55: ...otor will start across the line as soon as power is applied If the Safety Interlock and Run Enable input contacts are closed and the Smoke Control Override 1 input contact is closed the motor will sta...

Page 56: ...amaged or improper wiring If the ACH550 Control Panel displays any other drive faults correct the fault condition before proceeding to the next step CAUTION Check motor rotation direction as soon as t...

Page 57: ...e ACH550 UH User s Manual for programming instructions Note Run motor from drive before attempting bypass operation System check motor disconnected from the ACH550 with E Clipse Bypass If you are fami...

Page 58: ...ements make it necessary to use this type of motor control Operation using the Vector Speed setting is unnecessary for control of almost all fan and pump applications Refer to the ACH550 UH User s Man...

Page 59: ...BRK to GND frame size R1 R2 Terminals UC and UC frame size R3 R8 If the drive does not operate according to these steps refer to the ACH550 UH User s Manual 3 Check jumpers and switches The settings d...

Page 60: ...ction Sheet supplied with these units for additional information on the adjustment of these settings Operation E Clipse bypass configurations The ACH550 with E Clipse Bypass is an ACH550 AC adjustable...

Page 61: ...the front view of the ACH550 E Clipse Bypass standard configurations and identifies the major components BP0091 E Clipse Bypass E Clipse Bypass Control Panel Operating Handle for Disconnect Switch or...

Page 62: ...nterlock s and Run Enable contacts are closed The Safety Interlock contact s are closed with no Start command present The Enabled LED flashes green if the Run Enable contact is open and when the Safet...

Page 63: ...nctions have shut down the drive The specific nature of the fault is indicated on the drive control panel display Refer to the Diagnostics section on page 66 of the ACH550 UH User s Manual for more de...

Page 64: ...al different modes for configuring operating and diagnosing the bypass Select MENU and use the UP DOWN buttons to select modes The modes are Default Display mode Provides HAND OFF AUTO indication of t...

Page 65: ...to return to the Default Display 1 The Default Display indicates the Bypass Control mode 2 Press ENTER to enter the Main Menu 3 Select the Parameter List with the Up Down arrows and press ENTER 4 Sel...

Page 66: ...RBCU Change RBCU 3002 BYP CNTACT STUCK M2 contactor indicates it is not prepared to move on a power up check of the contactor or after contact is commanded to open Defective Contactor Defective RBCU...

Page 67: ...he drive phases back Message will appear in the fault log This message will only appear when drive contactor opens when drive is operating Loose J7 connector on RBCU unit Loose input wiring Incoming p...

Page 68: ...ge phase to ground 3013 DRIVE 1ST START Fault generated if attempting to close the bypass contactor with out running the bypass in drive mode first NA Run bypass unit in drive mode before attempting b...

Page 69: ...Fault is generated when current in Phase A is detected and the bypass contactor is open Loose CT connection Bad RBCU Bad CT Check J2 connector for proper seating Check connector on Current Assembly R...

Page 70: ...sformers in bypass unit Internal problem Cable problem Motor problem Check wiring in E Clipse Unit Check motor cabling Check Motor Check if 3006 is Disabled 3037 PCB TEMP RBCU unit has reached 190 deg...

Page 71: ...r Replace RBCU 3204 STACK OVERFLOW Program cycle is overloaded NA Contact ABB with information that proceeded fault Cycle Power Replace RBCU 3205 UNKNOWN CB Bypass control board type is unknown Firmwa...

Page 72: ...will trip on Fault 3012 if the bypass contactor is closed Loose J8 connector Loose wiring on Contactor assembly Blown upstream fuse Check J8 connector Check red wire on input block Check incoming volt...

Page 73: ...s Bypass Mode Check that J2 connector is firmly seated in RBCU Check input voltage Does overload condition exist 4011 MTR UNDERLOAD Alarm comes at half the time of a mtr underload fault See fault 3017...

Page 74: ...common on bypass when using external 24 v supply Check 24 Volts on RBCU unit Check for 24 volts on respective DI when condition is satisfied Check Parameter 0103 For status of digital input 4022 Sele...

Page 75: ...0103 For status of digital input 4025 LOCAL DISABLED Alarm is displayed if MODE LOCK 16 29 is set to AUTO MODE and the Hand or Off key is pressed 4026 AUTO DISABLED This alarm is displayed if MODE LOC...

Page 76: ...o the system AUTO TRANSFER NOT TRANSFERRED TRANSFERRED Displays if the system is in Auto Transfer state or not Does not reflect to PAR 16 08 AUTO XFER value itself BYP OVERRIDE 1 NOT ACTIVATED ACTIVAT...

Page 77: ...voltage 5 CAN T EDIT PAR IS HIDDEN Try to save value press the ENTER key in Parameter Edit State of a hidden parameter Should not be possible If hidden parameters are turned visible this message is n...

Page 78: ...78 ACH550 Installation Operation and Maintenance Manual ACH550 E Clipse Bypass...

Page 79: ...with Input Disconnect is connected to the line Disconnect and lock out power to the drive before servicing the drive Failure to disconnect power may cause serious injury or death 1 Install wiring WARN...

Page 80: ...pen rack system requires the use of the supplied 3R enclosure back plates to maintain 3R integrity ACH550 Input Power Terminals Motor Terminals Ground Lug s Disconnect Switch or Circuit Breaker Motor...

Page 81: ...floor mounted Floor mounted UL Type NEMA 1 12 Drive with Input Disconnect units are configured for wiring access from the top and include a removable conduit mounting plate The following figure shows...

Page 82: ...on disconnect switches for the following rated ACH550 PDR products is 7 in lbs Do not use a power driver or over tighten to prevent breaking screw heads or stripping the terminal 230 VAC 460 VAC 600...

Page 83: ...10 7 in lbs 10 7 in lbs Refer to Drive s power connection terminals 10 35 in lbs 10 35 in lbs 1 5 ACH550 PxR 06A6 2 R1 2 ACH550 PxR 07A5 2 R1 3 ACH550 PxR 012A 2 R1 5 ACH550 PxR 017A 2 R1 7 5 ACH550 P...

Page 84: ...in lbs 6 35 in lbs 15 ACH550 PxR 023A 4 R2 20 ACH550 PxR 031A 4 R3 3 50 in lbs 3 50 in lbs 3 50 in lbs 3 50 in lbs 25 ACH550 PxR 038A 4 R3 4 18 in lbs 4 18 in lbs 30 ACH550 PxR 045A 4 R3 40 ACH550 Px...

Page 85: ...in lbs 8 7 in lbs Refer to Drive s power connection terminals 6 35 in lbs 6 35 in lbs 3 ACH550 PxR 03A9 6 R2 5 ACH550 PxR 06A1 6 R2 7 5 ACH550 PxR 09A0 6 R2 10 ACH550 PxR 011A 6 R2 15 ACH550 PxR 017A...

Page 86: ...ine power Follow the procedure on page 12 Before proceeding with the insulation resistance measurements check that the ACH550 is disconnected from incoming line power Failure to disconnect line power...

Page 87: ...ut Disconnect is an ACH550 AC adjustable frequency drive packaged with an input disconnect switch or circuit breaker and with a door interlocked external operating handle The operating handle can be p...

Page 88: ...rd configurations and identifies the major components Operating Handle ACH550 Drive for Disconnect Switch or Circuit Breaker UL Type NEMA 1 12 UL Type NEMA 1 12 UL Type NEMA 1 12 Floor Mount UL Type N...

Page 89: ...ation Interval Instruction Check replace hinged door wall mount enclosure inlet air filter Hinged door wall mount UL Type NEMA 12 enclosures Check every 3 months Replace as needed Enclosure air filter...

Page 90: ...t the hooks catch on the enclosure 6 Replace the mounting screw Tighten until the gasket on the bracket is about 50 compressed Enclosure air filter replacement UL Type NEMA 12 floor mount enclosures F...

Page 91: ...07 RAMP SHAPE 2 2208 EM DEC TIME 2209 RAMP INPUT 0 GROUP 23 SPEED CONTROL 2301 PROP GAIN 2302 INTEGRATION TIME 2303 DERIVATION TIME 2304 ACC COMPENSATION 2305 AUTOTUNE RUN GROUP 25 CRITICAL SPEEDS 250...

Page 92: ...FAULT LOG 0401 LAST FAULT 0402 F1 TIME 1 0403 F1 TIME 2 0404 F1 VOLTAGE 0405 F1 CURRENT 0406 F1 EVENT 1 0407 F1 E1 TIME 0408 F1 EVENT 2 0409 F1 E2 TIME 0410 FAULT 2 0411 F2 TIME 1 0412 F2 TIME 2 0413...

Page 93: ...ACH550 Installation Operation and Maintenance Manual 93 ACH550 PCR PDR...

Page 94: ...tallation Operation and Maintenance Manual 3AUA0000081824 REV B Effective 04 15 2012 ABB Inc 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 1 800 752 0696 Fax 1 262 785 0397 Internet www...

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