Abb ACS550 User Manual

ACS550

User’s Manual ACS550-01 Drives (0.75 ACS550-U1 Drives (1

…200 hp)

…160 kW)

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 AC8-FLNGMT-R5

ACS800PNTG01U-ENAC8-FLNGMT-R6

1. Not available for ACS550-01 series

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

CANopen is a registered trademark of CAN in Automation e.V.

ControlNet™ is a trademark of ODVA™. DeviceNet™ is a trademark of ODVA™. DRIVECOM is a registered trademark of DRIVECOM User

Group e.V. EtherCAT® is registered trademark and patented

technology, licensed by Beckhoff Automation GmbH, Germany.

EtherNet/IP™ is a trademark of ODVA™. ETHERNET POWERLINK is a trademark of Bernecker +

Rainer Industrie-ElektronikGes.m.b.H. Modbus and Modbus/TCP are registered trademarks of

Schneider Automation Inc. PROFIBUS, PROFIBUS DP and PROFINET IO are

registered trademarks of Profibus International.

List of related manuals

GENERAL MANUALS

ACS550-01/U1 User's Manual (0.75…160 kW) / (1…200 hp)

3AFE64804588 (3AUA0000001418) (English)

Flange Mounting Instructions

OPTION MANUALS

(delivered with optional equipment)

RPBA-01 PROFIBUS DP Adapter User's Manual

3AFE64504215 (English)

SREA-01 Ethernet Adapter User's Manual

3AUA0000042896 (English)

Typical contents

•Safety

• Installation

• Programming/Start-up

• Diagnostics

• Technical data

MAINTENANCE MANUALS

Guide for Capacitor Reforming in ACS50, ACS55, ACS150, ACS310, ACS350, ACS355, ACS550, ACH550 and R1-R4 OINT-/SINT-boards

3AFE68735190 (English)

ACS550-01 manuals

MFDT-01 FlashDrop User's Manual

3AFE68591074 (English)

OHDI-01 115/230 V Digital Input Module User's Manual

3AUA0000003101 (English)

OREL-01 Relay Output Extension Module User's Manual

3AUA0000001935 (English)

OTAC-01 User’s Manual Pulse Encoder Interface Module User’s Manual

3AUA0000001938 (English)

RCAN-01 CANopen Adapter User's Manual

3AFE64504231 (English)

RCNA-01 ControlNet Adapter User's Manual

3AFE64506005 (English)

RDNA-01 DeviceNet Adapter User's Manual

3AFE64504223 (English)

RECA-01 EtherCAT Adapter Module User's Manual

3AUA0000043520 (English)

REPL-01 Ethernet POWERLINK Adapter Module User's Manual

3AUA0000052289 (English)

REPL-02 Ethernet POWERLINK Adapter Module User's Manual

3AUA0000090411 (English)

RETA-01 Ethernet Adapter Module User's Manual

3AFE64539736 (English)

RETA-02 Ethernet Adapter Module User's Manual

3AFE68895383 (English)

ACS550-01/U1 Drives

0.75…160 kW 1…200 hp

User’s Manual

3AFE64804588 (3AUA0000001418) Rev H

EFFECTIVE: 2014-07-04

SUPERSEDES: 3AFE64804588 (3AUA0000001418) Rev G 2009-07-07

ACS550-01/U1 User’s Manual 5

Safety instructions

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.

General safety

WARNING! Obey these instructions. If you ignore them, injury or death, or damage

to the equipment can occur.

• Use safety shoes to avoid foot injury.

• Handle the drive carefully.

• Beware of hot surfaces. Some parts, such as heatsinks, remain hot for a while after disconnection of the electrical supply. See chapter Technical data on page

277.

• Keep the drive in its package or protect it otherwise from dust and burr from drilling and grinding until you install it. Protect also the installed drive against dust and burr. Electrically conductive debris inside the drive can cause damage or malfunction.

Electrical safety

WARNING! The ACS550 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 and U2, V2, W2 and, depending on the frame size, UDC+ and UDC-, or BRK+ and BRK-.

Safety instructions

6 ACS550-01/U1 User’s Manual

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 ACS550, there may be dangerous voltage (from external sources) on the terminals of the relay outputs RO1…RO3.

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! If you install the drive on an IT system (an ungrounded power system or a high-resistance-grounded [over 30 ohms] power system), disconnect the internal EMC filter, otherwise the system will be connected to ground potential through the EMC filter capacitors. This can cause danger or damage the drive.

Maintenance

If you install the drive on a corner-grounded TN system, disconnect the internal EMC filter, otherwise the system will be connected to ground potential through the EMC filter capacitors. This will damage the drive.

Note: Disconnecting the internal EMC filter increases the conducted emission and reduces the drive EMC compatibility considerably.

See section Disconnecting the internal EMC filter on page 27. Also see sections IT

systems on page 286 and Corner-grounded TN systems on page 285.

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! The ACS550-01/U1 is not field repairable. Never attempt to repair a malfunctioning drive; contact your local ABB representative for replacement.

Safety instructions

ACS550-01/U1 User’s Manual 7

Control of the drive and motor

WARNING! Do not control the motor with the disconnecting device (disconnecting

means); instead, use the control panel start and stop keys and , 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! The ACS550 will start up automatically after an input voltage interruption if the external run command is on.

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

Safety instructions

8 ACS550-01/U1 User’s Manual

Safety instructions

ACS550-01/U1 User’s Manual 9

List of related manuals

Safety instructions

Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Control of the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Table of contents

Contents of this manual

Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installation

Installation flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Start-up, control with I/O and ID Run

How to start up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

How to control the drive through the I/O interface . . . . . . . . . . . . . . . . . . . . . . 44

How to perform the ID Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Control panels

About control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Assistant Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Basic Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Application macros

ABB Standard macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3-wire macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Alternate macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Motor Potentiometer macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Hand-Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

PID Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

PFC macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Torque Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Connection examples of two-wire and three-wire sensors . . . . . . . . . . . . . . . . 86

Connection for obtaining 0…10 V from analog outputs . . . . . . . . . . . . . . . . . . 87

User parameter sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Table of contents

10 ACS550-01/U1 User’s Manual

Macro default values for parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Parameters

Complete parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Complete parameter descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Embedded fieldbus

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Mechanical and electrical installation – EFB . . . . . . . . . . . . . . . . . . . . . . . . . 204

Communication set-up – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Activate drive control functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Feedback from the drive – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Diagnostics – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Modbus protocol technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

ABB control profiles technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Fieldbus adapter

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Mechanical and electrical installation – FBA . . . . . . . . . . . . . . . . . . . . . . . . . 240

Communication set-up – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Activate drive control functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Feedback from the drive – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Diagnostics – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

ABB Drives profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Generic profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Diagnostics

Diagnostic displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Correcting faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Correcting alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Maintenance

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Main fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Internal enclosure fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Technical data

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Input power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Brake components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Table of contents

ACS550-01/U1 User’s Manual 11

Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

IEC/EN 61800-3:2004 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Compliance with the IEC/EN 61800-3:2004 +A1:2012 . . . . . . . . . . . . . . . . . 311

Index

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . 325

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Table of contents

12 ACS550-01/U1 User’s Manual

Table of contents

ACS550-01/U1 User’s Manual 13

Contents of this manual

Compatibility

This manual covers ACS550-01/U1 drives. The manual is compatible with the ACS550-01/U1 drive firmware version 3.14e or later. See parameter 3301 FIRMWARE on page 155.

Intended use

The ACS550-01/U1 is a general purpose drive. 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

14 ACS550-01/U1 User’s Manual

Contents of this manual

ACS550-01/U1 User’s Manual 15

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 chapter Safety instructions on page 5.

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.

Installation flow chart

The installation of the ACS550 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 drive.

Task See

PREPARE for installation Preparing for installation on page 16

PREPARE the mounting location Prepare the mounting location on page 20

REMOVE the front cover Remove the front cover on page 21

MOUNT the drive Mount the drive on page 22

INSTALL wiring Wiring overview on page 23 and

CHECK installation Check installation on page 35

REINSTALL the cover Reinstall the cover on page 36

START-UP How to start up the drive on page 37

Check the insulation of the assembly on page 30

Installation

16 ACS550-01/U1 User’s Manual

IP2040

Serial number

Type designation

Serial number

Type designation

Serial number

Preparing for installation

Lifting the drive

Lift the drive only by the metal chassis.

Unpacking 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.

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 choke plate between the

mounting holes, or

• type designation label attached on the heat sink – on the right side of the drive

cover. Two examples of the type designation label are given below.

Installation

ACS550-01/U1 User’s Manual 17

AC, Standard Drive – 550 product series

Construction (region specific)

Output current rating

Voltage rating

Options

Examples of options: B055 = IP54 / UL type 12 (no specification = IP21 / UL type 1).

UL type 12 is not available for type ACS550-01-290A-4. 0J400 = No control panel J404 = ACS-CP-C Basic Control Panel L511 = OREL-01 Relay output extension K451 = RDNA-01 DeviceNet K454 = RPBA-01 PROFIBUS DP

ACS550-01-08A8-4+J404+…

e.g. 08A8 = 8.8 A, see section Ratings on page 277 for details

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

01 = Setup and parts specific to IEC installation and compliance U1= Setup and parts specific to US installation and NEMA compliance

The labels contain information on the Type designation (page 17), Ratings and frame

size (page 17), Serial number (page 17), degree of protection (see also Degrees of protection on page 306) and valid markings (see also Markings on page 309).

Type designation

Use the following chart to interpret the type designation found on both the type designation and the serial number label.

Ratings and frame size

The chart in section Ratings the drive’s frame size – significant, since some instructions in this document vary, depending on the drive’s frame size. To read the ratings table, you need the “Output current rating” entry from the type designation. Also, when using the ratings table, note that the table is broken into sections based on the drive’s “Voltage rating”.

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.

on page 277 lists technical specifications and identifies

Installation

18 ACS550-01/U1 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

Nominal frequency 10…500 Hz –

Voltage range Motor is compatible with

Insulation 500…600 V drives: Either

range: 0.2…2.0 · I (I

2hd

current)

the ACS550 voltage range.

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

Ver ify Refe rence

• Type designation label on drive, entry for

= drive heavy duty

2hd

Output I

• Type designation on drive and rating table in chapter Technical data on page 277.

208…240 V (for ACS550-X1-XXXX-2) or 380…480 V (for ACS550-X1-XXXX-4) or 500…600 V (for ACS550-U1-XXXX-6)

For ACS550-U1-XXXX-6

2hd

Tools required

To install the ACS550 you need the following:

• screwdrivers (as appropriate for the mounting hardware used)

• wire stripper

• tape measure

, or

• drill

• for installations involving ACS550-U1, frame sizes R5 or R6 and IP54 / UL type 12 enclosures: punch for creating conduit mounting holes

• for installations involving ACS550-U1, frame size R6: appropriate crimping tool for power cable lugs. See section Power terminal considerations – R6 frame size on page 287.

• mounting hardware: screws or nuts and bolts, four each. The type of hardware depends on the mounting surface and the frame size. For the dimensions and weights of the frames, see Dimensions and weights on page 303.

Frame size Mounting hardware

R1…R4 M5

R5 M6

R6 M8

#10

1/4 in

5/16 in

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 307.

Installation

ACS550-01/U1 User’s Manual 19

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

• IP21 / UL type 1 enclosure: The site must be free of airborne dust, corrosive gases or liquids, and conductive contaminants such as dripping water, condensation, carbon dust and metallic particles.

• IP54 / UL type 12 enclosure: This enclosure provides protection from airborne dust and light sprays or splashing water from all directions.

• 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 hood, see the note in chapter

Technical data, page 310.

Suitable mounting location

Confirm that the mounting location meets the following constraints:

• The drive must be mounted vertically on a smooth, solid surface, and in a suitable environment as defined above. For horizontal installation, contact your local ABB representative for more information.

• The minimum space requirements for the drive are the outside dimensions (see section Outside dimensions on page

304), plus air flow space around the drive

(see section Losses, cooling data and noise on page 301).

• The distance between the motor and the drive is limited by the maximum motor cable length. See section Motor connection specifications

on page 289.

• The mounting site must support the drive’s modest weight. See section Weight on page 306.

Installation

20 ACS550-01/U1 User’s Manual

X0002

Installing the drive

WARNING! Before installing the ACS550, ensure the input power supply to the drive

is off.

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

R6 AC8-FLNGMT-R6

1. Not available in ACS550-01 series.

IP21 / UL type 1 IP54 / UL type 12

Kit Code (English) Kit Code (English)

ACS800-PNTG01U-EN--

Prepare the mounting location

The ACS550 should only be mounted where all of the requirements defined in section Preparing for installation on page 16 are met.

1. Mark the position of the mounting holes with the help of the mounting template provided with the drive.

2. Drill the 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: ACS400 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 ACS550 drives match ACS400 mounts.

Installation

ACS550-01/U1 User’s Manual 21

IP2000

…R5

Remove the front cover

IP21 / 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.

IP54 / UL type 12

1. If hood is present: Remove screws (2) holding 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.

Installation

22 ACS550-01/U1 User’s Manual

IP2002

1, 4

Mount the drive

IP21 / UL type 1

1. Position the ACS550 onto the mounting screws or bolts and securely tighten in all four corners.

Note: Lift the ACS550 by its metal chassis (frame size R6 by the lifting holes on both sides at the top).

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

IP54 / UL type 12

For the IP54 / 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 ACS550 onto the mounting screws or bolts and securely tighten in all four corners.

Note: Lift the ACS550 by its metal chassis (frame size R6 by the lifting holes on both sides at the top).

4. Reinstall 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.

Installation

ACS550-01/U1 User’s Manual 23

Wiring overview

Conduit/Gland kit

Wiring drives with the IP21 / UL type 1 enclosure requires a conduit/gland kit with the following items:

• conduit/gland box

• five (5) cable clamps (ACS550-01 only)

• screws

•cover.

The kit is included with IP21 / UL type 1 enclosures.

Wiring requirements

WARNING! Ensure the motor is compatible for use with the ACS550. The drive must be installed by a competent person in accordance with the considerations defined in section Preparing for installation on page 16. If in doubt, contact your local ABB representative.

As you install the wiring, observe the following:

• There are four sets of wiring instructions – one set for each combination of drive enclosure type (IP21 / UL type and IP54 / UL type 12) and wiring type (conduit or cable). Be sure to select the appropriate procedure.

• Determine electro-magnetic compliance (EMC) requirements per local codes. See section Motor cable requirements for CE & C-Tick compliance on page 293. In general:

– Follow local codes for cable size. – Keep these four classes of wiring separated: input power wiring, motor wiring,

control/communications wiring and braking unit wiring.

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

Terminal Description Specifications and notes

U1, V1, W1

PE Protective Ground Ground connections on page 285

U2, V2, W2 Power output to motor Motor connections on page 289

The ACS550 -x1-xxxx-2 (208…240 V 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.

3-phase power supply input Input power connections on page 281

• To locate input power and motor connection terminals, see section Power

connection diagrams on page 25. For specifications on power terminals, see

section Drive’s power connection terminals on page 286.

• For corner-grounded TN systems, see section Corner-grounded TN systems on page 285.

• For IT systems, see section IT systems on page 286.

Installation

24 ACS550-01/U1 User’s Manual

• For frame size R6, see section Power terminal considerations – R6 frame size on page 287 to install the appropriate cable lugs.

• For drives using braking (optional), refer to the following, as appropriate:

Frame size Terminal Description Braking accessory

R1, R2 BRK+, BRK- Braking resistor Braking resistor. See section Brake

components on page 295.

R3, R4, R5, R6 UDC+, UDC- DC bus Contact your ABB representative to

order either:

• braking unit or

• chopper and resistor

• When installing control wiring, refer to the following chapters or sections, as appropriate:

– Control terminals table on page 28 – Control connections

on page 299

– Application macros on page 77 – Complete parameter descriptions on page 106 – Embedded fieldbus on page 203 – Fieldbus adapter on page 237.

Installation

ACS550-01/U1 User’s Manual 25

Panel connector

Fault LED (red)

Optional module 1

J2 – DIP switch

X1 – Communications

Optional module 2

GND

Power output to motor

Power input

EM1

X1 – Analog inputs and outputs

X1 – Digital inputs

X1 – Relay outputs

off position on position

for RS485 termination

(and 10 V ref. voltage output)

(and 24 V aux. voltage output)

(U1, V1, W1)

(U2, V2, W2)

Optional braking

Frame

size

Term ina l

labels

Brake options

R1, R2 BRK+, BRK- Brake resistor R3, R4 UDC+, UDC- • Braking unit

• Chopper and resistor

(RS485)

R5/R6 differ.

See

Frame sizes

next page.

Diagram shows the R3 frame.

Other frames have similar layouts.

AI1: (in voltage position) AI2: (in current position)

J1 – DIP switches for analog inputs (two types can be used)

FlashDrop option

Power LED (green)

3AUA0000001571

EM3

Power connection diagrams

The following diagram shows the terminal layout for frame size R3, which, in general, applies to frame sizes R1 terminals.

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

WARNING! To avoid danger, or damage to the drive, on IT systems and cornergrounded TN systems, see section Disconnecting the internal EMC filter on page 27.

Installation

26 ACS550-01/U1 User’s Manual

GND

Power input

(U1, V1, W1)

Optional braking

Frame

size

Term ina l

labels

Brake options

R5, R6 UDC+, UDC- • Braking unit

• Chopper and resistor

X0011

Power input

(U1, V1, W1)

X0013

Power output to motor

(U2, V2, W2)

R5 R6

GND

Power output to motor

(U2, V2, W2)

The following diagram shows the power and ground terminal layout for frame sizes R5 and R6end

WARNING! To avoid danger, or damage to the drive, on IT systems and cornergrounded TN systems, see section Disconnecting the internal EMC filter on page 27.

Installation

ACS550-01/U1 User’s Manual 27

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: Disconnecting the internal EMC filter increases the conducted emission and reduces the drive EMC compatibility considerably.

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 IT systems on page 286 and

Corner-grounded TN systems on page 285.

The locations of screws EM1 and EM3 are shown in the diagram on page 25. The locations of screws F1 and F2 are shown in the diagram on page 26.

Frame

sizes

R1…R3

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.)

ACS550-U1 drives are shipped with screw EM3 already removed.

Screw

EM1 x x

EM3

EM1 x x –

EM3

F1 x x –

F2 x x –

Symmetrically

grounded TN systems

(TN-S systems)

x ––

Corner-grounded

TN systems

IT systems (ungrounded

or high-resistance-

grounded [> 30 ohm])

Installation

28 ACS550-01/U1 User’s Manual

Analog I/O

Digital inputs

Control terminals table

The following provides information for connecting control wiring at X1 on the drive.

X1 Hardware description

1 SCR Terminal for signal cable shield (screen). (Connected internally to chassis ground.)

2 AI1 Analog input channel 1, programmable. Default

0.1%, accuracy ±1%.

Two different DIP switch types can be used.

J1: AI1 OFF: 0…10 V (R

J1: AI1 ON: 0…20 mA (R

= 312 kohm)

= 100 ohm)

3 AGND Analog input circuit common (connected internally to chassis gnd. through 1 Mohm).

4 +10 V Potentiometer reference source: 10 V ±2%, max. 10 mA (1 kohm <

5 AI2 Analog input channel 2, programmable. Default

accuracy ±1%.

Two different DIP switch types can be used.

J1: AI2 OFF: 0…10 V (R

J1: AI2 ON: 0…20 mA (R

= 312 kohm)

= 100 ohm)

6 AGND Analog input circuit common (connected internally to chassis gnd. through 1 Mohm).

7 AO1 Analog output, programmable. Default

= frequency. 0…20 mA (load < 500 ohm).

Accuracy ±3%.

8 AO2 Analog output, programmable. Default

= current. 0…20 mA (load < 500 ohm).

Accuracy ±3%.

9 AGND Analog output circuit common (connected internally to chassis gnd. through 1 Mohm).

10 +24V Auxiliary voltage output 24 V DC / 250 mA (reference to GND), short circuit

protected.

11 GND Auxiliary voltage output common (connected internally as floating).

12 DCOM Digital input common. To activate a digital input, there must be 10 V

(or  -10 V) between that input and DCOM. The 24 V may be provided by the ACS550 (X1-10) or by an external 12…24 V source of either polarity.

13 DI1 Digital input 1, programmable. Default

14 DI2 Digital input 2, programmable. Default

15 DI3 Digital input 3, programmable. Default

16 DI4 Digital input 4, programmable. Default

17 DI5 Digital input 5, programmable. Default

18 DI6 Digital input 6, programmable. Default

= start/stop.

=fwd/rev.

= constant speed sel (code).

= ramp pair selection (code).

= not used.

= frequency reference. Resolution

R < 10 kohm).

= not used. Resolution 0.1%,

Installation

ACS550-01/U1 User’s Manual 29

Relay outputs

NPN connection (sink)PNP connection (source)

10 +24V 11 GND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6

X1 Hardware description

19 RO1C Relay output 1, programmable. Default2= Ready

20 RO1A

21 RO1B

22 RO2C Relay output 2, programmable. Default

23 RO2A

24 RO2B

25 RO3C Relay output 3, programmable. Default

26 RO3A

27 RO3B

Digital input impedance 1.5 kohm. Maximum voltage for digital inputs is 30 V.

Default values depend on the macro used. Values specified are for the default macro. See chapter

Application macros on page 77.

Maximum: 250 V AC / 30 V DC, 2 A Minimum: 500 mW (12 V, 10 mA)

= Running

= Fault (-1)

Note: Terminals 3, 6 and 9 are at the same potential.

Note: For safety reasons the fault relay signals a “fault” when the ACS550 is

powered down.

WARNING! All ELV (Extra Low Voltage) circuits connected to the drive must be used within a zone of equipotential bonding, i.e. within a zone where all simultaneously accessible conductive parts are electrically connected to prevent hazardous voltages appearing between them. This is accomplished by a proper factory grounding.

The terminals on the control board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 50178, provided that the external circuits connected to the terminals also fulfil the requirements and the installation site is below 2000 m (6562 ft).

You can wire the digital input terminals in either a PNP or NPN configuration.

Installation

30 ACS550-01/U1 User’s Manual

ohm

X0004

Check the insulation of the assembly

Drive

Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chassis at the factory. Also, there are voltagelimiting circuits inside the drive which cut down the testing voltage automatically.

Supply cable

Check the insulation of the supply (input) cable according to local regulations before connecting to the drive.

Motor and motor cable

Check the insulation of the motor and motor cable as follows:

1. Check that the motor cable is connected to the motor, and disconnected from the drive output terminals U2, V2 and W2.

2. Measure the insulation resistance between phase conductors and between each phase conductor and the Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, please consult the manufacturer’s instructions. Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement.

Install the wiring

Wiring IP21 / UL type 1 enclosure with cables

1. Open the appropriate knockouts in the conduit/gland box. (See section Conduit/Gland kit on page 23.)

2. Install the cable clamps for the power/motor cables.

Installation

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