ABB ACH550-UH User Guide

ACH550-UH User’s Manual 1-1

ACH550-UH HVAC Drives

1…550 HP

User’s Manual

ACH550-UH_UM (3AUA0000004092) Rev I

EN

EFFECTIVE: 2010-04-01

SUPERSEDES: ACH550-UH_UM (3AUA0000004092) Rev H 2008-04-01

 2010 ABB. All Rights Reserved.

ACH550-UH User’s Manual 1-3

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 conditions which 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.

General warning warns about conditions, other than those caused by electricity,
which can result in 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.

Safety

1-4 ACH550-UH User’s Manual

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.

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-UH User’s Manual 1-5

Table of contents

Safety

Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Table of contents

Installation

Installation flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Control panel

HVAC control panel features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

HVAC control panel modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

Start-up

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

Application macros

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

HVAC Default macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51

Supply Fan macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Return Fan macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

Cooling Tower Fan macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

Condenser macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

Booster Pump macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56

Pump Alternation macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

Internal Timer macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58

Internal Timer with Constant Speeds / PRV macro . . . . . . . . . . . . . . . . . . . 1-59

Floating Point macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60

Dual Setpoint with PID macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61

Dual Setpoint with PID and Constant Speeds . . . . . . . . . . . . . . . . . . . . . . . 1-62

E-bypass macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63

Hand Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64

E-Clipse macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65

Parameters

Complete parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67

Complete parameter descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80

Table of contents

1-6 ACH550-UH User’s Manual

Embedded fieldbus

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-187

Mechanical and electrical installation – EFB . . . . . . . . . . . . . . . . . . . . . . . 1-189

Communication setup – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-191

Activate drive control functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-195

Feedback from the drive – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-200

Diagnostics – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-202

N2 protocol technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-207

FLN protocol technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-215

BACnet protocol technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-229

Modbus protocol technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-241

ABB control profiles technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-249

Fieldbus adapter

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-261

Mechanical and electrical installation – FBA . . . . . . . . . . . . . . . . . . . . . . . 1-264

Communication setup – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-265

Activate drive control functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-265

Feedback from the drive – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-268

Diagnostics – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-269

ABB drives profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-271

Generic profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-279

Diagnostics

Diagnostic displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-281

Correcting faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-282

Correcting alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-288

Maintenance

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-291

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-291

Drive module fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-292

Enclosure fan replacement – UL Type 12 enclosures . . . . . . . . . . . . . . . . 1-293

Enclosure air filter replacement – UL Type 12 enclosures . . . . . . . . . . . . . 1-295

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-298

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-298

Table of contents

ACH550-UH User’s Manual 1-7

Technical data

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-299

Input power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-303

Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-311

Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-317

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-320

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-320

Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-322

Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-327

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-328

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-329

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-330

Liability limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-332

Index

Table of contents

1-8 ACH550-UH User’s Manual

Table of contents

ACH550-UH User’s Manual 1-9

Installation

Study these installation instructions carefully before proceeding. Failure to observe
the warnings and instructions may cause a malfunction or personal hazard.

WARNING! Before you begin read Safety on page 1-3.

Installation flow chart

The installation of the ACH550 adjustable speed AC drive follows the outline below.
The steps must be carried out in the order shown. At the right of each step are
references to the detailed information needed for the correct installation of the unit.

Task Se e

PREPARE for installation Preparing for installation on page 1-10.

PREPARE the mounting location Prepare the mounting location on page 1-14.

REMOVE the front cover Remove front cover on page 1-16.

MOUNT the drive Mount the drive on page 1-17.

INSTALL wiring Wiring overview on page 1-18 and

CHECK installation Check installation on page 1-27.

REINSTALL the cover Re-install cover on page 1-27.

APPLY power Apply power on page 1-29.

START-UP Start-up on page 1-30.

Install the wiring on page 1-23.

Installation

1-10 ACH550-UH User’s Manual

IP2040

PC00005

R70010

2

PC00003

30

o

Preparing for installation

Lifting the drive

R1…R6

Lift the drive only by the metal chassis.

R7…R8

WARNING! Handle and ship floor mounted enclosures
only in the upright position. These units are not designed
to be laid on their backs.

1. Use a pallet truck to move the transport package/
enclosure to the installation site.

2. Remove the cabinet side panels for access to the
cabinet/pallet mounting bolts. (6 torx screws hold each
cabinet side panel in place. Leave the side panels off
until later.)

3. Remove the 4 bolts that secure the cabinet to 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.)

Unpack the drive

1. Unpack the drive.

2. Check for 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.

Installation

ACH550-UH User’s Manual 1-11

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

AC, HVAC Drive – 550 product series

Construction (region specific)

UH = Setup and parts specific to US installation and NEMA compliance

Output current rating

e.g. 08A8 = 8.8A See section Ratings for details on page 1-299

Volta g e r a ting

2 = 208…240 VAC
4 = 380…480 VAC
6 = 500…600 VAC

Enclosure protection class

No specification = UL type 1 / NEMA 1 / IP 21
+B055 = UL type 12 / NEMA 12 / IP 54

Fieldbus Adapter

+K451 = DeviceNet Adapter +K462 = ControlNet Adapter
+K452 = LonWorks Adapter +K466 = EtherNet Adapter
+K454 = Profibus Adapter

I/O Options

+L511 = Relay Output Extension
+L512 = 115/230 V Digital Input Interface

ACH550-UH-08A8-4+...

Drive identification

Drive labels

To determine the type of drive you are installing, refer to 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.

Type code

Use the following chart to interpret the type code found on either label.

Ratings and frame size

The chart in section Ratings on page 1-299 lists technical specifications, and
identifies the drive’s frame size. To read the Ratings table, you need the “Output
current rating” entry from the type code (see above). Also, when using the Ratings
tables, note that there are different tables for each drive “Voltage rating”.

Installation

1-12 ACH550-UH User’s Manual

Motor compatibility

The motor, drive, and supply power must be compatible:

Motor

Specification

Motor type 3-phase induction motor –
Nominal current Motor value is within this

range: 0.15…1.5 * I
(I

2N

Nominal frequency 10…500 Hz –
Voltage range Motor is compatible with

Insulation 500…600 V drives: Either

the ACH550 voltage range.

the motor complies with
NEMA MG1 Part 31, or a
du/dt filter is used between
the motor and drive.

Verify Reference

• Type code label on drive, entry for Output I

= normal use current)

2N

or

• Type code on drive and rating table in

Technical data on page 1-299.

208…240 V (for ACH550-xx-xxxx-2) or
380…480 V (for ACH550-xx-xxxx-4)
500…600 V (for ACH550-xx-xxxx-6)

For ACH550-xx-xxxx-6

Tools required

To install the ACH550 you need the following:

• Screwdrivers (as appropriate for the mounting hardware used)

• Wire stripper

• Tape measure

2N

,

•Drill

• Frame sizes R5…R8 with UL type 12 enclosure: Punch for conduit mounting
holes

• Frame sizes R7/R8: pallet truck and hoist

• For installations involving frame size R6…R8: The appropriate crimping tool for
power cable lugs. See Power terminal considerations – R6 Frame size.

• Mounting hardware: screws or nuts and bolts, four each. The type of hardware
depends on the mounting surface and the frame size:

Frame Size Mounting Hardware Note

R1…R4 M5
R5 M6
R6 M8
R7…R8 M10

#10
1/4 in
5/16 in
7/16 Secures free standing cabinets if required.

• For installations involving frame size R7…R8: Hoist.

Installation

ACH550-UH User’s Manual 1-13

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 Ambient conditions on
page 1-328.

Confirm that the enclosure is appropriate, based on the site contamination level:

• UL type 1 enclosure. The site must be free of airborne dust, corrosive gases or
liquids, and conductive contaminants such as condensation, carbon dust, and
metallic particles.

• UL type 12 enclosure. This enclosure provides protection from airborne dust and
light sprays or splashing water from all directions.

Suitable mounting location

Confirm that the mounting location meets the following constraints:

• R1…R6: The drive must be mounted vertically on a smooth, solid surface, and in
a suitable environment as defined above.

• The drive must be located in a suitable environment as defined above.

• The minimum space requirements for the drive are the outside dimensions (see

Outside dimensions – R1…R6 on page

on page 1-326), plus air flow space around the unit (see Cooling

• The distance between the motor and the drive is limited by the maximum motor
cable length. See either Motor connection specifications on page 1-311, or

EN 61800-3 compliant motor cables on page 1-314.

• The mounting site must support the drive’s weight. See Weight on page 1-324.

Installing the drive

WARNING! Before installing the ACH550, 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. Where parts, such as conduit plates
require cutting or drilling, first remove the part. If that is not practical, cover nearby
electrical components to protect them from all shavings or debris.

1-325 or Outside dimensions – R7…R8

on page 1-320).

Installation

1-14 ACH550-UH User’s Manual

X0002

1

For flange mounting (mounting the drive in a cooling air duct), see the appropriate
Flange Mounting Instructions:

Frame size

R1 FMK-A-R1 100000982 FMK-B-R1 100000990
R2 FMK-A-R2 100000984 FMK-B-R2 100000992
R3 FMK-A-R3 100000986 FMK-B-R3 100000994
R4 FMK-A-R4 100000988 FMK-B-R4 100000996
R5 AC8-FLNGMT-R5 ACS800-PNTG01U-EN - ­R6 AC8-FLNGMT-R6 - -

IP21 / UL type 1 IP54 / UL type 12

Kit Code (English) Kit Code (English)

Prepare the mounting location

The ACH550 should only be mounted where all of the
requirements defined in Preparing for installation on
page 1-10 are met.

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 fan for
maintenance).

Note: ACH400 drives can be replaced using the original mounting holes. For R1 and
R2 frame sizes, the mounting holes are identical. For R3 and R4 frame sizes, the
inside mounting holes on the top of ACH550 drives match ACH400 mounts.

Installation

ACH550-UH User’s Manual 1-15

PC00023

Fastening points when installed
back against a wall (Top view)

Fastening points when installed
back against back

Cabinet top

M12 bolt (1/2 to 9/16 in)

L-bracket

Fastening the cabinet at the top
using L-brackets (side view)

Note: Frame sizes R7 and R8 have
mounting holes inside the enclosure base.
See Mounting dimensions on page 1-323.

Where it is not possible to use either
mounting hole at the back of the base, use
an L-bracket at the top of the enclosure to
secure the cabinet to a wall or to the back of
another enclosure. Bolt the L-bracket to the
enclosure using the lifting lug bolt hole on
the top of the enclosure.

2. Drill holes of appropriate size in the
mounting location.

Installation

1-16 ACH550-UH User’s Manual

3

IP2000

1

2

3

4

1

2

FM

1

R70020

Remove front cover

R1…R6, UL type 1

1. Remove the control panel, if attached.

2. Loosen the captive screw at the top.

3. Pull near the top to remove the cover.

R1…R6, UL type 12

1. If 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, Cabinet Door

1. To open the cabinet door, loosen the quarter­turn screws that hold the cabinet door closed.

R7…R8, Side Panels

The side panels were removed to take the
cabinet off the pallet. Installation access is
easier if these panels are kept off throughout
the installation.

Installation

ACH550-UH User’s Manual 1-17

IP2002

1

2

2

1, 3

FM

PC00003

30

o

Mount the drive

R1…R6, UL type 1

1. Position the ACH550 onto the mounting screws
or bolts and securely tighten in all four corners.

Note: Lift the ACH550 by its metal chassis.

2. Non-English speaking locations: Add a warning
sticker in the appropriate language over the
existing warning on the top of the module.

R1…R6, UL type 12

For the UL type 12 enclosures, rubber plugs are required in the holes provided for
access to the drive mounting slots.

1. As required for access, remove the rubber plugs.
Push plugs out from the back of the drive.

2. R5 & R6: Align the sheet metal hood (not shown)
in front of the drive’s top mounting holes. (Attach
as part of next step.)

3. Position the ACH550 onto the mounting screws
or bolts and securely tighten in all four corners.

Note: Lift the ACH550 by its metal chassis
(frame size R6 by the lifting holes on both 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 hoist to move the cabinet into position.

Note: If the cabinet location does not provide access to
the cabinet sides, be sure to re-mount side panels before
positioning cabinet.

2. Install and tighten mounting bolts.

Installation

1-18 ACH550-UH User’s Manual

Wiring overview

Conduit kit

Wiring R1…R6 drives with the UL type 1 Enclosure requires a conduit kit with the
following items:

• conduit box

• screws

• cover
The kit is included with UL type 1 Enclosures.

Wiring requirements

WARNING! Ensure the motor is compatible for use with the ACH550. The ACH550
must be installed by a competent person in accordance with the considerations
defined in Preparing for installation on page 1-10. If in doubt, contact your local ABB
sales or service office.

As you install the wiring, observe the following:

• There are two sets of wiring instructions – one set for each enclosure type (UL
type 1 and UL type 12). Be sure to select the appropriate procedure.

• For the power connection points on the drive see the Connection diagrams
section below.

• Use separate, metal conduit runs to keep these three classes of wiring apart:
– Input power wiring.

– Motor wiring. (Use a separate, metal conduit run for each drive)
– Control/communications wiring.

• When installing input power and motor wiring, refer to the following, as
appropriate:

Terminal Description Specifications and Notes

U1, V1, W1* 3-phase power supply input Input power connections on page 1-303.
PE Protective Ground Ground connections on page 1-307.
U2, V2, W2 Power output to motor Motor connections on page 1-311.
* The ACH550 -xx-xxxx-2 (208…240V series) can be used with a single phase supply, if output

current is derated by 50%. For single phase supply voltage connect power at U1 and W1.

• To locate input power and motor connection terminals, see Connection diagrams
starting on page 1-20. For specifications on power terminals, see Drive’s power

connection terminals on page 1-309.

Installation

• For corner grounded TN systems, see section Unsymmetrically grounded

networks on page 1-307.

• For IT systems, see section Floating networks on page 1-308.

• For frame size R6, see Power terminal considerations – R6 Frame size on page

1-309 to install the appropriate cable lugs.

ACH550-UH User’s Manual 1-19

• For details on control connections, refer to the following sections:
– Drive’s control connection terminals on page 1-318.

– Control connections on page 1-317.
– Application macros starting on page 1-49.
– Complete parameter descriptions on page 1-80.
– Embedded fieldbus on page 1-187.
– Fieldbus adapter on page 1-261.

• For electro-magnetic compliance (EMC), follow local codes and the requirements
in Motor cable requirements for CE & C-Tick compliance on page 1-313. For
example:

– Properly ground the wire screen cable shields.
– Keep individual un-screened wires between the cable clamps and the screw

terminals as short as possible.

– Route control cables away from power cables.

Installation

1-20 ACH550-UH User’s Manual

Panel Connector

Power LED (Green)

Fault 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)

(and 24 V Aux. Voltage Output)

EM3

PE

(U1, V1, W1)

(U2, V2, W2)

X0003

(RS485)

R5/R6 differ.

See next page.

Frame Sizes

R1…R4 (Diagram shows the R3 frame.)

J2 – DIP Switches

J2

ON

off position on position

for RS485 Termination

J2

ON

Terminals Not Used

J1 – DIP Switches for Analog Inputs

AI1: (in Voltage Position)

AI2: (in Current Position)

ON

ON

The switch is one of two types:

Alternate

Original

Illustration of available switch

positions; not default settings

Illustration of available switch

positions; not default settings

Connection diagrams

The following diagrams show:

• The terminal layout for frame size R3, which, in general, applies to frame sizes
R1

• The R5/R6 power and ground terminals.

• The terminal layout for R7/R8.

…R6, except for the R5/R6 power and ground terminals.

Installation

WARNING! To avoid danger, or damage to the drive, on IT systems and corner
grounded TN systems, see section Disconnecting the internal EMC filter on
page 1-22.

ACH550-UH User’s Manual 1-21

GND

Power Input

PE

(U1, V1, W1)

X0011

F1

F2

Power Input

PE

(U1, V1, W1)

F1

F2

X0013

Power Output to Motor

(U2, V2, W2)

R5 R6

GND

GND

Power Output to Motor

(U2, V2, W2)

Terminals Not Used

Terminals Not Used

The following diagram shows the power and ground terminal layout for frame sizes
R5 and R6.

WARNING! To avoid danger, or damage to the drive, on IT systems and corner
grounded TN systems, see section Disconnecting the internal EMC filter on
page 1-22.

Installation

1-22 ACH550-UH User’s Manual

Ground Lug

Bar

ACH550

R7

Motor

Terminals

Input Power

Te rm in a ls

Control Wires

(X1)

Terminal Strip

Only on

ACH550-UH

The following diagram shows the power and ground terminal layout for frame size
R7 (R8 is similar).

Disconnecting the internal EMC filter

On certain types of systems, you must disconnect the internal EMC filter, otherwise
the system will be connected to ground potential through the EMC filter capacitors,
which might cause danger, or damage the drive.

Note: When the internal EMC filter is disconnected, the drive is not EMC compatible.

The following table shows the installation rules for the EMC filter screws in order to
connect or disconnect the filter, depending on the system type and the frame size.
For more information on the different system types, see Floating networks on page

1-308 and Unsymmetrically grounded networks on page 1-307.

Installation

ACH550-UH User’s Manual 1-23

PE

M

ohm

The locations of screws EM1 and EM3 are shown in the diagram on page 1-20. The
locations of screws F1 and F2 are shown in the diagram on page 1-21.

Frame

sizes

R1…R3

R4

R5…R6

x = Install the screw. (EMC filter will be connected.)

= Replace the screw with the provided polyamide screw. (EMC filter will be disconnected.)

–

= Remove the screw. (EMC filter will be disconnected.)

Screw

EM1 x x
EM3 x
EM1 x x –
EM3 x ––

F1 x x –
F2 x x –

Symmetrically

grounded TN systems

(TN-S systems)

Corner grounded

TN systems

IT systems (ungrounded

or high-resistance-

grounded [> 30 ohm])

Install the wiring

Checking motor and motor cable insulation

WARNING! Check the motor and motor cable insulation before connecting the drive
to input power. For this test, make sure that motor cables are NOT connected to the
drive.

1. Complete motor cable connections to the motor, but NOT to the drive output
terminals (U2, V2, W2).

2. At the drive end of the motor cable, measure the insulation
resistance between each motor cable phase and Protective
Earth (PE): Apply a voltage of 1 kV DC and verify that
resistance is greater than 1 Mohm.

Installation

1-24 ACH550-UH User’s Manual

2

X0007

3

X0005

4

IP2004

7

7

5

10

8

IP2005

12

R1…R6, wiring UL type 1 enclosure

1. Open the appropriate knockouts in the
conduit box. (See Conduit kit on page 1-18.)

2. Install thin-wall conduit clamps (not supplied).

3. Install conduit box.

4. Connect conduit runs for input power, motor
and control cables to the box.

5. Route input power and motor wiring through
separate conduits.

6. Strip wires.

7. Connect power, motor, and ground wires to
the drive terminals. See Wiring requirements
on page 1-18 and table on the tightening
torques on page 1-309.

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 1-309.

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 tie strap
landings to permanently secure control wiring
at a minimum distance of 6 mm (1/4") from
power wiring.

10. Strip the control cable sheathing and twist the
copper screen into a pig-tail.

11. Connect the ground screen pig-tail for digital
and analog I/O cables at X1-1. (Ground only
at drive end.)

12. Connect the ground screen pig-tail for RS485
cables at X1-28 or X1-32. (Ground only at
drive end.)

Installation

13. Strip and connect the individual control wires to the drive terminals. See Wiring

requirements on page 1-18.

14. Install the conduit box cover (1 screw).

ACH550-UH User’s Manual 1-25

IP50131

R1…R4

IP5023

1

R5, R6

2

IP5006

3

IP5007

6

4

7

IP5008

9…11

R1…R6, wiring UL type 12 enclosure

1. Step depends on Frame Size:

• Frame Sizes R1…R4: Remove and discard the
cable seals where conduit will be installed. (The
cable seals are cone-shaped, rubber seals on
the bottom of the drive.)

• Frame Sizes R4 and R5: Use punch to create
holes for conduit connections as needed.

2. For each conduit run (input power, motor and
control wiring must be separate), install water tight
conduit connectors (not supplied).

3. Route the power wiring through conduit.

4. Route the motor wiring through conduit (not the
same conduit as input power wiring run).

5. Strip the wires.

6. Connect the power, motor, and ground wires to
the drive terminals. See Wiring requirements on
page 1-18, Connection diagrams on page 1-20 and
table for tightening torques on page 1-309.

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 1-309.

7. Route the control cables through the conduit (not
the same conduit as either input power or motor
wiring runs).

8. Use available secure points and tie strap landings to
permanently secure control wiring at a minimum
distance of 6 mm (1/4") from power wiring.

9. Strip the control cable sheathing and twist the
copper screen into a pig-tail.

10. Connect the ground screen pig-tail for digital and
analog I/O cables at X1-1. (Ground only at drive
end.)

11. Connect the ground screen pig-tail for RS485 cables
at X1-28 or X1-32. (Ground only at drive end.)

12. Strip and connect the individual control wires to the drive
terminals. See Wiring requirements on page 1-18.

13. Install the conduit box cover (1 screw).

Installation

1-26 ACH550-UH User’s Manual

BP0054

Input Power

Gnd

Cable

Term in al St r ip

Only on

ACH550-UH

BP0054

Motor

Gnd

Cable

R7…R8, wiring (both enclosure types)

The figures show connections in the R7 cabinet, the R8 cabinet is similar.

1. Remove the conduit connection plate from the top of the left bay.

2. Route the input power, motor and control cables to the top of the cabinet. Each cable
type (input power, motor, and control) must be in separate conduit.

3. Use punch to create holes for conduit connections as needed.

4. UL type 12 Enclosure: For each conduit
run (input power, motor and control wiring
must be separate), install water tight
conduit connectors (not supplied).

5. Connect input power and motor cables to
the bus terminals. See Wiring requirements
on page 1-18, Connection diagrams on
page 1-20.

6. Connect grounds to ground bar.

7. Use available secure points and tie strap
landings to permanently secure control
wiring at a minimum distance of 6 mm
(1/4") from power wiring.

8. Strip the control cable sheathing and twist
the copper screen into a pig-tail.

9. Connect the ground screen pig-tail for
digital and analog I/O cables at X1-1.
(Ground only at drive end.)

10. Connect the ground screen pig-tail for
RS485 cables at X1-28 or X1-32. (Ground
only at drive end.)

11. Strip and connect the individual control wires to the drive terminals. See Wiring

requirements on page 1-18.

Installation

ACH550-UH User’s Manual 1-27

3

1

2

IP2009

Check installation

Before applying power, perform the following checks.

Check

Installation environment conforms to the drive’s specifications for ambient conditions.
The drive is mounted securely.
Space around the drive meets the drive’s specifications for cooling.
The motor and driven equipment are ready for start.
For floating networks (R1…R6): The internal RFI filter is disconnected (screws EM1 & EM3 or

F1 & 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 power branch circuit protection is installed.
The motor connections at U2, V2, and W2 are connected and tightened as specified.
The input power, motor and control wiring are routed through separate conduit runs.
NO power factor compensation capacitors are in the motor cable.
The control connections are connected and tightened as specified.
NO tools or foreign objects (such as drill shavings) are inside the drive.
NO alternate power source for the motor (such as a bypass connection) is connected – no

voltage is applied to the output of the drive.

Re-install cover

R1…R6, UL type 1

1. Align the cover and slide it on.

2. Tighten the captive screw.

3. Re-install the control panel.

Installation

1-28 ACH550-UH User’s Manual

2

1

4

3

5

6

FM

1

R70020

R1…R6, UL type 12

1. Align the cover and slide it on.

2. Tighten the captive screws around the edge of
the cover.

3. R1…R4: Slide the hood down over the top of
the cover.

4. R1…R4: Install the two screws that attach the
hood.

5. Re-install the control panel.

Note: The control panel window must be closed
to comply with UL type 12.

6. Optional: Add a lock (not supplied) to secure
the control panel window.

R7…R8, Covers

1. If side panels were removed and not remounted,
mount them now. Each panel requires 6 torx
screws.

2. Re-mount all high voltage shields.

3. Close all internal swing-out panels and secure in
place with the quarter-turn screws.

4. Close the cabinet door and secure in place with
the quarter-turn screws.

Installation

ACH550-UH User’s Manual 1-29

U1 V1 W1 U2 V2 W2

L1

L2

L3

Motor

Drive

Input

FM

U1 V1 W1 U2 V2 W2

L1

L2

L3

Motor

Drive

Input

To change rotation direction,

switch motor leads

GND

GND

GND

GND

Apply power

Always re-install the covers before turning power on.

WARNING! The ACH550 will start up automatically at power up, if the external run
command is on.

1. Apply input power.
When power is applied to the ACH550, the green LED comes on.

Note: Before increasing motor speed, check that the motor is running in the desired
direction. To change rotation direction, switch motor leads as shown below.

Installation

1-30 ACH550-UH User’s Manual

Start-up

The ACH550 has default parameter settings that are sufficient for many 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
following options.

• Press Exit to commission the drive as described in section Start-up by changing

the parameters individually on page 1-47.

• Press Enter to move to the following options:
– Select “Commission Drive” to commission the drive as described in section

Start-Up by Start-up by using the Start-Up Assistant on page 1-47.

– Select “Spin Motor” to operate the motor prior to commissioning. This option

operates the motor without any commissioning, except entry of the motor data
as described below. Spin Motor is useful, for example, to operate ventilation
fans prior to commissioning.

Note: When using Spin Motor, the motor speed is limited to the range 1/3…2/3 of
maximum speed. Also, no interlocks are activated. Finally, once the drive is
commissioned, the welcome screen and this option no longer appear.

Motor data

The motor data on the ratings plate may differ from the defaults in the ACH550. The
drive provides more precise control and better thermal protection if you enter the
rating plate data.

1. Gather the following 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 Assistant walks you through this data entry
(see page 1-37).

• Basic Control Panel: Refer to Parameters Mode on page 1-35, for parameter
editing instructions.

Installation