ABB ACS550 Users Manual

User’s Manual

ACS550-PC/PD Packaged Drive with Disconnect Supplement to ACS550-01/U1 User’s Manual

ii ACS550-PC/PD Packaged Drive with Disconnect

ACS550 Drive Manuals

GENERAL MANUALS

ACS550-01/U1 User's Manual (1…200 HP)

•Safety

•Installation

• Start-Up

• Embedded Fieldbus

• Fieldbus Adapter

• Diagnostics

• Maintenance

• Technical Data

ACS550 Technical Reference Manual (available in electronic format only)

• Detailed Product Description

• Practical Engineering Guides

ACS550-PC/PD Packaged Drive with Disconnect Supplement for ACS550-01/U1 User’s Manual

•Safety

•Installation

• Start-Up

• Maintenance

• Technical Data

ACS550- CC Packaged Drive with Bypass Supplement for ACS550-01/U1 User’s Manual

•Safety

•Installation

• Start-Up

• Maintenance

• Technical Data

ACS550-PC/PD Packaged Drive with Disconnect 1

Safety

WARNING! The ACS550 adjustable speed AC drive with Input Disconnect should ONLY be instal led 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-.

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 removed from the input terminals of the ACS550, there may be dangerous voltage (from external sources) on the terminals of the relay outputs.

WARNING! When the control terminals of two or more drive units are connected in parallel, t he auxi liar y voltage for these control connect ions must be taken from a single source which can either be one of the units or an external supply.

WARNING! The ACS550 will start up automatically after an input voltage interruption if the external run command is on.

WARNING! When the ACS550 with Input Disconne ct is connected to the line power, the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do not make any connections when the ACS550 with Input Disconnect is connected to the line. Disconnect and lock out power to the drive before servicing the drive. Failure to disconnect power may cause serious injury or death.

Note! For more technical information, contact the factory or your local ABB sales

representative.

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 subj

ect.

• Warnings caution you about condi tions whi ch can resul t in seri ous inju ry or death and/o

r damage to the equipment. They also tell you how to avoid th e danger. The

warning symbols are used as follows:

Dangerous voltage warning warns of high voltage which can cause physical injury and/or damage to the equipment.

Safety

2 ACS550-PC/PD Packaged Drive with Disconnect

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

Safety

ACS550-PC/PD Packaged Drive with Disconnect 3

Safety

Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Table of Contents Installation

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Input Disconnect Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Preparing for Installation (Supplement to ACS550-01/U1 User’s Manual) . . . . . 7

Preparing for Installation (Supplement to ACS550-01/U1 User’s Manual) . . . . . 8

Installing the Drive (Supplement to ACS550-01/U1 User’s Manual ) . . . . . . . . . 9

Installing the Wiring (Supplement to ACS550-01/U1 User’s Manual) . . . . . . . 12

Maintenance

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Drive Module Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Enclosure Fan Replacement – UL Type / NEMA 12 Floor Mount Enclosur es . . 18 Enclosure Air Filter Replacement – UL Type / NEMA 12 Hinged Door

Wall Mount Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Floor Mount - UL Type / NEMA 12 Filter Material . . . . . . . . . . . . . . . . . . . . . . 19

Technical Data

Ratings (Sup p lement to ACS 550 -01/U1 User’s M a nu a l) . . . . . . . . . . . . . . . . . 23

Input Power Connections (Supplement to ACS550-01/U1 User’s Manual) . . . 24 Drive’s Power Connection Terminals (Supplement to ACS550-01/U1

User’s Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Cooling – R7/R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Dimensional References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dimensions and Weights (Supplement to ACS550-01/U1 User’s Manual) . . . 34

Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Index

Table of Contents

4 ACS550-PC/PD Packaged Drive with Disconnect

ACS550

Drive with Input Disconnec t

Motor

3 Phase

Drive

Disconnect Switch

or Circuit Breaker

Input Power

Installation

Study t hese ins t a llat ion ins tr uctions car efu lly be for e proceedi ng. Failure t o observe the warnings and instructions may cause a malfunction or personal hazard.

WARNING! Before you begin read “Safety” on page 1.

Application

This manual contains supplemental i nformation that is unique to ACS550 input disconnect configurations (PC or PD). Refer to the base manual, AC550-01/U1 User’s Manual, for all other information.

Input Disconnect Features and Functions

The ACS550 with Input Disconnect is an ACS550 AC adjustable frequency dri ve packaged with an input disconnect switch or circuit breaker, and with a door mounted, external operating handle. The operat ing handle can be padlocked in the OFF position (padlock not supplied). Enclosure options are UL Type 1, UL Type 12, and UL Type 3R (NEMA 1, NEMA 12, and NEMA 3R).

The following is a typical power diagram.

Installation

ACS550-PC/PD Packaged Drive with Disconnect 5

BP0093

ACS550 Drive

UL Type / NEMA 1 & 12 UL Type / NEMA 1 & 12

BP0094

BP0096

Enclosures Enclosures

UL Type / NEMA 1 & 12

Enclosures

Control Panel

Vertical Construction Hinged Door Wall Mount

Floor Mount

PC00071

ACS550 Drive Control Pa nel with Hinged Cover

UL Type

/ NEMA 3R

Enclosures

Operating Handle

for Disconnect Switch

or Circuit Breaker

The following figures show the front view of the ACS550 Drive with Input Discon nect standard configurations, and identify the major components.

Note! UL Type 3R, PX3R-1, PX3R-2, PX3R-3 & PX3R-4 enclosu res are designed to be mounted on a wall. Mounting these 3R enclosures on an open rack system requires the use of the supplied 3R enclosure back plat es to maintain 3R integrity. See section

“Prepare the UL Type 3R ACS550 PX3R-1, PX3R-2, PX3R-3, PX3R-4

for UNISTRUT® mounting” for more details.

Installation

6 ACS550-PC/PD Packaged Drive with Disconnect

Installation Flow Chart

The installation of Input Disconnect configurations for ACS550 drives follows the outline below. The steps must be carried out in th e order shown. At the right of each step are references to the detailed information needed for the correct in stallation of the unit.

Note! References in the middle column below are to the ACS550-01/U1 User’s Manual. References in the third column below are to this manual.

Task

PREPARE fo

installation

PREPARE the Mounting Location

REMOVE the front cover

MOUNT the drive “Mount the Drive” R7/R8: “Mount the Drive” on

ACS5

“Preparing for Installation” • R7/R8: “Lifting the Drive” on

“Prepare the Mounting Loc ation” • R7/R8: “Prepare the Mounting

“Remove Front Cover” R7/R8: “Remove Side Panel- R7

Refer to the

50-01/U1 User’s Manual

“Installation” section

Additional Reference in this

nual

page 7.

• “Drive Identification” on page 8.

• “Suitable Mounting Location” on page 9.

Location – R7 and R8” on page 9.

• “Dimensions and Weights (Supplement to A CS550-01/ U1 User’s Manual)” on page 34.

and R8 UL Type/NEMA 1 & 12 Enclosures” on page 10.

page 10.

Installation

INSTALL wiring “Wiring Overview” and

“Install the Wiring”

CHECK installation “Check Installation” --

RE-INSTALL the

cover

APPLY power “Apply Power” --

START-UP “Start-Up” --

“Re-install Cove r” --

“Installing the Wirin g (Su ppl em ent to ACS550-01/U1 User’s Manual)” starting on page 12.

ACS550-PC/PD Packaged Drive with Disconnect 7

PC00005

R70010

PC00003

Preparing for Installation (Supplement to ACS550-01/U1 User’s Manual)

Lifting the Drive

R7…R8

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

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

2. Remove the cabinet side panels from UL Type/NEMA 1 and 12 enclosures for access to the cabinet/ pallet mount panel in place. Leave the side p anels off until later.)

3. Remove the 4 bolts that secure the cabi net to the shippi ng pa

ing bolts. (6 torx screws hold each cabinet side

llet.

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.)

Installation

8 ACS550-PC/PD Packaged Drive with Disconnect

Preparing for Installation (Supplement to ACS550-01/U1 User’s Manual)

Drive Identification

To identify the type of device you are install ing, r efer to t he ty pe code number on the devi

ce identification label.

• Wall mounting base drives – label attached on the side surface of the heat sink.

• Packaged drive with screw cover – label attached to outside surface on the lef t ide

of the enclosure.

• Enclosure with hinged cover/door – label on inside surface of the cover/door.

Type Code Number

Use the following to interpret the type code found on the identification label.

ACS550-U1-015A-4 +…+…

AC Drive = 550 Product Series Construction

U1 = Base Drive CC = Bypass with circuit breaker PC = Drive with circuit breaker PD = Drive with disconnect switch

Output current rating (See ratings chart for details) Voltage rating

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

Enclosure protection class

No specification = UL Type 1/NEMA 1 +B055 = UL Type 12/NEMA 12 +B058 = UL Type 3R/NEMA 3R

Power options

+F267 = Service switch

Input/Output option modules

+L502 = Pulse encoder interface +L511 = Relay output extension +L512 = 115/230 V digital input interface

Fieldbus adaptors

+K451 – DeviceNet Adapter +K454 = Prof ibus Adapter +K457 = CANopen Adapter +K462 = ControlNet Adapter +K466 = Ethernet Adapter

+K467 = PROFINET IO Adapter

Installation

Ratings and Frame Size

Charts in the “Ratings” sections of the ACS550-01/U1 User’s Manual and this manual list technical specificati ons, and identify the drive’s frame size.

Note! Some instructions in th is document var y, depending on the drive’s frame size. To read the Ratings table, you need the “Output current rating” entry from the type code (see above).

ACS550-PC/PD Packaged Drive with Disconnect 9

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)

Suitable Mounting Location

For selecting a suitable mounting location for PC/PD configurations, refer to:

• Preparing for installation in the ACS550-01/U1 User’s Manual, and

• The Technical Data section of this manual for information on dimensions and wei

ghts.

Installing the Drive (Supplement to ACS550-01/U1 User’ s Manual)

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.

Prepare the Mounting Location – R7 and R8

The ACS550 should only be mounted where “Preparing for In stallation” are met.

all of the requirements defined in

Frame sizes R7 and R8 have mounting holes inside the enclosure base. See “UL Type/NEMA 1&12, Floor Mount Enclosure Mounting Dimensions” on page 37.

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. Bol t the L-bracket to the enclosure using the li fting lug bolt hole on the top of the enclosure.

Installation

10 ACS550-PC/PD Packaged Drive with Disconnect

R70020

PC00003

Remove Side Panels – R7 and R8 UL Type/NEMA 1 & 12 Enclosures

Cabinet Door

1. To open the cabinet door, loosen the quarter-turn screws t

hat hold the cabinet door closed.

2. Installation access is easier if these panels are kept off t

hroughout the installation.

Mount the Drive

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

ACS550-PC/PD Packaged Drive with Disconnect 11

Vent on back of cabinet for cooling.

Prepare the UL Type 3R ACS550 PX3R-1, PX3R-2, PX3R-3, PX3R-4 for UNISTRUT® mounting

The ACS550 UL Type 3R cabinet fr ame sizes PX3R-1, PX3R-2, PX3R-3, PX3R-4, PX3R-5,

PX3R-6 are designed to be mounted on a solid vertical surface or using UNISTRUT. On frame sizes PX3R-1, PX3R-2, PX3R-3, PX3R-4, the d esign requi res the use of a back plate that is provided with each UL Type 3R PX3R-1, PX3R-2, PX3R-3, PX3R-4 shipment.

As delivered, UL Type 3R ACS550 drives PX3R-1, PX3R-2, PX3R-3, PX3R-4 frame sizes are supplied such that mounting the cabinet on an open back allows rain/sn ow to enter the pre-cut vent. To meet UL Type 3R requirements, install back plate provided with the drive.

ACx550 UL Type 3R Back Plate Instructions

1. Install back plate.

Note! If cabinet is mounted on a soli d surface, bac k plate shipp ed with cabi net is not required but may still be installed.

2. Install 2 bolts on top and bottom with back plate installed behind cabinet.

Note! If cabinet is mounted on a soli d surface, bac k plate shipp ed with cabi net is not required, but may still be installed.

Installation

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