ABB ACH580 Series Installation, Operation And Maintenance Manual Download Page 1

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ACH580

Installation, Operation and Maintenance Manual (I, O & M)

ACH580-01 HVAC Drives (0.75…250 kW, 1…350 HP)

ACH580-BCR/BDR/VCR/VDR E-Clipse Bypass Drives

(0.75…150 kW, 1…200 HP)

ACH580-PCR/PDR Packaged Drives with Disconnect

(0.75…150 kW, 1…200 HP)

Summary of Contents for ACH580 Series

Page 1: ...n Operation and Maintenance Manual I O M ACH580 01 HVAC Drives 0 75 250 kW 1 350 HP ACH580 BCR BDR VCR VDR E Clipse Bypass Drives 0 75 150 kW 1 200 HP ACH580 PCR PDR Packaged Drives with Disconnect 0...

Page 2: ...drive carefully Frames R5 R9 Lift the drive with a lifting device Use the lifting eyes of the drive Frames R5 R9 Do not tip the drive over The drive is heavy and its center of gravity is high An over...

Page 3: ...ype and 20 07 Ext2 start trigger type in ACH580 HVAC control program firmware manual 3AXD50000027537 English When the control location is not set to Local text Hand is not shown on the top row of the...

Page 4: ...e drive will be connected on a corner grounded TN system make sure the EMC filter is not connected metal screws should not be installed Connections with metal screws in these systems can cause danger...

Page 5: ...he supply if the protective earth conductor breaks Additional instructions for Safety Functions WARNING Bypass configurations ACH580 VxR ACH580 BxR do not support Safe Torque Off STO functionality in...

Page 6: ...fault reset functions of the drive control program make sure that no dangerous situations can occur These functions reset the drive automatically and continue operation after a fault Note When the dr...

Page 7: ...top mounting plate between the mounting holes Type code label attached to the base frame on the side of the enclosure 2 According to the construction code proceed to your drive s installation operati...

Page 8: ...2 Beside c 3 mm in mm in mm in R1 200 7 87 150 5 91 150 5 91 R2 200 7 87 150 5 91 150 5 91 R3 200 7 87 200 7 87 150 5 91 R4 53 2 09 200 7 87 150 5 91 R5 100 3 94 200 7 87 150 5 91 R6 155 6 10 300 11...

Page 9: ...any damage and notify the shipper immediately if damaged components are found 3 Check the contents against the order and the shipping label to verify that all parts have been received 1 Free space ab...

Page 10: ...G Before installing the ACH580 ensure the input power supply to the drive is off WARNING Metal shavings or debris in the enclosure can damage electrical equipment and create a hazardous condition Wher...

Page 11: ...holes and start the bolts into the anchors or plugs Use long enough bolts to make them carry the weight of the drive 4 Position the drive onto the bolts on the wall 5 Tighten the bolts in the wall sec...

Page 12: ...te under the drive The drive dimensions and hole locations are also shown in the drawings in the ACH580 Hardware manual publication number 3AXD50000044839 2 Drill the mounting holes 3 Insert anchors o...

Page 13: ...screws 7b 8 Put the tabs at the top of the front cover in their counterparts on the housing and then press at the bottom 8a and tighten the retaining screws 8b IP21 UL NEMA Type 1 IP55 UL NEMA Type 1...

Page 14: ...e holes and start the bolts into the anchors or plugs Use a sufficient number of bolts that are long enough to make them carry the weight of the drive 4 Position the drive onto the bolts on the wall L...

Page 15: ...3 8c IP55 UL NEMA Type 12 9 Remove the front cover Remove the fastening screws a with a T20 Torx screwdriver move the cover to the top side b and then up c Note Install the hood on UL NEMA Type 12 dri...

Page 16: ...nsulation of the input cable according to local regulations before connection to the drive Minimum cable temperature rating of 167 F 75 C must be used 2 With the motor cable connected to the motor but...

Page 17: ...ections with metal screws in these systems can cause danger or damage EMC filter The AC and DC EMC filters are not suitable for use on an IT ungrounded system or on a corner grounded TN system UL NEC...

Page 18: ...screw Maintain the plastic screw VAR Metal Maintain the metal screw Remove the metal screw Remove the metal screw R4 R5 EMC AC Plastic Can install metal screw Maintain the plastic screw2 Maintain the...

Page 19: ...7 45 14 2 1 2 10 70 2 2 R6 1 1 77 45 4 25 300 MCM 150 2 2 R7 1 2 13 54 3 0 95 500 MCM 240 2 2 R8 2 1 77 45 2 1 0 2 50 2 300 MCM 2 150 2 2 R9 2 2 13 54 2 3 0 2 95 2 500 MCM 2 240 2 2 1 Screwdrivers R1...

Page 20: ...cable length 4 kHz1 2 Scalar control Vector control m ft m ft Standard drive without external options R1 100 330 100 330 R2 200 660 200 660 R3 300 990 300 990 R4 300 990 300 990 R5 300 990 300 990 R6...

Page 21: ...24 14 0 4 26 14 0 4 R4 4 0 67 24 14 0 4 26 14 0 4 R5 3 0 67 24 14 0 4 26 14 0 4 R6 4 0 67 26 14 0 4 26 14 0 4 R7 4 0 67 26 14 0 4 26 14 0 4 R8 4 0 67 26 14 0 4 26 14 0 4 R9 4 0 67 26 14 0 4 26 14 0 4...

Page 22: ...88A 2 88 619 82 R5 40 ACH580 01 114A 2 114 835 82 R5 50 ACH580 01 143A 2 143 1035 256 R6 60 ACH580 01 169A 2 169 1251 265 R7 75 ACH580 01 211A 2 211 1521 265 R7 100 ACH580 01 273A 2 273 2061 324 R8 Ou...

Page 23: ...A1 6 6 1 133 59 R2 7 5 ACH580 01 09A0 6 9 174 59 R2 10 ACH580 01 011A 6 11 228 59 R2 15 ACH580 01 017A 6 17 322 59 R2 20 ACH580 01 022A 6 22 430 105 R3 25 ACH580 01 027A 6 27 525 105 R3 30 ACH580 01 0...

Page 24: ...rotection can be used Refer to local codes and regulations 208 240 volt fuse requirements ACH580 01 Input current A UL Maximum current Voltage rating Bussmannn type1 UL class A V 3 phase UN 208 V 04A6...

Page 25: ...30 600 JJS 30 T 023A 4 23 0 30 600 JJS 30 T 027A 4 27 0 40 600 JJS 40 T 034A 4 34 0 60 600 JJS 60 T 044A 4 44 0 60 600 JJS 60 T 052A 4 52 80 600 JJS 80 T 065A 4 62 100 600 JJS 100 T 077A 4 77 100 600...

Page 26: ...15 Class CC or T 017A 6 17 30 600 KTK R 30 or JJS 30 Class CC or T 022A 6 22 40 600 JJS 40 Class T 027A 6 27 40 600 JJS 40 Class T 032A 6 32 40 600 JJS 40 Class T 041A 6 41 100 600 JJS 100 Class T 052...

Page 27: ...1 Analog inputs and outputs X2 Aux voltage output X3 Programmable digital inputs X4 Safe torque off connection X5 Embedded fieldbus X6 Relay output 3 X7 Relay output 2 X8 Relay output 1 X10 Auxiliary...

Page 28: ...ion X1 Analog inputs and outputs X2 Aux voltage output X3 Digital inputs X4 Safe torque off connection X5 Connection to embedded EIA 485 fieldbus adapter module X6 Relay output 3 X7 Relay output 2 X8...

Page 29: ...uit box Ensure grommets pointing down are inserted into all unused holes 3 Route the input power and motor wiring through separate conduits 4 Strip wires 5 Connect the motor and ground wires to the dr...

Page 30: ...6 N m WARNING To avoid danger or damage to the drive on IT systems and corner grounded TN systems see section Checking the compatibility with IT ungrounded and corner grounded TN systems North America...

Page 31: ...ctors for IP55 UL NEMA Type 12 not supplied Type 12 has a Pressfit gasket 2 Connect conduit runs for input power motor and control cables to the conduit box Ensure grommets pointing down are inserted...

Page 32: ...nd corner grounded TN systems North America on page 17 Power wiring torque table Frame size R3 lb ft N m T1 U T2 V T3 W 2 6 3 5 L1 L2 L3 2 6 3 5 R R 2 6 3 5 PE Ground 1 1 1 5 BREAKERS INPUT PE MOTOR R...

Page 33: ...conduit clamps for IP21 UL NEMA Type 1 or liquid tight conduit connectors for IP55 UL NEMA Type 12 not supplied Type 12 has a Pressfit gasket 2 Connect conduit runs for input power motor and control c...

Page 34: ...bility with IT ungrounded and corner grounded TN systems North America on page 17 Note UDC and UDC terminals are used for external brake chopper units Power wiring torque table Frame size R4 lb ft N m...

Page 35: ...Type 1 or liquid tight conduit connectors for IP55 UL NEMA Type 12 not supplied Type 12 has a Pressfit gasket 2 Connect conduit runs for input power motor and control cables to the conduit box Ensure...

Page 36: ...and corner grounded TN systems see section Checking the compatibility with IT ungrounded and corner grounded TN systems North America on page 17 Note UDC and UDC terminals are used for external brake...

Page 37: ...wn in the Power wiring torque table Note Frames R8 R9 If you connect only one conductor to the connector we recommend that you put it under the upper pressure plate 6 Connect the input power and groun...

Page 38: ...ge 17 Note UDC and UDC terminals are used for external brake chopper units Power wiring torque table Frame size R6 R7 R8 R9 lb ft N m lb ft N m lb ft N m lb ft N m T1 U T2 V T3 W 22 1 30 29 5 40 29 6...

Page 39: ...creen 2 AI1 Output frequency speed reference 0 to 10 V 3 AGND Analog input circuit common 4 10V Reference voltage 10 V DC 5 AI2 Actual feedback 0 to 20 mA 6 AGND Analog input circuit common 7 AO1 Outp...

Page 40: ...og input 1 3 AGND Analog input circuit common 4 10V Reference voltage 10 V DC 5 AI2 Actual feedback 0 to 20 mA 6 AGND Analog input circuit common 7 AO1 Output frequency 0 to 10 V 8 AO2 Motor current 0...

Page 41: ...or last unit on the link Bus not terminated default Bus terminated S5 BIAS Switches on the biasing voltages to the bus One and only one device preferably at the end of the bus must have the bias on Bi...

Page 42: ...ctor between the motor and the drive All protective earth ground conductors have been connected to the appropriate terminals and the terminals have been tightened The supply voltage matches the nomina...

Page 43: ...cover 1b 2 Tighten the retaining screw at the bottom with a screwdriver Frame R5 cover installations 1 Slide the conduit box upwards 1a and tighten the retaining screws 1b 2 Install the cover press i...

Page 44: ...ng on page 50 The ACH580 can be controlled by two default configurations HVAC default direct I O control Used for typical I O controlled BMS applications In the Auto mode this configuration uses a dir...

Page 45: ...ht corner of the display The arrow keys The up and down arrow keys and are used to highlight selections in menus and selection lists to scroll up and down on text pages and to adjust values when for e...

Page 46: ...it running Off key Stops the drive and switches to the Off mode Auto key In local control The drive will switch to external control Control panel display 1 Control location and related icons 2 Status...

Page 47: ...n or a Normal ID run is required during the drive start up when the load torque is higher than 20 or the machinery is not able to withstand the nominal torque transient during the ID run Note For addi...

Page 48: ...ed row by pressing Scroll the view with and Go to the next view by pressing Next 6 To select a value in an edit view Use and to select the value Press Save to accept the new setting or press Cancel to...

Page 49: ...change the value Press Save to accept the new setting or press Cancel to go back to the previous view without making changes 10 This step is optional and requires rotating the motor Do not do this if...

Page 50: ...D control submenu of the Primary Settings menu after you have commissioned the drive to use PID control 1 Press the Hand key to start the motor The Home view is shown on the panel Select Menu press on...

Page 51: ...the two assistants Go through the items on the menu Set the start stop and reference Commissioning with Primary settings Set the ramps Commissioning with parameters For advanced users only 5 Set the...

Page 52: ...he control program In the Main menu select a I O and press Select to enter the I O menu 2 Select the connection you want to check and press Select or 3 To view the details of a parameter that cannot b...

Page 53: ...After making the additional adjustments and checking the I O connections use the Diagnostics menu to make sure that the setup is functioning correctly In the Main menu select Diagnostics and press Se...

Page 54: ...y allow forward direction 1 Make sure that the control connections are wired according to the connection diagram given for the HVAC default See section Default control connections for the HVAC default...

Page 55: ...elect or and continue to the next step 4 Select Vector control and press Select or 5 Warning message Identification run is shown for a moment 6 Check the motor speed limits The following must be true...

Page 56: ...r them here The originals limits will be restored after the ID run unless you select Set values as permanent 11 Press the Hand key to start the ID run In general it is recommended not to press any con...

Page 57: ...cable including phasing and delta star connection Check for an earth fault in motor or motor cables by measuring the insulation resistances of motor and motor cable See Checking the insulation of the...

Page 58: ...ly or may overload the brake chopper or resistor Check the supply voltage If the problem persists contact your local ABB representative A3A2 DC link undervoltage Intermediate circuit DC voltage too lo...

Page 59: ...of the drive Check drive module cooling air flow and fan operation Check inside of cabinet and heatsink of drive module for dust pick up Clean whenever necessary A4B0 Excess temperature Power unit mo...

Page 60: ...the drive Contact your local ABB representative A5EB PU board powerfail Power unit power supply failure Contact your local ABB representative A5ED Measurement circuit ADC Measurement circuit fault Co...

Page 61: ...time is not set Timed functions cannot be used and fault log dates are not correct Set the system time manually or connect the panel to the drive to synchronize the clock If basic panel is used synchr...

Page 62: ...corresponding underload point 37 21 37 25 0003 Overload point below underload point A780 Motor stall Programmable warning 31 24 Stall function Motor is operating in stall region because of e g excessi...

Page 63: ...munication between drive and fieldbus adapter module A or between PLC and fieldbus adapter module A is lost Check status of fieldbus communication See user documentation of fieldbus interface Check se...

Page 64: ...Relay output 2 Select a different signal with parameter 10 27 RO2 source 0003 Relay output 3 Select a different signal with parameter 10 30 RO3 source A8B0 ABB Signal supervision 1 Editable message t...

Page 65: ...or current is being monitored Check the definition of the load curve parameter group 37 User load curve A981 External warning 1 Editable message text Programmable warning 31 01 External event 1 sourc...

Page 66: ...onfigured a season which starts before the previous season Configure the seasons with increasing start dates see parameters 34 60 Season 1 start date 34 63 Season 4 start date AF8C Process PID sleep m...

Page 67: ...verride active Drive is in override mode Informative warning B5A0 STO event Programmable event 31 22 STO indication run stop Safe torque off function is active ie safety circuit signal s connected to...

Page 68: ...ncy control Also check parameters 46 01 Speed scaling 46 02 Frequency scaling and 46 03 Torque scaling Check motor and motor cable including phasing and delta star connection Check there are no contac...

Page 69: ...23 Wiring or earth fault Incorrect input power and motor cable connection ie input power cable is connected to drive motor connection Check input power connections 3210 DC link overvoltage Excessive...

Page 70: ...ry 42F1 IGBT temperature Drive IGBT temperature is excessive Check ambient conditions Check air flow and fan operation Check heatsink fins for dust pick up Check motor power against drive power 4310 E...

Page 71: ...connections For more information see chapter The Safe torque off function in the Hardware manual of the drive and parameter 31 22 STO indication run stop Check the value of parameter 95 04 Control boa...

Page 72: ...problem persists contact your local ABB representative 6487 Stack overflow Internal fault Reboot the control unit using parameter 96 08 Control board boot or by cycling power If the problem persists c...

Page 73: ...ersists contact your local ABB representative 64B2 User set fault Loading of user parameter set failed because requested set does not exist set is not compatible with control program drive was switche...

Page 74: ...n mismatch between EFB protocol firmware and drive firmware 6685 EFB fault 2 Fault reserved for the EFB protocol application Check the documentation of the protocol 6686 EFB fault 3 Fault reserved for...

Page 75: ...ged Check the electrical specifications of the brake resistor against chapter Resistor braking in the Hardware manual of the drive Replace brake chopper if replaceable 7192 BC IGBT excess temperature...

Page 76: ...group 06 Control and status words Check settings of parameter group 60 DDCS communication Check the corresponding settings in the control program of the supply unit Check cable connections If necessar...

Page 77: ...ervision function 3 Check the source of the fault parameter 32 27 Supervision 3 signal 80B3 Signal supervision 4 Editable message text Programmable fault 32 36 Supervision 4 action Fault generated by...

Page 78: ...connections For more information see chapter The Safe torque off function in the Hardware manual of the drive and parameter 31 22 STO indication run stop Check the value of parameter 95 04 Control bo...

Page 79: ...al ABB representative 0005 0008 Internal error Contact your local ABB representative 0009 Asynchronous motors only Acceleration did not finish within reasonable time Contact your local ABB representat...

Page 80: ...e same as in the motor nameplate Contact your local ABB representative FF63 STO diagnostics failure SW internal malfunction Reboot the control unit using parameter 96 08 Control board boot or by cycli...

Page 81: ...escription I Inspection visual inspection and maintenance action if needed P Performance of on off site work commissioning tests measurements or other work R Replacement Action Description P Quality o...

Page 82: ...olled and the speed of the fan matches the cooling needs When the drive is stopped the main fan is kept running at a low speed to cool the control board Replacement fans are available from ABB Do not...

Page 83: ...the fan cable 4 Install the fan in reverse order 5 Restore power Frame Sizes R5 R8 To replace the fan 1 Remove power from drive 2 Remove the 2 screws attaching the fan mounting plate at the bottom of...

Page 84: ...er 8 Restore power Auxiliary cooling fan replacement Auxiliary cooling fans are not speed controlled and run all the time that the control board is powered Replacement fans are available from ABB Do n...

Page 85: ...e cover 2b Press the retaining clip of the control panel at the top 2c and pull it forward from the top edge 2d 3 Remove the front cover Loosen the retaining screws with a screwdriver 3a and lift the...

Page 86: ...Remove the control panel Press the retaining clip of the IP55 panel cover 2a and open the cover 2b Press the retaining clip of the control panel at the top 2c and pull it forward from the top edge 2d...

Page 87: ...ps 6 Pull off the fan 7 Install the fan in reverse order Note Make sure that the arrow on the fan points up 8 Restore power Second auxiliary cooling fan replacement IP55 UL NEMA Type 12 Frame Sizes R8...

Page 88: ...in storage or unused for a year or more See label on page 7 for how to find out the manufacturing date from the serial number For information on reforming the capacitors see Converter module capacito...

Page 89: ...NG Bypass configurations ACH580 VxR ACH580 BxR do not support Safe Torque Off STO functionality Enclosure Designation Horsepower Range by Voltage Rating 208V 460V 575V2 V1 1 to 3 HP 1 to 7 5 HP N A V2...

Page 90: ...havings or debris in the enclosure can damage electrical equipment and create a hazardous condition Where parts such as conduit plates require cutting or drilling first remove the part If that is not...

Page 91: ...following figures show the layout and wiring connection points For drive control wiring see pages 29 41 Maintain appropriate separation of control and power wires Drive Control Panel E Clipse Bypass C...

Page 92: ...pse Bypass E Clipse Bypass Control Panel Motor Input Motor Ground Lug Terminals Terminals Input Ground Lug Service Switch V3 V4 ACH580 Drive E Clipse Bypass Control Board Terminals X2 Fuses Drive Cont...

Page 93: ...or UL NEMA Type 3R The following figures show the layout and wiring connection points For drive control wiring see pages 29 41 Maintain appropriate separation of control and power wires ACH580 Drive M...

Page 94: ...se Bypass ACH580 Drive Motor Terminals Disconnect Switch or Circuit Breaker B2 Service Switch Optional E Clipse Bypass Control Board Terminals X2 User Power Cable Guides Input Ground Lug Fuses Bx1 2 B...

Page 95: ...E Clipse Bypass ACH580 Drive Disconnect Service Switch Optional E Clipse Bypass Control Board Terminals X2 Motor Ground Lug Input Terminals Fuses B3 600V 41A 77A Input Ground Lug Motor Terminals Switc...

Page 96: ...Clipse Bypass B3 Units above 77A ACH580 Drive Disconnect Service Switch Optional E Clipse Bypass Control Board Terminals X2 Motor Ground Lug Input Terminals Fuses Input Ground Lug Motor Terminals Swit...

Page 97: ...minals Fuses B2 Bx3R 2 Input Ground Lug Switch or Circuit Breaker Motor The alternate HI setting further reduces the likelihood of condensate in high humidity environments RHTR Temperature HI LO Jumpe...

Page 98: ...witch or circuit breaker Connect the equipment grounding conductor to the ground lug at the top of the enclosure The figure below shows the connection points for Standard E Clipse Bypass configuration...

Page 99: ...log inputs and outputs and additional digital input and relay output connections AI1 AI2 AO1 AO2 DI1 DI6 and RO1 RO6 are available for use Note The E Clipse Bypass control circuitry uses serial commun...

Page 100: ...2 7 5 R2 ACH580 VxR 031A 2 30 8 10 R2 4 55 in lbs 1 35 in lbs 2 50 in lbs ACH580 VxR 046A 2 46 2 15 R3 2 62 in lbs 2 55 in lbs 2 0 110 in lbs ACH580 VxR 059A 2 59 4 20 R3 1 55 in lbs ACH580 VxR 075A 2...

Page 101: ...Type 1 and 2 Motor Terminals UL NEMA Type 3R Ground Lugs UL NEMA Type 1 and 2 Ground Lugs UL NEMA Type 3R A HP 208 230 Volts ACH580 BxR 04A6 2 4 6 1 R1 12 62 in lbs 12 62 in lbs 10 55 in lbs 10 55 in...

Page 102: ...0 R2 10 62 in lbs 10 62 in lbs 8 55 in lbs 8 55 in lbs ACH580 BxR 023A 4 23 15 R2 6 55 in lbs 6 55 in lbs ACH580 BxR 027A 4 27 20 R3 8 62 in lbs 8 62 in lbs 4 55 in lbs 4 55 in lbs 1 35 in lbs 1 35 in...

Page 103: ...A 6 11 10 R2 ACH580 BxR 017A 6 17 15 R2 10 62 in lbs 10 62 in lbs 6 55 in lbs 6 55 in lbs ACH580 BxR 022A 6 22 20 R3 1 35 in lbs 1 35 in lbs 2 50 in lbs ACH580 BxR 027A 6 27 25 R3 4 55 in lbs 4 55 in...

Page 104: ...ses in the table are provided in the purchased product Replacement fuses are required to be of the same class current rating and voltage rating Fuses from other manufacturers can be used if they are 6...

Page 105: ...s J 60A ACH580 VxR 034A 4 34 25 R3 Class T 60A Class J 60A ACH580 VxR 044A 4 44 30 R3 Class T 60A Class J 60A ACH580 VxR 052A 4 52 40 R4 Class T 80A Class J 100A ACH580 VxR 065A 4 65 50 R4 Class T 90A...

Page 106: ...ACH580 BxR 114A 2 114 40 R5 Class T 150A Class J 300A ACH580 BxR 143A 2 143 50 R6 Class T 200A Class J 350A ACH580 BxR 169A 2 169 60 R7 Class T 250A Class J 350A ACH580 BxR 211A 2 211 75 R7 Class T 30...

Page 107: ...C 15A Class J 15A ACH580 BxR 09A0 6 9 7 5 R2 Class CC 15A Class J 20A ACH580 BxR 011A 6 11 10 R2 Class CC 15A Class J 25A ACH580 BxR 017A 6 17 15 R2 Class CC 30A Class J 40A ACH580 BxR 022A 6 22 20 R3...

Page 108: ...Parameter 1605 1701 NOT SEL Digital Input 6 Fixed SMOKE CONTROL OVERRIDE 1 10 11 X2 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Relay Output 1 parameter 1401 BYP NOT FLT Default Operation Bypass Not Fa...

Page 109: ...to be properly set before proceeding Refer to the ACH580 HVAC control program firmware manual and set the parameters as required Note The settings for ALL external serial communication between the AC...

Page 110: ...top Start Interlock and Run Permissive input contacts are closed and the system is in the Bypass mode and in either Hand or Auto the motor will start across the line as soon as power is applied If the...

Page 111: ...stop If the drive does not operate according to these steps refer to the ACH580 HVAC control program firmware manual If the drive operates according to these steps your ACH580 with E Clipse Bypass is...

Page 112: ...ct device and the bypass disconnect switch or circuit breaker 4 The ACH580 Control Panel display should be illuminated On the E Clipse Bypass control panel both the display and Enabled LED should be i...

Page 113: ...ass control panel causes the E Clipse Bypass display to indicate Bypass in Off 10 Press the HAND key on the drive control panel Note that the top line of the control panel display indicates HAND and r...

Page 114: ...he SW1 DIP switch on the E Clipse Bypass control board The function and setting of this switch is explained in the following paragraph DIP switch settings The DIP switch is used to configure the seria...

Page 115: ...door mounted control lever The lever can be padlocked in the OFF position padlock not supplied Bypass starter Motor overload protection Local operator panel with indicating lights and multifunction d...

Page 116: ...CH580 Box E Clipse Bypass configurations and identifies the major components E Clipse Bypass E Clipse Bypass Control Panel Operating Handle for Disconnect Switch or Circuit Breaker Drive Control Panel...

Page 117: ...or Disconnect Switch or Circuit Breaker E Clipse Bypass Control Panel Left and Drive Control Panel Right behind door B1 B2 Bx3R 1 Bx3R 2 ACH580 Drive with E Clipse Bypass Motor 3 Phase Drive 3 3 Disco...

Page 118: ...s are closed and Start command is present The Enabled LED is illuminated red when the Start Interlock contact s are open Motor Run LED The Motor Run LED is illuminated green when the motor is running...

Page 119: ...hes green when the system has automatically transferred to bypass operation The bypass event log will also record this event Auto Indication The Auto Indication is provided on the bypass control panel...

Page 120: ...modes The modes are Default Display mode Provides HAND OFF AUTO indication of the bypass operating control mode Bypass Status mode Provides status indications of the current system operating conditio...

Page 121: ...leave the Parameter Edit mode or 7 Press ESC to return to the Main Menu and again to return to the Default Display 1 The Default Display indicates the Bypass Control mode 2 Press ENTER to enter the M...

Page 122: ...eter value or press ESC to leave the Parameter Edit mode 6 Press the Up Down arrows to change the Parameter Value 7 Press ENTER to store the modified value or press ESC to leave the Parameter Edit mod...

Page 123: ...fective RBCU Disconnect incoming power from unit Check if contactor armature moves freely If armature moves freely then change the RBCU If armature does not move freely then change individual contacto...

Page 124: ...or the J7 connector location Use clam p meter to verify mtr current vs display in parameter 0101 Check input voltage 3010 INP PHASE A LOSS Fault will be generated when the bypass contactor is requeste...

Page 125: ...percentage of motor power as defined in the drive via parameter 9909 Fault only applies to bypass mode Broken belt Check load Reset bypass keypad Check fault code A780 on page 62 for further action 30...

Page 126: ...mation communicated via 485 link RBCU unit from a different size bypass used to replace a defective RBCU Parameters not matched after Firmware change Contact ABB at 1 800 752 0696 option 1 3028 EXT CO...

Page 127: ...rs 3101 SFLASH CORRUPT Internal checksum error NA Cycle power Replace RBCU Upgrade firmware 3102 PMAP FILE Parameter file is corrupt Cycle Power Contact ABB with information that preceded fault 3201 T...

Page 128: ...Manual ACH580 E Clipse Bypass 3207 UNKNOWN BYPASS NA NA Replace RBCU or load most current firmware Contact ABB at 1 800 752 0696 option 1 Replace RBCU or load most current firmware Fault Code Fault Na...

Page 129: ...osed Unit 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 inc...

Page 130: ...Bypass Mode Check that J2 connector is firmly seated in RBCU Check input voltage Does overload condition exist 4011 MTR UNDERLOAD Warning comes at half the time of a mtr underload fault See fault 3017...

Page 131: ...Digital input 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 i...

Page 132: ...g is displayed if MODE LOCK 1629 is set to LOCAL MODE and the Auto key is pressed 4027 COMM CONFIG ERR Warning is displayed if the drive and bypass MAC addresses are equal or invalid E Clipse paramete...

Page 133: ...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 ACTIVATED Sta...

Page 134: ...insufficient 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...

Page 135: ...vings or debris in the enclosure can damage electrical equipment and create a hazardous condition Where parts such as conduit plates require cutting or drilling first remove the part If that is not pr...

Page 136: ...configured for wiring access from the bottom only The following figures show the layout and wiring connection points For drive control wiring see pages 29 41 Maintain appropriate separation of contro...

Page 137: ...lation Operation and Maintenance Manual 137 ACH580 PCR PDR ACH580 Disconnect Switch or Circuit Breaker Motor Ground Lug Fuses P3 P4 Input Ground Lug Drive Input Terminals Motor Terminals Px1 3 Px12 3...

Page 138: ...ing access from the top for UL NEMA Type 1 and 12 and from the bottom for UL NEMA Type 3R The following figures show the layout and wiring connection points For drive control wiring see pages 29 41 AC...

Page 139: ...Maintenance Manual 139 ACH580 PCR PDR ACH580 Disconnect Switch or Circuit Breaker Motor Ground Lug User Power Input Terminals Drive Input Ground Lug Motor Terminals PB2 Cable Guides PxB1 2 PxB12 2 Fu...

Page 140: ...Maintenance Manual ACH580 PCR PDR PB3 PxB1 3 PxB12 3 ACH580 Drive Disconnect Motor Ground Lug Input Terminals Fuses Input Ground Lug Motor Terminals Switch or Circuit User Power Cable Guide Breaker Us...

Page 141: ...setting further reduces the likelihood of condensate in high humidity environments RHTR Temperature HI LO Jumber X1 Heater ON Temperature Heater OFF Temperature Default Setting X1 jumper in LO positi...

Page 142: ...017A 2 16 7 5 R1 6 62 in lbs 6 62 in lbs 6 55 in lbs 6 55 in lbs ACH580 PxR 024A 2 24 2 7 5 R2 6 1 1 ft lbs ACH580 PxR 031A 2 30 8 10 R2 4 62 in lbs 4 62 in lbs 4 55 in lbs 4 55 in lbs ACH580 PxR 046...

Page 143: ...6 1 1 ft lbs ACH580 PxR 023A 4 23 15 R2 6 55 in lbs 6 55 in lbs ACH580 PxR 027A 4 27 20 R3 8 62 in lbs 8 62 in lbs 4 55 in lbs 4 55 in lbs 2 2 6 ft lbs ACH580 PxR 034A 4 34 25 R3 6 62 in lbs 6 62 in l...

Page 144: ...62 in lbs 6 62 in lbs 6 55 in lbs 6 55 in lbs ACH580 PxR 022A 6 22 20 R3 2 2 6 ft lbs ACH580 PxR 027A 6 27 25 R3 4 62 in lbs 4 62 in lbs 4 55 in lbs 4 55 in lbs ACH580 PxR 032A 6 32 30 R3 ACH580 PxR...

Page 145: ...e rating Fuses from other manufacturers can be used if they are 600V rated and meet the specifications given in the table Fuses with higher current rating than specified must not be used 208 Volt fuse...

Page 146: ...Class T 80A N A N A ACH580 PxR 065A 4 65 50 R4 Class T 90A N A N A ACH580 PxR 077A 4 77 60 R4 Class T 100A N A N A ACH580 PxR 096A 4 96 75 R5 Class T 150A N A N A ACH580 PxR 124A 4 124 100 R6 Class T...

Page 147: ...144 150 R8 Class T 200A N A N A ACH580 PxR 180A 4 180 150 R2 Class T 300A N A N A ACH580 PxR 240A 4 240 200 R2 Class T 350A Class J or RK1 400A Max 1 PxR represents both PCR and PDR 2 PCR is rated 60...

Page 148: ...e operating handle can be padlocked in the OFF position padlock not supplied Enclosure options are UL NEMA Type 1 UL NEMA Type 12 and UL NEMA Type 3R NEMA 1 NEMA 12 and NEMA 3R The following is a typi...

Page 149: ...ed Drive configurations and identifies the major components Operating Handle Drive Control Panel for Disconnect Switch or Circuit Breaker PB1 PB2 PxB1 1 PxB12 1 PxB1 2 PxB12 2 PB3 PxB12 3 Hood and fil...

Page 150: ...ilter bracket in place 2 Remove the filter kit from the enclosure 3 Lift the filter out of the filter bracket and replace as appropriate 4 With the filter in the filter bracket reinstall filter kit on...

Page 151: ...filter time 12 27 AI2 min 12 28 AI2 max 12 29 AI2 scaled at AI2 min 12 30 AI2 scaled at AI2 max 12 101 AI1 percent value 12 102 AI2 percent value GROUP 13 Standard AO 13 02 AO force selection 13 11 A...

Page 152: ...7 duration 34 32 Timer 8 configuration 34 33 Timer 8 start time 34 34 Timer 8 duration 34 35 Timer 9 configuration 34 36 Timer 9 start time 34 37 Timer 9 duration 34 38 Timer 10 configuration 34 39 Ti...

Page 153: ...ss t out 50 04 FBA A ref1 type 50 05 FBA A ref2 type 50 06 FBA A SW sel 50 07 FBA A actual 1 type 50 08 FBA A actual 2 type 50 09 FBA A SW transparent source 50 10 FBA A act1 transparent source 50 11...

Page 154: ...atus 76 02 Multipump system status 76 11 Pump fan status 1 76 12 Pump fan status 2 76 13 Pump fan status 3 76 14 Pump fan status 4 76 21 Multipump configuration 76 25 Number of motors 76 26 Min number...

Page 155: ...2 ABB ACCESS 16 43 FB LOCK 16 44 DNLD LOCK GROUP 17 OVERRIDE 2 17 01 OVERRIDE 2 17 02 PERMIS OVR 17 03 INTLK1 OVR 17 04 INTLK2 OVR 17 06 INTLK4 OVR 17 07 FAULTS OVR 17 08 OVRD2 MODE GROUP 30 FLT FUNCT...

Page 156: ...3AXD50000049127 REV D Effective 2018 08 15 Supersedes 2018 06 08 ABB Inc 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 1 800 752 0696 Fax 1 262 785 0397 Internet www abb com drives...

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