ABB ACH550 Instruction Manual

ACH550

Installation, Operation and Maintenance Manual (I, O & M) ACH550-UH HVAC Drives (1 ACH550-BCR/BDR/VCR/VDR E-Clipse Bypass Drives (1

…550 HP)

…400 HP)

ACH550-PCR/PDR Packaged Drives with Disconnect (1

…550 HP)

2 ACH550 Installation, Operation and Maintenance Manual

Safety

Use of warnings and notes

There are two types of safety instructions throughout this manual:

• Notes draw attention to a particular condition or fact, or give information on a subject.

• Warnings caution you about con ditions whic h can result in serious injury or death and/or damage to the equipment. They also tell you how to avoid the danger . The warning symbols are used as follows:

Electricity warning warns of hazards from electricity which can cause physical injury and/or damage to the equipment.

• WARNING! The ACH550 adjustable speed AC drive should ONLY be installed by a qualified electrician.

• WARNING! Even when the motor is stopped, dangerous voltage is present at the power circuit terminals U1, V1, W1 (L1, L2, L3) and U2, V2, W2 (T1, T2 T3) and, depending on the frame size, UDC+ and UDC-, or BRK+ and BRK-.

• WARNING! Dangerous voltage is present when input power is connected. After disconnecting the supply, wait at least 5 minutes (to let the intermediate circuit capacitors discharge) before removing the cover.

• WARNING! Even when power is switched off from the input terminals of the ACH550, there may be dangerous voltage (from external sources) 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 single source which can either be one of the drives or an external supply.

• WARNING! Disconnect the internal EMC filter when installing the drive on an IT system (an ungrounded power system or a

high-resistance-grounded [over 30 ohm] power system).

• WARNING! Do not attempt to install or remove EM1, EM3, F1 or F2 screws while power is applied to the drive’s input terminals.

General warning warns about conditions, other than those caused by electricity, which can result in physical injury and/or damage to the equipment.

• WARNING! Do not control the motor with the disconnecting device (disconnecting means); instead, use the control panel keys 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.

• WARNING! Never attempt to repair a malfunctioning ACH550; contact the factory or your local Authorized Service Center for repair or replacement.

• WARNING! The ACH550 will start up automatically after an input voltage interruption if the external run command is on.

• WARNING! The heat sink may reach a high temperature.

Note: For more technical information, contact the factory or your local ABB representative.

Safety

ACH550 Installation, Operation and Maintenance Manual 3

S/N

ACH550-UH-059A-2

2030700001

SW: V.2.06B 2030700001

Input Voltage (U1) Current (I1n)

3 PH 48…63 Hz 200…240 Vac

59.4 A

1 PH 4…63 Hz 200…240 Vac

59.4 A

Output Voltage (U2) Current (I2n)

3 PH 0…500 Hz 0…U1 Vac

59.4 A

3 PH 0…500 Hz 0…U1 Vac 28 A

ACH550-UH-059A-2

Power (Pn)

Mfg. Date: 01-December-2005

Org. Firmware: V.2.06B

ABB Inc. Made in USA of foreign parts

10 HP20 HP

kAIC

S/N

2030700001

Construction

code

Contents

This manual is the Operation and Maintenance Manual for the ACH550 Drives. Complete technical details and programming information are available in the ACH550 User’s Manual, publication number 3AUA0000081823.

1. To determine the type of your drive, refer to its construction code on either:

• Serial number label attached on upper part of the chokeplate between the mounting holes.

• Type code label attached on the heat sink – on the side of the enclosure.

ACH550 Installation, Operation and Maintenance Manual 39

ACH550 E-Clipse Bypass

Installation – drive

Follow the Installation instructions for the drive on page 3. Failure to observe the warnings and instructions may cause a malfunction or personal hazard.

WARNING! Before you begin read Safety on page 2.

Installation – bypass

WARNING! When the ACH550 with E-Clip se Byp ass is connected to the line power,

the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do not make any connections when the ACH550 with E-Clipse Bypass 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 – bypass

WARNING!

• Do not connect or disconnect input or output power wiring, or control wires, when power is applied.

• Never connect line voltage to drive output Terminals T1, T2, and T3.

• Do not 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.

Enclosure

Designation

V1/V2 1 to 7.5 HP 1 to 15 HP 2 to 15 HP V3/V4 10 to 25 HP 20 to 60 HP 20 to 60 HP

B1 1 to 7.5 HP 1 to 15 HP 2 to 15 HP B2 10 to 25 HP 20 to 60 HP 20 to 60 HP B3 30 to 100 HP 75 to 200 HP 75 to 150 HP B4 N/A 250 to 550 HP N/A

208/240V 480V 600V

Horsepower Range by Voltage Rating

ACH550 E-Clipse Bypass

40 ACH550 Installation, Operation and Maintenance Manual

BP0054

ACH550

E-Clipse Bypass

Control Board

Terminals (X2)

Disconnect Switch

or Circuit Breaker

Output

Input Power

Output Ground

Lug(s)

Cable

Terminals

Output

Ground Lug(s)

Output

Terminals

V1/V2

V3/V4

Service Switch

(Optional)

Input

Ground Lug

Terminals

Service Switch

(Optional)

Connection diagrams – Vertical E-Clipse Bypass

ACH550 Vertical E-Clipse Bypass units are configured for wiring access from the bottom only. The following figure shows the Vertical E-Clipse Bypass wiring connection points.

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual 41

ACH550

Motor

Input Power

Output Ground

Terminals

Disconnect Switch

or Circuit Breaker

Service Switch

(Optional)

E-Clipse Bypass

Control Board

Terminals X2

User Power

Cable Guides

Input Ground

Lug(s)

Lug

Connection diagrams – Standard E-Clipse Bypass (wall mounted)

ACH550 Standard E-Clipse Bypass units are configured for wiring access from the top. The following figure shows the St anda rd E-Clip se Bypass (wall mounted) wiring connection points.

ACH550 E-Clipse Bypass

42 ACH550 Installation, Operation and Maintenance Manual

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

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual 43

ACH550 Drive

E-Clipse Bypass

Control Board Terminals ( x2)

Disconnect Switch

or Circuit Breaker

Ground Lug Bar

Input Power

Terminals

Motor Terminals

Service Switch

(optional)

ACH550 Control Board Terminals ( x1)

Connection diagrams – Standard E-Clipse Bypass (R8, floor mounted)

ACH550 Standard E-Clipse Bypass units are configured for wiring access from the top. The following figure shows the S ta ndard E-Clipse Byp ass (floor mounted) wiring connection points.

ACH550 E-Clipse Bypass

44 ACH550 Installation, Operation and Maintenance Manual

Ground

Input Power

Cables

Motor

Cables

Power connections – Vertical E-Clipse Bypass configurations Line input connections

Connect the input power to the terminals at the bottom of the disconnect switch or circuit breaker as shown below. Also see

Connection diagrams – Vertical E-Clipse Bypass on page 40. Connect the

equipment grounding conductor to the ground lug near the input power connection point.

Motor connections

Connect the motor cables to the terminals at the bottom of the bypass section as shown in the figure. Also see Connection

diagrams – Vertical E-Clipse Bypass on

page 43. Connect the motor grounding conductor to the ground lug near the motor cable terminal block connection point.

Power connections – Standard E-Clipse Bypass configurations (wall mounted) Line input 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 below shows the connection points for Standard E-Clipse Bypass configurations. Also see Connection diagrams – Standard E-Clipse Bypass

(wall mounted) on page 41 and Connection diagrams – Standard E-Clipse Bypass (R8, floor mounted) on page 43.

Motor connections

Connect the motor cables to the output terminal block as shown in the figure below. Also see Connection diagrams – St andard E-Clipse Bypass (wall mounted) on page

41 and Connection diagrams – Standard E-Clipse Bypass (R8, floor mounted) on

page 43. The motor grounding conductor can be connected to the ground lug near the terminal block.

Note: Route cables through the cable guides on the left side of the enclosure. Use separate conduits for input power and motor cables. Follow the guides to separate the cables from each other.

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual 45

Standard Configuration (B3)

Input

Ground

Standard Configuration (B1/B2)

Power

Cables

User Power

Cable Guides

Motor

Cables

Ground

Motor

Cables

Input Power

Cables

Ground

UL Type 3R Configuration (B1/B2)

Motor Cables

Ground

Input Power

Cables

RHTR Temperature

HI / LO Jumper (X1)

Heater ON

Temperature

Heater OFF

Temperature

Default Setting

(X1 jumper in LO position)

14.4 °C 58 °F

21.4 °C

70.5 °F

Alternate Setting

(X1 jumper in HI position)

17.8 °C 64 °F

24.7 °C

76.5 °C

The alternate (HI) setting further reduces the likelihood of condensate in high humidity environments.

Note: UL Type 3R, B1/B2 enclosures are designed to be mounted on a wall.

Mounting these 3R enclosures on an open rack system requires the use of the supplied 3R enclosure back plates to maintain 3R integrity.

ACH550 E-Clipse Bypass

46 ACH550 Installation, Operation and Maintenance Manual

WARNING! Check the motor and motor wiring insulation before connecting the ACH550 to line power . Follow the procedure on page 12. Before proce eding with the insulation resistance measurements, check that the ACH550 is disconnected from incoming line power. Failure to disconnect li ne power could result in death or serious injury.

Install the control wiring

Connect control wiring to terminal block X1 on the ACH550 control board and to terminal block X2 on the E-Clipse Bypass control board. For more information on these connections, refer to the following:

• X1 terminal 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 page 40.

• X2 terminal data are provided in Basic control connections for E-Clipse HVAC

Default on page 53.

• Basic connections are described in the following paragraphs. Alternate configurations using the E-Clipse Bypass macro are described in the ACH550 User’s Manual.

• On Terminal Block X1 inside the ACH550, analog 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 communications connections (X1:28…X1:32) inside the ACH550. These connections are not available for any other purpose and must not be reconfigured.

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual 47

EIA-485

port

control

terminals

Digital I/O

control

terminals

Basic connections

The figure on page 53 shows the basic control connections for use with the EClipse Bypass HVAC Default macro. These connections are described in the following paragraphs.

In typical installations, only analog input wires connect to the ACH550 terminal block, with other control 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") spacing from power wiring.

Drive’s power connection terminals

The following tables list power and motor cable terminal sizes for connections to an input circuit breaker or disconnect switch, a motor terminal block and ground lugs. The tables also list torque that should be applied when tightening the terminals.

ACH550 E-Clipse Bypass

48 ACH550 Installation, Operation and Maintenance Manual

Vertical enclosure terminals

HP Identification

1 ACH550-VxR-04A6-2 R1

1.5 ACH550-VxR-06A6-2 R1 2 ACH550-VxR-07A5-2 R1 3 ACH550-VxR-012A-2 R1 5 ACH550-VxR-017A-2 R1

7.5 ACH550-VxR-024A-2 R2

10 ACH550-VxR-031A-2 R2

15 ACH550-VxR-046A-2 R3 20 ACH550-VxR-059A-2 R3

25 ACH550-VxR-075A-2 R4

1/1.5 ACH550-VxR-03A3-4 R1

2 ACH550-VxR-04A1-4 R1 3 ACH550-VxR-06A9-4 R1 5 ACH550-VxR-08A8-4 R1

7.5 ACH550-VxR-012A-4 R1

10 ACH550-VxR-015A-4 R2 15 ACH550-VxR-023A-4 R2 20 ACH550-VxR-031A-4 R3 25 ACH550-VxR-038A-4 R3 30 ACH550-VxR-045A-4 R3 40 ACH550-VxR-059A-4 R4

50 ACH550-VxR-072A-4 R4

60 ACH550-VxR-078A-4 R4

Frame

Size

Maximum Wire Size Capacities of Power Terminals

Circuit

Breaker

208…240 Volt

#10

35 in-lbs

40 in-lbs

50 in-lbs

380…480 Volt

#10

35 in-lbs

40 in-lbs

50 in-lbs

Disconnect

Switch

#10

7 in-lbs

18 in-lbs

55 in-lbs

#10

7 in-lbs

18 in-lbs

55 in-lbs

70 in-lbs

Motor

Termination

30 in-lbs

50 in-lbs

#2/0

120 in-lbs

30 in-lbs

50 in-lbs

#2/0

120 in-lbs

Ground

Lugs

35 in-lbs

50 in-lbs

35 in-lbs

50 in-lbs

ACH550 E-Clipse Bypass

ACH550 Installation, Operation and Maintenance Manual 49

HP Identification

2 ACH550-VxR-02A7-6 R2 3 ACH550-VxR-03A9-6 R2 5 ACH550-VxR-06A1-6 R2

7.5 ACH550-VxR-09A0-6 R2 10 ACH550-VxR-011A-6 R2 15 ACH550-VxR-017A-6 R2 20 ACH550-VxR-022A-6 R3 25 ACH550-VxR-027A-6 R3 30 ACH550-VxR-032A-6 R4 40 ACH550-VxR-041A-6 R4 50 ACH550-VxR-052A-6 R4

60 ACH550-VxR-062A-6 R4

Frame

Size

Maximum Wire Size Capacities of Power Terminals

Circuit

Breaker

500…600 Volt

62 in-lbs

Disconnect

Switch

18 in-lbs

55 in-lbs

70 in-lbs

Motor

Termination

30 in-lbs

50 in-lbs

#2/0

120 in-lbs

Ground

Lugs

35 in-lbs

50 in-lbs

ACH550 E-Clipse Bypass

+ 31 hidden pages