Abb ACS550 User Manual

ACS550

User’s Manual

ACS550-01 Drives (0.75…160 kW) ACS550-U1 Drives (1…200 hp)

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
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 1	R5	ACS800-
AC8-FLNGMT-R6 1	R6	PNTG01U-EN
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

OPTION MANUALS

(delivered with optional equipment)

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)

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

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.

ACS550-01/U1 Drives 0.75…160 kW 1…200 hp

User’s Manual

3AFE64804588 (3AUA0000001418) Rev H

EN

EFFECTIVE: 2014-07-04

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

2014 ABB Oy. All Rights Reserved.

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.

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.

Maintenance

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

Table of contents

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 the insulation of the assembly on page 30
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

Installation

16	ACS550-01/U1 User’s Manual

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.

IP2040

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

Serial number

•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.

Serial number

Type designation

Serial number

Type designation

Installation

ACS550-01/U1 User’s Manual

17

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.

ACS550-01-08A8-4+J404+…

AC, Standard Drive – 550 product series

Construction (region specific)

01 = Setup and parts specific to IEC installation and compliance

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

Output current rating

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

Voltage rating

2 = 208…240 V AC

4 = 380…480 V AC

6 = 500…600 V AC

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

Ratings and frame size

The chart in section Ratings on page 277 lists technical specifications and identifies 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.

Installation

18	ACS550-01/U1 User’s Manual

Motor compatibility

The motor, drive and supply power must be compatible:

	Motor	Verify	Reference
	specification
	Motor type	3-phase induction motor	–
	Nominal current	Motor value is within this	• Type designation label on drive, entry for
		range: 0.2…2.0 · I2hd	Output I2hd, or
		(I2hd = drive heavy duty	• Type designation on drive and rating table in
		current)	chapter Technical data on page 277.
	Nominal frequency	10…500 Hz	–
	Voltage range	Motor is compatible with	208…240 V (for ACS550-X1-XXXX-2) or
		the ACS550 voltage range.	380…480 V (for ACS550-X1-XXXX-4) or
			500…600 V (for ACS550-U1-XXXX-6)
	Insulation	500…600 V drives: Either	For ACS550-U1-XXXX-6
		the motor complies with
		NEMA MG1 Part 31, or a
		du/dt filter is used between
		the motor and drive.

Tools required

To install the ACS550 you need the following:

•screwdrivers (as appropriate for the mounting hardware used)

•wire stripper

•tape measure

•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	#10
R5	M6	1/4 in
R6	M8	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

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	IP21 / UL type 1			IP54 / UL type 12
	Kit	Code (English)	Kit		Code (English)
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 1	ACS800-PNTG01U-	-		-
		EN
R6	AC8-FLNGMT-R6 1		-		-

1. Not available in ACS550-01 series.

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 1
the mounting template provided with the drive.	X0002

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

Remove the front cover

IP21 / UL type 1

1. Remove the control panel, if attached.

2

2. Loosen the captive screw at the top. 3. Pull near the top to remove the cover.

1

IP2000

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.

R6

R1…R5

1 1 2

3

4

FM

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22	ACS550-01/U1 User’s Manual

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

1

2

IP2002

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.	3
	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.)	1, 4

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).

5

4. Reinstall the rubber plugs.

FM

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, W11	3-phase power supply input	Input power connections on page 281
PE	Protective Ground	Ground connections on page 285
U2, V2, W2	Power output to motor	Motor connections on page 289

1The 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.

•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.

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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

Power connection diagrams

The following diagram shows the terminal layout for frame size R3, which, in general, applies to frame sizes R1…R6, except for the R5/R6 power and ground terminals.

	J1 – DIP switches for analog inputs (two types can be used)
	<![if ! IE]> <![endif]>ON	J1		J1	AI1: (in voltage position)
		<![if ! IE]> <![endif]>ON	<![if ! IE]> <![endif]>2 1	<![if ! IE]> <![endif]>ON
					AI2: (in current position)

Diagram shows the R3 frame. Other frames have similar layouts.

Panel connector

X1 – Analog inputs and

(and 10 V ref. voltage output)

X1 – Digital inputs				FlashDrop option
				Power LED (green)
(and 24 V aux. voltage output)
				Fault LED (red)
X1 – Relay outputs
J2 – DIP switch				Optional module 1
for RS485 termination
J2	J2			X1 – Communications
				(RS485)
	ON
ON				Optional module 2
off position	on position
	Power input			Power output to motor
Frame sizes	(U1, V1, W1)			(U2, V2, W2)
R5/R6 differ.				EM3
See	EM1
next page.				GND
	PE
				3AUA0000001571
	Optional braking
	Frame	Terminal		Brake options
	size	labels
	R1, R2 BRK+, BRK-		Brake resistor
	R3, R4 UDC+, UDC-		•	Braking unit
			•	Chopper and resistor

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.

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26	ACS550-01/U1 User’s Manual

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

R5
F1
F2
PE	GND
	X0011
	GND

Power input			Power output to motor
(U1, V1, W1)				(U2, V2, W2)
Optional braking
	Frame	Terminal		Brake options
	size	labels
	R5, R6	UDC+, UDC-	•	Braking unit
			•	Chopper and resistor

R6

F2

F1

PE	GND	X0013
Power input	Power output to motor
(U1, V1, W1)	(U2, V2, W2)

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.

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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		Symmetrically	Corner-grounded	IT systems (ungrounded
		Screw	grounded TN systems		or high-resistance-
	sizes			TN systems
			(TN-S systems)		grounded [> 30 ohm])
	R1…R3	EM1	x	x
		EM31	x
	R4	EM1	x	x	–
		EM31	x	–	–
	R5…R6	F1	x	x	–
		F2	x	x	–

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.)

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

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28	ACS550-01/U1 User’s Manual

Control terminals table

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

<![if ! IE]>

<![endif]>Analog I/O

<![if ! IE]>

<![endif]>Digital inputs1

X1

Hardware description

1

SCR

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

2

AI1

Analog input channel 1, programmable. Default2 = frequency reference. Resolution

0.1%, accuracy ±1%.

Two different DIP switch types can be used.

J1: AI1 OFF: 0…10 V (Ri = 312 kohm)

<![if ! IE]> <![endif]>ON

<![if ! IE]> <![endif]>1

<![if ! IE]> <![endif]>ON

J1: AI1 ON: 0…20 mA (Ri = 100 ohm)

<![if ! IE]> <![endif]>ON

<![if ! IE]> <![endif]>1

<![if ! IE]> <![endif]>ON

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 < R < 10 kohm).

5

AI2

Analog input channel 2, programmable. Default2 = not used. Resolution 0.1%,

accuracy ±1%.

Two different DIP switch types can be used.

J1: AI2 OFF: 0…10 V (Ri = 312 kohm)

<![if ! IE]> <![endif]>ON

<![if ! IE]> <![endif]>1

<![if ! IE]> <![endif]>ON

J1: AI2 ON: 0…20 mA (Ri = 100 ohm)

<![if ! IE]> <![endif]>ON

<![if ! IE]> <![endif]>1

<![if ! IE]> <![endif]>ON

6

AGND

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

7

AO1

Analog output, programmable. Default2 = frequency. 0…20 mA (load < 500 ohm).

Accuracy ±3%.

8

AO2

Analog output, programmable. Default2 = 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. Default2 = start/stop.

14

DI2

Digital input 2, programmable. Default2 = fwd/rev.

15

DI3

Digital input 3, programmable. Default2 = constant speed sel (code).

16

DI4

Digital input 4, programmable. Default2 = constant speed sel (code).

17

DI5

Digital input 5, programmable. Default2 = ramp pair selection (code).

18

DI6

Digital input 6, programmable. Default2 = not used.

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ACS550-01/U1 User’s Manual				29
			X1					Hardware description
		19	RO1C					Relay output 1, programmable. Default2 = Ready
								Maximum: 250 V AC / 30 V DC, 2 A
		20	RO1A
								Minimum: 500 mW (12 V, 10 mA)
	<![if ! IE]> <![endif]>outputs	21	RO1B
		23	RO2A					Maximum: 250 V AC / 30 V DC, 2 A
		22	RO2C					Relay output 2, programmable. Default2 = Running
	<![if ! IE]> <![endif]>Relay							Minimum: 500 mW (12 V, 10 mA)
		24	RO2B
		25	RO3C					Relay output 3, programmable. Default2 = Fault (-1)
								Maximum: 250 V AC / 30 V DC, 2 A
		26	RO3A
								Minimum: 500 mW (12 V, 10 mA)
		27	RO3B

1Digital input impedance 1.5 kohm. Maximum voltage for digital inputs is 30 V.

2Default values depend on the macro used. Values specified are for the default macro. See chapter

Application macros on page 77.

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.

PNP connection (source)							NPN connection (sink)
			X1						X1
				10	+24V
										10	+24V
				11	GND					11	GND
				12	DCOM					12	DCOM
				13	DI1
										13	DI1
				14	DI2
										14	DI2
				15	DI3
										15	DI3
				16	DI4
										16	DI4
				17	DI5
										17	DI5
				18	DI6
										18	DI6

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30	ACS550-01/U1 User’s Manual

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 U1 M

the Protective Earth conductor using a measuring		V1	3~
	ohm
voltage of 1000 V DC. The insulation resistance of an		W1 PE

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.	2
	1	X0004

Installation