ABB ACH550 User Manual
ACH550
User’s Manual
ACH550-01 Drives
Kit, IP21 /
UL type 1
Frame
size
Code (English)
FMK-A-R1 R1 100000982
FMK-A-R2 R2 100000984
FMK-A-R3 R3 100000986
FMK-A-R4 R4 100000988
Kit, IP54 /
UL type 12
Frame
size
Code (English)
FMK-B-R1 R1 100000990
FMK-B-R2 R2 100000992
FMK-B-R3 R3 100000994
FMK-B-R4 R4 100000996
ACH550-01 Drive manuals
GENERAL MANUALS
ACH550-01 User's Manual
3AFE68258537 (English)
HVAC Info Guide CD
3AFE68338743 (English)
• Detailed product description
– Technical product description incl.
dimensional drawings
– Cabinet mounting information
including power losses
– Software and control
– User interfaces and control
connections
– Complete options descriptions
– Spare parts etc.
• Practical engineering guides
– PID & PFA engineering guide
– Dimensioning and sizing
– Diagnostics and maintenance
–Etc.
Flange Mounting Instructions
RBIP-01 BACnet/IP Router
Module Installation Manual
3AUA0000040168 (English)
RBIP-01 BACnet/IP Router
Module User’s Manual
3AUA0000040159 (English)
RCAN-01 CANopen Adapter
User's Manual
3AFE64504231 (English)
RCCL-01 CC-Link Adapter
Module User's Manual
3AUA0000061340 (English)
RCNA-01 ControlNet Adapter
User's Manual
3AFE64506005 (English)
RDNA-01 DeviceNet Adapter
User's Manual
3AFE64504223 (English)
OPTION MANUALS
(delivered with optional equipment)
ACH550-01+B055+F278 Drives
Installation Supplement
3AUA0000040634 (Multilingual)
BACnet® Protocol
3AUA0000004591 (English)
Embedded Fieldbus (EFB)
Control
3AFE68320658 (English)
REPL-01 Ethernet POWERLINK
Adapter Module User's Manual
3AUA0000052289 (English)
RETA-01 Ethernet Adapter
Module User's Manual
3AFE64539736 (English)
RETA-02 Ethernet Adapter
Module User's Manual
3AFE68895383 (English)
RLON-01 L
ONWORKS® Adapter
Module User’s Manual
3AFE64798693 (English)
RPBA-01 PROFIBUS DP Adapter
User's Manual
3AFE64504215 (English)
SREA-01 Ethernet Adapter User's
Manual
3AUA0000042896 (English)
MAINTENANCE MANUALS
MFDT-01 FlashDrop User’s
Manual
3AFE68591074 (English)
OREL-01 Relay Output Extension
Module User's Manual
3AUA0000001935 (English)
Guide for Capacitor Reforming in
ACS50, ACS55, ACS150, ACS310,
ACS320, ACS350, ACS550 and
ACH550
3AFE68735190 (English)
1. Contents of this manual
2. Preparing for installation
3. Installing the drive
4. Start-up and control panel
5. Application macros and wiring
6. Real-time clock and timed functions
7. Serial communications
8. Parameter listing and descriptions
3AFE68258537 REV F
EN
EFFECTIVE: 2009-07-07
9. Diagnostics and maintenance
10. Technical data
Index
ACH550-01 User's Manual
Table of contents
1. Contents of this manual ............................................. 5
What this chapter contains .......................................... 5
Compatibility ................................................................5
Intended use................................................................5
Intended audience ....................................................... 5
Use of warnings and notes.......................................... 6
Safety instructions ....................................................... 6
Drive package..............................................................9
Lifting the drive .......................................................... 10
Product and service inquiries..................................... 11
Product training..........................................................11
Providing feedback on ABB Drives manuals .............11
Document library on the Internet ............................... 11
2. Preparing for installation.......................................... 13
What this chapter contains ........................................ 13
Drive identification ..................................................... 14
Frame size.................................................................17
Motor identification..................................................... 19
Motor compatibility.....................................................21
Suitable environment and enclosure ......................... 22
Suitable mounting location......................................... 23
Wiring and EMC considerations ................................ 26
Cabling instructions ................................................... 28
Input power (mains) cables........................................ 28
Motor cables .............................................................. 28
Control cables............................................................32
Tools required............................................................35
Checklist for installation preparations........................36
3. Installing the drive..................................................... 37
What this chapter contains ........................................ 37
Preparing the mounting location................................38
Table of contents 1
ACH550-01 User's Manual
Removing front cover (IP54)......................................39
Removing front cover (IP21)......................................40
Mounting the drive (IP54)........................................... 41
Mounting the drive (IP21)........................................... 42
Overview of wiring installation (R1…R4) ...................43
Overview of wiring installation (R5…R6) ...................44
Checking the insulation of the assembly....................46
Power wiring (IP54)....................................................47
Control wiring (IP54)..................................................50
Power wiring (IP21)....................................................51
Control wiring (IP21)..................................................54
Check installation.......................................................56
Re-install cover (IP54) ...............................................58
Re-install cover (IP21) ...............................................59
Apply power...............................................................60
4. Start-up and control panel........................................ 63
What this chapter contains.........................................63
Control panel compatibility.........................................63
HVAC control panel (ACH-CP-B) features................. 63
Start-up......................................................................64
Modes........................................................................67
Output (Standard display) mode................................ 68
Parameters mode ......................................................70
Assistants mode.........................................................72
Changed parameters mode.......................................76
Drive parameter backup mode................................... 77
Time and date mode..................................................84
I/O settings mode.......................................................87
Fault logger mode......................................................88
5. Application macros and wiring................................ 89
What this chapter contains.........................................89
Applications................................................................89
Selecting an application macro..................................90
Restoring defaults......................................................91
1. HVAC default.........................................................92
2. Supply fan..............................................................94
2 Table of contents
ACH550-01 User's Manual
3. Return fan..............................................................96
4. Cooling tower fan................................................... 98
5. Condenser ........................................................... 100
6. Booster pump ...................................................... 102
7. Pump alternation.................................................. 104
8. Internal timer........................................................106
9. Internal timer with constant speeds / Powered
roof ventilator .......................................................108
10. Floating point ..................................................... 110
11. Dual setpoint PID............................................... 112
12. Dual setpoint PID with constant speeds ............ 114
13. E-bypass (USA only) ......................................... 116
14. Hand control ...................................................... 118
Connection examples of two-wire and three-wire
sensors................................................................. 120
6. Real-time clock and timed functions..................... 121
What this chapter contains ...................................... 121
Real-time clock and timed functions........................121
Using the timer.........................................................122
Example of timer use...............................................129
7. Serial communications........................................... 133
What this chapter contains ...................................... 133
System overview...................................................... 134
Embedded fieldbus (EFB)........................................ 136
Fieldbus adapter (EXT FBA).................................... 141
Drive control parameters ......................................... 147
Fault handling .......................................................... 156
8. Parameter listing and descriptions ....................... 159
What this chapter contains ...................................... 159
Parameter groups....................................................159
Complete parameter list........................................... 322
9. Diagnostics and maintenance................................ 363
What this chapter contains ...................................... 363
Table of contents 3
ACH550-01 User's Manual
Diagnostics displays ................................................364
Correcting faults.......................................................365
Fault resetting..........................................................374
History......................................................................375
Correcting alarms.....................................................375
Maintenance intervals..............................................380
Heatsink...................................................................381
Main fan replacement ..............................................381
Internal enclosure fan replacement.......................... 385
Capacitors................................................................386
Control panel............................................................387
10. Technical data........................................................ 389
What this chapter contains.......................................389
Ratings.....................................................................389
Input power (mains) cable, fuses and circuit
breakers ...............................................................395
Input power and motor connection terminals........... 402
Input power (mains) connection...............................403
Motor connection .....................................................404
Control connections.................................................408
Efficiency..................................................................412
Cooling.....................................................................412
Dimensions and weights..........................................414
Ambient conditions...................................................434
Materials ..................................................................435
Applicable standards................................................436
CE marking..............................................................436
C-Tick marking.........................................................437
UL marking...............................................................437
IEC/EN 61800-3 (2004) Definitions..........................438
Compliance with the IEC/EN 61800-3 (2004)..........438
Product protection in the USA..................................440
Contact information..................................................441
Index........................................................................445
4 Table of contents
ACH550-01 User's Manual
Contents of this manual
What this chapter contains
This chapter contains the 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, the motor or driven equipment. Read the
safety instructions before you work on the unit.
This chapter also contains an introduction to the contents of this
manual.
At the end of the chapter you find instructions on how to make
inquiries about products and service, find information on product
training and give feedback on the drive manuals.
Compatibility
This manual covers ACH550-01 drives. For ACH550-UH drive
data and instructions, please refer to ACH550-UH HVAC Drives
User’s Manual (3AUA0000004092 [English]).
The manual is compatible with the ACH550-01 drive firmware
version 3.13d or later. See parameter 3301 FIRMWARE on page
250.
Intended use
The ACH550 and the instructions in this manual are intended for
use in HV AC applications. The macros should only be applied to
the applications defined in the respective section.
Intended audience
This manual is intended for personnel who install, commission,
operate and service the drive. Read the manual before working
on the drive. The reader is expected to know the fundamentals
of electricity, wiring, electrical components and electrical
schematic symbols.
Contents of this manual 5
Use of warnings and notes
There are two types of safety instructions throughout this
manual:
• Warnings caution you about conditions which can result in
serious injury or death and/or damage to the equipment.
They also tell you 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:
Electricity warning warns of hazards from electricity
which can cause physical injury and/or damage to the
equipment.
General warning warns about conditions, other than
those caused by electricity, which can result in physical
injury and/or damage to the equipment.
ACH550-01 User's Manual
Safety instructions
WARNING! The ACH550 should ONLY be installed by a
qualified technician.
WARNING! Even when the motor is stopped, dangerous voltage
is present at the power circuit terminals U1, V1, W1 and U2, V2,
W2, and, depending on the frame size, UDC+/BRK+ and
UDC-/BRK-.
WARNING! Dangerous voltage is present when input power is
connected. After disconnecting the supply, wait at least 5
minutes before removing the cover. To check, measure for zero
voltage at the DC terminals, which are, depending on the frame
size, UDC+/BRK+ and UDC-/BRK-.
6 Contents of this manual
ACH550-01 User's Manual
WARNING! Even when the 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
RO1…RO3 and, if the relay extension board is included in the
installation, RO4…RO6.
WARNING! When the control terminals of two or more drive
units 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 units or an external supply.
WARNING! Disconnect the EMC filter when installing the drive
on an IT system (an unearthed power system, a high-resistanceearthed [over 30 ohms] power system or a power system
equipped with residual current circuit breakers), otherwise the
system will be connected to earth potential through the EMC
filter capacitors. This may cause danger or damage the drive.
Disconnect the EMC filter when installing the drive on a cornerearthed TN system, otherwise the drive will be damaged.
Note: When the EMC filter is disconnected, the drive is not EMC
compatible.
For disconnecting the EMC filter, see Disconnecting the internal
EMC filter on page 45.
WARNING! The ACH550 is not a field repairable unit. Never
attempt to repair a malfunctioning unit; contact the factory or
your local Authorized Service Centre for 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. See
chapter Technical data.
Contents of this manual 7
ACH550-01 User's Manual
WARNING! Do not control the motor with an AC contactor or
disconnecting device (disconnecting means); use instead the
control panel (operator keypad) start (HAND ), AUTO )
and stop (OFF ) keys or external commands (I/O or
fieldbus). The maximum allowed number of charging cycles of
the DC capacitors (i.e. power-ups by applying power) is five in
ten minutes.
Note: For more technical information, contact your local ABB
representative (see page 441).
8 Contents of this manual
ACH550-01 User's Manual
1
2
3
4
5
6
Drive package
After opening the package, check that the following items are
included:
• ACH550 drive (1)
• type IP21: box containing clamps and connection box (2),
type IP54: top cover
• box containing control panel (operator keypad) ACH-CP-B
and panel connector (3)
• cardboard mounting template (4)
• user’s manual (5)
• warning stickers
• polyamide screws (in the R1, R2 and R3 packages) (6).
The figure below shows the contents of the drive package.
Contents of this manual 9
Lifting the drive
The figure below shows how to lift the drive.
Note: Lift the drive only from the metal chassis.
ACH550-01 User's Manual
10 Contents of this manual
ACH550-01 User's Manual
Product and service inquiries
Address any inquiries about the product to your local ABB
representative, quoting the type designation and serial number
of the unit in question. A listing of ABB sales, support and
service contacts can be found by navigating to
www.abb.com/drives and selecting Sales, Support and Service
Network.
Product training
For information on ABB product training, navigate to
www.abb.com/drives
and select Training courses.
Providing feedback on ABB Drives manuals
Your comments on our manuals are welcome. Go to
www.abb.com/drives and select Document Library – Manuals
feedback form (LV AC drives).
Document library on the Internet
You can find manuals and other product documents in PDF
format on the Internet. Go to www.abb.com/drives and select
Document Library. You can browse the library or enter selection
criteria, for example a document code, in the search field.
Contents of this manual 11
ACH550-01 User's Manual
12 Contents of this manual
ACH550-01 User's Manual
Preparing for installation
What this chapter contains
This chapter contains instructions for preparing for the
installation of the drive. It contains the drive identification, wiring
and EMC guidelines and a list of tools necessary for the
installation.
Note: The installation must always be designed and made
according to applicable local laws and regulations. ABB does
not assume any liability whatsoever for any installation which
breaches the local laws and/or other regulations. Furthermore, if
the recommendations given by ABB are not followed, the drive
may experience problems that the warranty does not cover.
Preparing for installation 13
Drive identification
IP54 drive labels
The location and the contents of the labels for the IP54 degree
of protection are shown in the figure below.
ACH550-01 User's Manual
Note: The location of the labels may vary between different
frame sizes.
14 Preparing for installation
ACH550-01 User's Manual
IP21 drive labels
The location and the contents of the labels for the IP21 degree
of protection are shown in the figure below.
Note: The location of the labels may vary between different
frame sizes.
Preparing for installation 15
ACH550-01 User's Manual
ACH550-01-08A8-4+…
AC, HVAC Drive – 550 product series
Construction (region specific)
Output current rating
Voltage rating
Degree of protection
No specification = IP21
B055 = IP54
08A8 = 8.8 A, see the table in section
Frame size
on page 17 for details
2 = 208…240 VAC
4 = 380…480 VAC
01 = Setup and parts specific to IEC installation and compliance
UH = Setup and parts specific to US installation and NEMA compliance
Type designation
The contents of the drive type designation shown on the labels
are described below.
Serial number
The format of the drive serial number shown on the labels is
described below.
Serial number is of format CYYWWXXXXX, where
C: Country of manufacture
YY: Year of manufacture
WW: Week of manufacture; 01, 02, 03, … for week 1, week 2, week 3, …
XXXXX: Integer starting every week from 00001.
16 Preparing for installation
ACH550-01 User's Manual
Frame size
Type
ACH550-01-
I
2N
A
P
N
kW
Frame size
Three-phase supply voltage, 220…240 V
04A6-2 4.6 0.75 R1
06A6-2 6.6 1.1 R1
07A5-2 7.5 1.5 R1
012A-2 11.8 2.2 R1
017A-2 16.7 4.0 R1
024A-2 24.2 5.5 R2
031A-2 30.8 7.5 R2
046A-2 46 11 R3
059A-2 59 15 R3
075A-2 75 18.5 R4
088A-2 88 22 R4
114A-2 114 30 R4
143A-2 143 37 R6
178A-2 178 45 R6
221A-2 221 55 R6
248A-2 248 75 R6
Three-phase supply voltage, 380…480 V
02A4-4 2.4 0.75 R1
03A3-4 3.3 1.1 R1
04A1-4 4.1 1.5 R1
05A4-4 5.4 2.2 R1
06A9-4 6.9 3.0 R1
08A8-4 8.8 4.0 R1
012A-4 11.9 5.5 R1
015A-4 15.4 7.5 R2
023A-4 23 11 R2
031A-4 31 15 R3
038A-4 38 18.5 R3
045A-4 45 22 R3
Preparing for installation 17
ACH550-01 User's Manual
Type
ACH550-01-
I
2N
A
P
N
kW
Frame size
059A-4 59 30 R4
072A-4 72 37 R4
087A-4 87 45 R4
125A-4 125 55 R5
157A-4 157 75 R6
180A-4 180 90 R6
195A-4 205 110 R6
246A-4 246 132 R6
290A-4 290 160 R6
00467918.xls C
Mark the frame size of your drive in the box on
the right.
Note: For detailed technical information, see chapter Technical
data.
18 Preparing for installation
ACH550-01 User's Manual
6313/C3
F
M3JP 250SMA 4 EExd IIB T4 B3
3492820
IEC 60034-1
LV Motors, Vaasa, Finland
ABB Oy, Electrical Machines
5814795550Y690
Prod.code 3GJP252210-ADG138148
6315/C3
LCIE 00 ATEX 6030
415
380
660
400
D
D
50
50
D
Y
50
50
ABB
1480
1475
1475
1479
99
104
101
60
IEC 250S/M 65
S1
3 Motor
VHz r/minkW
No.
Ins.cl.
A
0.83
450 kg
0.82
0.85
0.83
0.85
55
Duty
cos
IP
LJ-20964-1 / 2001
440 D 60 1775 103 0.85
55
55
55
63
55
Motor identification
An example motor rating plate for an IEC motor is shown below.
Collect the following information:
•voltage
• nominal motor current
• nominal frequency
• nominal speed
• nominal power.
Preparing for installation 19
ACH550-01 User's Manual
L1 L2 L3 L1 L2 L3
W2 U2 V2 W2 U2 V2
U1 V1 W1 U1 V1 W1
The figure below shows a motor with star and delta connections.
For the highlighted row of the example motor rating plate on
page 19, the connection is delta.
Note: Check which connection is correct for your motor type.
20 Preparing for installation
ACH550-01 User's Manual
Motor compatibility
The motor, drive and supply power must be compatible:
Motor
specification
Motor type 3-phase induction
motor
Nominal current type dependent • type designation
Nominal frequency 10…500 Hz Voltage range Motor requirement
and supply voltage
are both 3-phase
voltage and are
within the ACH550
voltage range.
Verify Reference
-
label on drive,
entry for “Output
I2N” (current), or
• type designation
on drive and
rating table in
Ratings in
chapter
Technical data.
208…240 V
380…480 V
Preparing for installation 21
ACH550-01 User's Manual
Suitable environment and enclosure
Confirm that the site meets the environmental requirements. To
prevent damage prior to installation, store and transport the
drive according to the environmental requirements specified for
storage and transportation. See section Ambient conditions on
page 434.
Confirm that the enclosure (degree of protection) is appropriate,
based on the site containment level:
• IP21 type enclosure. The site must be free from airborne
dust, corrosive gases or liquids, and conductive
contaminants such as dripping water, condensation, carbon
dust, and metallic particles.
• IP54 type enclosure. This enclosure provides protection from
airborne dust and light sprays or splashing water from all
directions.
Compared to the IP21 enclosure, the IP54 enclosure has:
• the same internal plastic shell as the IP21 enclosure
• a different outer plastic cover
• an additional internal fan to improve cooling
• larger dimensions
• the same rating (does not require a derating).
If, for some reason, an IP21 drive needs to be installed without
the conduit box or cover, or an IP54 drive without the conduit
plate or top cover, see the note on page 437.
22 Preparing for installation
ACH550-01 User's Manual
R1…R6
IP21 & IP54: 200 mm [8 in]
IP21 & IP54: 200 mm [8 in]
IP21 & IP54: 0 mm [0 in]IP21 & IP54: 0 mm [0 in]
Suitable mounting location
Confirm that the mounting location meets the following
constraints:
• The drive must be mounted vertically on a smooth,
non-flammable, solid surface or frame, and in a suitable
environment as defined in section Suitable environment and
enclosure on page 22.
• For horizontal installation, contact ABB for more information
(see page 441).
Mounting on a machine frame is also possible. No additional
plates are needed for cooling as the drive has an integral
heatsink backplate.
See section Mounting dimensions on page 415 for mounting
dimensions for all frame sizes and protection types.
The figure below shows the necessary free space for the
installation of the unit.
Preparing for installation 23
ACH550-01 User's Manual
200 mm
200 mm
Make sure that the hot air does not re-circulate into the drive.
The figure below show the minimum space for cooling air.
24 Preparing for installation
ACH550-01 User's Manual
200 mm
200 mm
200 mm
200 mm
Stop the hot air from a drive from entering the cooling air intake
of another drive with an adequate mechanical obstacle between
the drives. The figure below shows the minimum space for
cooling air.
Preparing for installation 25
Wiring and EMC considerations
Determine electro-magnetic compliance (EMC) requirements
per local codes. In general:
• Follow local codes for cable size.
• Keep these three classes of wiring separated: input power
wiring, motor wiring and control/communications wiring.
• Check the operational limits for the allowed maximum motor
cable length in section Motor connection on page 404.
• If the installation must meet the European EMC Directive
requirements (see section Compliance with the IEC/
EN 61800-3 (2004) on page 438), check also the EMC limits
for the allowed maximum motor cable length in section Motor
connection on page 404.
Note: Non-proper wiring is the source of the majority of EMC
problems. Please follow the instructions to avoid these
problems.
ACH550-01 User's Manual
26 Preparing for installation
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