Grieve Corporation ACS550 Installation Manual
ACS550
User’s Manual
ACS550-01 Drives (0.75
ACS550-U1 Drives (1
…200 hp)
…132 kW)
ACS550 Drive Manuals
GENERAL MANUALS
ACS550-01/U1 User's Manual (0.75…132 kW) /
(1…200 hp)
3AFE64804588 (3AUA0000001418) (English)
ACS550-02/U2 User's Manual (160…355 kW) /
(200…550 hp)
3AFE64804626 (English)
•Safety
•Installation
• Start-up, control with I/O and ID Run
• Control panels
• Application macros
• Parameters
• Embedded fieldbus
• Fieldbus adapter
• Diagnostics
• Maintenance
• Technical data
ACS550 Technical Reference Manual
(available in electronic format only)
• Detailed Product Description
– Technical product description including dimensional
drawings
– Cabinet mounting information including power
losses
– Software and control including complete parameter
descriptions
– User interfaces and control connections
– Complete options descriptions
– Spare parts
–Etc.
• Practical Engineering Guides
– PID & PFC engineering guides
– Dimensioning and sizing guidelines
– Diagnostics and maintenance information
–Etc.
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)
RETA-01 Ethernet Adapter User's Manual
3AFE64539736 (English)
RLON-01 LonWorks Adapter Module User’s Manual
3AFE64798693 (English)
RPBA-01 PROFIBUS-DP Adapter User's Manual
3AFE64504215 (English)
Typical contents
•Safety
• Installation
• Programming/Start-up
• Diagnostics
• Technical data
MAINTENANCE MANUALS
Guide for Capacitor Reforming in ACS50/150/350/550
3AFE68735190 (EN)
The IndustrialIT wordmark and Product names in the form
IT
are registered or pending trademarks of ABB.
Drive
CANopen is a registered trademark of CAN in Automation
e.V.
ControlNet is a registered trademark of ControlNet
International.
DeviceNet is a registered trademark of Open DeviceNet
Vendor Association.
DRIVECOM is a registered trademark of DRIVECOM User
Organization.
Interbus is a registered trademark of Interbus Club.
LonWorks is a registered trademark of Echelon Corp.
Metasys is a registered trademark of Johnson Controls Inc.
Modbus and Modbus Plus are registered trademarks of
Schneider Automation Inc.
PROFIBUS is a registered trademark of Profibus Trade Org.
PROFIBUS-DP is a registered trademark of Siemens AG.
ACS550-01/U1 Drives
0.75…132 kW
1…200 hp
User’s Manual
3AFE64804588 (3AUA0000001418) Rev F
SUPERSEDES: 3AFE64804588 Rev D 24.06.2004
SUPERSEDES: 3AUA0000001418 Rev E 06.12.2004
© 2007 ABB Oy. All Rights Reserved.
EN
EFFECTIVE: 16.04.2007
ACS550 User’s Manual 5
Safety
Use of warnings and notes
There are two types of safety instructions throughout this manual:
• Notes draw attention to a particular condition or fact, or give information on a
subject.
• Warnings caution you about conditions which can result in serious injury or death
and/or damage to the equipment. They also tell you how to avoid the danger. The
warning symbols are used as follows:
Dangerous voltage warning warns of high voltage which can cause physical injury
and/or damage to the equipment.
General warning warns about conditions, other than those caused by electricity,
which can result in physical injury and/or damage to the equipment.
WARNING! The 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-.
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.
Safety
6 ACS550 User’s Manual
WARNING! If a drive whose internal EMC filter is not disconnected is installed on an
IT system [an ungrounded power system or a high resistance-grounded (over
30 ohm) power system], the system will be connected to earth potential through the
EMC filter capacitors of the drive. This may cause danger or damage the drive.
If a drive whose internal EMC filter is not disconnected is installed on a corner
grounded TN system, the drive will be damaged.
Disconnect the internal EMC filter by removing EM1 and EM3 screws (frame size
…R4, see the diagram in section Power connection diagrams on page 20) or F1
R1
and F2 screws (frame size R5 or R6, see the diagram on page 21). Also see
sections IT systems on page 268 and Corner grounded TN systems on page 267.
WARNING! Do not attempt to install or remove EM1, EM3, F1 or F2 screws while
power is applied to the drive’s input terminals.
WARNING! Do not control the motor with the disconnecting device (disconnecting
means); instead, use the control panel 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 six in ten minutes.
WARNING! The ACS550-01/U1 is not field repairable. Never attempt to repair a
malfunctioning drive; contact the factory or your local Authorized Service Center for
replacement.
WARNING! The ACS550 will start up automatically after an input voltage interruption
if the external run command is on.
WARNING! The heat sink may reach a high temperature. See chapter Technical
data on page 259.
Note: For more technical information, contact the factory or your local ABB
representative.
Safety
ACS550 User’s Manual 7
Table of contents
Safety
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table of contents
Installation
Installation flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Start-up, control with I/O and ID Run
How to start up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
How to control the drive through the I/O interface . . . . . . . . . . . . . . . . . . . . . . 38
How to perform the ID Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control panels
About control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Assistant Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Basic Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Application macros
ABB Standard macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3-wire macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Alternate macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Motor Potentiometer macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Hand-Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
PID Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
PFC macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Torque Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connection example of a two-wire sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
User parameter sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Macro default values for parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Parameters
Complete parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Complete parameter descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Embedded fieldbus
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Mechanical and electrical installation – EFB . . . . . . . . . . . . . . . . . . . . . . . . . 190
Communication set-up – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Activate drive control functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Table of contents
8 ACS550 User’s Manual
Feedback from the drive – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Diagnostics – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Modbus protocol technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
ABB control profiles technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Fieldbus adapter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Mechanical and electrical installation – FBA . . . . . . . . . . . . . . . . . . . . . . . . . 224
Communication set-up – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Activate drive control functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Feedback from the drive – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Diagnostics – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
ABB Drives profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Generic profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Diagnostics
Diagnostic displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Correcting faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Correcting alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Maintenance
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Main fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Internal enclosure fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Technical data
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Input power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Brake components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
C-Tick marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
UL/CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
IEC/EN 61800-3 (2004) Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Compliance with the IEC/EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . 293
Liability limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Product protection in the USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Table of contents
ACS550 User’s Manual 9
Index
Contact ABB
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . 309
Table of contents
10 ACS550 User’s Manual
Table of contents
ACS550 User’s Manual 11
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 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 Se e
PREPARE for installation Preparing for installation on page 12
PREPARE the mounting location Prepare the mounting location on page 16
REMOVE the front cover Remove the front cover on page 16
MOUNT the drive Mount the drive on page 17
INSTALL wiring Wiring overview on page 18 and
CHECK installation Check installation on page 29
REINSTALL the cover Reinstall the cover on page 30
START-UP How to start up the drive on page 31
Install the wiring on page 24
Installation
12 ACS550 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.
3. Check the contents against
the order and the shipping label to verify that all parts have been received.
Drive identification
Drive labels
IP2040
To determine the type of drive you are installing, refer to either:
• serial number label attached on upper part of the chokeplate between the
mounting holes, or
Type code
Serial number
• type code label attached on the heat sink – on the right side of the drive cover.
Two examples of the type code label are given below.
Serial number
Type code
Installation
Serial number
Type code
ACS550 User’s Manual 13
Type code
Use the following chart to interpret the type code found on both the type code 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 259 for details
Vol tag e rati ng
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)
0J400 = No control panel
J404 = ACS-CP-C Basic Control Panel
L511 = OREL-01 Relay output extension
K451 = RDNA-01 DeviceNet
K452 = RLON-01 LonWorks
K454 = RPBA-01 PROFIBUS DP
Ratings and frame size
The chart in section Ratings
on page 259 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 code. 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 0001.
Installation
14 ACS550 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.
Verify Reference
• Type code label on drive, entry for Output I
= drive heavy duty
2hd
or
• Type code on drive and rating table in chapter
Technical data on page 259.
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
Tools required
To install the ACS550 you need the following:
• screwdrivers (as appropriate for the mounting hardware used)
• wire stripper
• tape measure
2hd
,
• 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 269.
• mounting hardware: screws or nuts and bolts, four each. The type of hardware
depends on the mounting surface and the frame size:
Frame size Mounting hardware
R1…R4 M5 #10
R5 M6
R6 M8
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 289.
Installation
ACS550 User’s Manual 15
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 292.
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.
• The minimum space requirements for the drive are the outside dimensions (see
section Outside dimensions on page
(see section Cooling
on page 283).
287), plus air flow space around the drive
• The distance between the motor and the drive is limited by the maximum motor
cable length. See section Motor connection specifications
on page 271.
• The mounting site must support the drive’s modest weight. See section Weight on
page 288.
Installation
16 ACS550 User’s Manual
Installing the drive
WARNING! Before installing the ACS550, ensure the input power supply to the drive
is off.
Prepare the mounting location
The ACS550 should only be mounted where all of the
requirements defined in section Preparing for installation
on page 12 are met.
1. Mark the position of the mounting holes with the help of
1
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.
Remove the front cover
IP21 / UL type 1
3
1. Remove the control panel, if attached.
2. Loosen the captive screw at the top.
2
3. Pull near the top to remove the cover.
X0002
Installation
1
IP2000
ACS550 User’s Manual 17
IP54 / UL type 12
R6
1. If hood is present: Remove screws
(2) holding hood in place.
2. If hood is present: Slide hood up and
1
off of the cover.
3. Loosen the captive screws around
the edge of the cover.
4. Remove the cover.
Mount the drive
IP21 / UL type 1
1. Position the ACS550 onto the mounting screws or
bolts and securely tighten in all four corners.
R1
…R5
1
2
3
4
FM
1
Note: Lift the ACS550 by its metal chassis (frame
size R6 by the lifting holes on both sides at the top).
2
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.)
1, 4
3. Position the ACS550 onto the mounting screws or
bolts and securely tighten in all four corners.
5
Note: Lift the ACS550 by its metal chassis (frame
size R6 by the lifting holes on both sides at the top).
IP2002
3
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
18 ACS550 User’s Manual
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 12. If in doubt, contact your local ABB
sales or service office.
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 274.
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
1
U1, V1, W1
PE Protective Ground Ground connections on page 266
U2, V2, W2 Power output to motor Motor connections on page 271
1
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 263
• To locate input power and motor connection terminals, see section Power
connection diagrams on page 20. For specifications on power terminals, see
section Drive’s power connection terminals on page 268.
Installation
• For corner grounded TN systems, see section Corner grounded TN systems on
page 267.
• For IT systems, see section IT systems on page 268.
ACS550 User’s Manual 19
• For frame size R6, see section Power terminal considerations – R6 frame size on
page 269 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 277.
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 22
– Control connections
on page 281
– Application macros on page 71
– Complete parameter descriptions on page 98
– Embedded fieldbus on page 189
– Fieldbus adapter on page 221.
Installation
20 ACS550 User’s Manual
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)
J1
ON
ON
X1 – Analog inputs and outputs
(and 10 V ref. voltage output)
J1
12
AI1: (in voltage position)
ON
AI2: (in current position)
Diagram shows the R3 frame.
Other frames have similar layouts.
Panel connector
(and 24 V aux. voltage output)
X1 – Digital inputs
X1 – Relay outputs
J2 – DIP switch
for RS485 termination
J2
ON
off position on position
Frame sizes
R5/R6 differ.
See
next page.
J2
ON
Power input
(U1, V1, W1)
EM1
PE
Optional braking
Frame
size
R1, R2 BRK+, BRK- Brake resistor
R3, R4 UDC+, UDC- • Braking unit
Term inal
labels
• Chopper and resistor
FlashDrop option
Power LED (green)
Fault LED (red)
Optional module 1
X1 – Communications
(RS485)
Optional module 2
Power output to motor
(U2, V2, W2)
EM3
GND
3AUA0000001571
Brake options
Installation
WARNING! For IT systems and corner grounded TN systems, disconnect the
internal EMC filter by removing:
- On ACS550-01: screws EM1 and EM3
- On ACS550-U1: screw EM1 (drive is shipped with EM3 already removed).
See IT systems on page 268 and Corner grounded TN systems on page 267.
ACS550 User’s Manual 21
The following diagram shows the power and ground terminal layout for frame sizes
R5 and R6
R5 R6
F2
F1
F2
PE
GND
Power input
(U1, V1, W1)
Optional braking
Frame
size
R5, R6 UDC+, UDC- • Braking unit
Term inal
labels
Power output to motor
(U2, V2, W2)
Brake options
• Chopper and resistor
X0011
GND
Power input
(U1, V1, W1)
F1
PE
GND
Power output to motor
(U2, V2, W2)
WARNING! For IT systems and corner grounded TN systems, disconnect the
internal EMC filter by removing screws F1 and F2.
See IT systems on page 268 and Corner grounded TN systems on page 267.
X0013
Installation
22 ACS550 User’s Manual
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 screen. (Connected internally to chassis ground.)
ON
ON
2
= frequency reference. Resolution
ON
ON
ON
1
1
R < 10 kohm).
2
= not used. Resolution 0.1%,
ON
ON
ON
1
1
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)
i
= 100 ohm)
i
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%.
Analog I/O
Two different DIP switch types can be used.
J1: AI2 OFF: 0…10 V (R
J1: AI2 ON: 0…20 mA (R
= 312 kohm)
i
= 100 ohm)
i
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
1
13 DI1 Digital input 1, programmable. Default
14 DI2 Digital input 2, programmable. Default
15 DI3 Digital input 3, programmable. Default
Digital inputs
16 DI4 Digital input 4, programmable. Default
17 DI5 Digital input 5, programmable. Default
18 DI6 Digital input 6, programmable. Default
(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.
2
= start/stop.
2
=fwd/rev.
2
= constant speed sel (code).
2
= constant speed sel (code).
2
= ramp pair selection (code).
2
= not used.
Installation
ACS550 User’s Manual 23
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
Relay outputs
25 RO3C Relay output 3, programmable. Default
26 RO3A
27 RO3B
1
Digital input impedance 1.5 kohm Maximum voltage for digital inputs is 30 V.
2
Default values depend on the macro used. Values specified are for the default macro. See chapter
Application macros on page 71.
Maximum: 250 VAC / 30 V DC, 2 A
Minimum: 500 mW (12 V, 10 mA)
Maximum: 250 VAC / 30 V DC, 2 A
Minimum: 500 mW (12 V, 10 mA)
Maximum: 250 VAC / 30 V DC, 2 A
Minimum: 500 mW (12 V, 10 mA)
2
= Running
2
= 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.
NPN connection (sink)PNP connection (source)
X1
10 +24V
11 GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
X1
10 +24V
11 GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
Installation
24 ACS550 User’s Manual
Install the wiring
Checking motor and motor cable insulation
WARNING! Check the motor and motor cable insulation before connecting the drive
to input power. For this test, make sure that motor cables are NOT connected to the
drive.
1. Complete motor cable connections to the motor, but NOT to the drive output
terminals (U2, V2, W2).
2. At the drive end of the motor cable, measure the insulation
resistance between each motor cable phase and Protective
Earth (PE): Apply a voltage of 1 kV DC and verify that
resistance is greater than 1 Mohm.
ohm
PE
M
Installation
ACS550 User’s Manual 25
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 18.)
2. Install the cable clamps for the power/motor cables.
3. On the input power cable, strip the sheathing back
2
1
6
X0004
far enough to route individual wires.
4. On the motor cable, strip the sheathing back far
7
enough to expose the copper wire screen so that the
screen can be twisted into a pig-tail. Keep the pigtail short to minimize noise radiation.
6
3
4
360° grounding under the clamp is recommended
8
for the motor cable to minimize noise radiation. In
this case, remove the sheathing at the cable clamp.
5. Route both cables through the clamps.
6. Strip and connect the power/motor wires and the
8
power ground wire to the drive terminals.
Note: For R5 frame size, the minimum power cable
size is 25 mm
2
(4 AWG).
For R6 frame size, refer to section Power terminal
considerations – R6 frame size on page 269.
7. Connect the pig-tail created from the motor cable screen to the GND terminal.
8. Install conduit/gland box and tighten the cable clamps.
9. Install the cable clamp(s) for the control cable(s).
(Power/motor cables and clamps not shown in the
figure.)
10. Strip control cable sheathing and twist the copper
screen into a pig-tail.
9
11. Route control cable(s) through clamp(s) and tighten
clamp(s).
12. Connect the ground screen pig-tail for digital and
analog I/O cables at X1-1. (Ground only at drive
12
14
end.)
IP2001
X0005
X0006
13. Connect the ground screen pig-tail for RS485 cables
at X1-28 or X1-32. (Ground only at drive end.)
14. Strip and connect the individual control wires to the
drive terminals. See section Control terminals table
on page 22.
15. Install the conduit/gland box cover (1 screw).
11
IP2003
Installation
26 ACS550 User’s Manual
Wiring IP21 / UL type 1 enclosure with conduit
1. Open the appropriate knockouts in the conduit/gland
box. (See section Conduit/Gland kit on page 18.)
2. Install thin-wall conduit clamps (not supplied).
2
3. Install conduit/gland box.
4. Connect conduit runs to box.
5. Route input power and motor wiring through conduits
(must be separate conduit runs).
3
7
6. Strip wires.
7. Connect power, motor and ground wires to the drive
7
terminals.
5
4
Note: For R5 frame size, the minimum power cable
size is 25 mm
2
(4 AWG).
For R6 frame size, refer to section Power terminal considerations – R6 frame size on
page 269.
8. Route the control cable through the conduit (must be
separate from input power and motor conduit runs).
9. Strip the control cable sheathing and twist the copper
screen into a pig-tail.
10
12
10. Connect the ground screen pig-tail for digital and
analog I/O cables at X1-1. (Ground only at drive end.)
X0007
X0005
IP2004
Installation
11. Connect the ground screen pig-tail for RS485 cables
at X1-28 or X1-32. (Ground only at drive end.)
12. Strip and connect the individual control wires to the
drive terminals. See section Control terminals table
on page 22.
13. Install the conduit/gland box cover (1 screw).
8
IP2005
ACS550 User’s Manual 27
Wiring IP54 / UL type 12 enclosure with cables
1. Cut the cable seals as needed for the power,
motor and control cables. (The cable seals are
cone-shaped, rubber seals on the bottom of the
drive.)
1
2. On the input power cable, strip the sheathing back
far enough to route individual wires.
5
3. On the motor cable, strip the sheathing back far
enough to expose the copper wire screen so that
the screen can be twisted into a pig-tail. Keep the
2
4
pig-tail short to minimize noise radiation.
360° grounding under the clamp is recommended
for the motor cable to minimize noise radiation. In
this case, remove the sheathing at the cable
IP5004
clamp.
4. Route both cables through the clamps and tighten the clamps.
5. Strip and connect the power/motor wires and the power ground wire to the drive
terminals.
Note: For R5 frame size, the minimum power cable size is 25 mm2 (4 AWG).
For R6 frame size, refer to section Power terminal considerations – R6 frame size on
page 269.
IP5003
3
4
6. Connect the pig-tail created from the motor cable
screen to the GND terminal.
7. Strip control cable sheathing and twist the copper
screen into a pig-tail.
8. Route control cable(s) through clamp(s) and
tighten clamp(s).
9. Connect the ground screen pig-tail for digital and
analog I/O cables at X1-1. (Ground only at drive
end.)
10. Connect the ground screen pig-tail for RS485
cables at X1-28 or X1-32. (Ground only at drive
end.)
11. Strip and connect the individual control wires to
the drive terminals. See section Control terminals
table on page 22.
9…11
8
IP5005
Installation
28 ACS550 User’s Manual
7
Wiring IP54 / UL type 12 enclosure with conduit
1. Depends on frame size:
• R1…R4: Remove and discard the cable seals
where conduit will be installed. (The cable seals are
cone-shaped, rubber seals on the bottom of the
drive.)
• R5 and R6: Use punch to create holes for conduit
connections as needed.
2. For each conduit run, install water tight conduit
connectors (not supplied).
3. Route the power wiring through the conduit.
4. Route the motor wiring through the conduit.
R1…R4
R5, R6
2
6
1
1
IP5013
IP5023
IP5016
5. Strip the wires.
6. Connect the power, motor and ground wires to the
drive terminals.
3
Note: For R5 frame size, the minimum power cable
size is 25 mm
2
(4 AWG).
For R6 frame size, refer to section Power terminal considerations – R6 frame size on
page 269.
7. Route the control cable through the conduit.
8. Strip the control cable sheathing and twist the copper screen into a pig-tail.
9. Connect the ground screen pig-tail for digital and analog I/O cables at X1-1. (Ground
only at drive end.)
10. Connect the ground screen pig-tail for RS485 cables at X1-28 or X1-32. (Ground
only at drive end.)
11. Strip and connect the individual control wires to the drive terminals. See section
Control terminals table on page 22.
4
IP500
Installation
ACS550 User’s Manual 29
Check installation
Before applying power, perform the following checks.
Check
Installation environment conforms to the drive’s specifications for ambient conditions.
The drive is mounted securely.
Space around the drive meets the drive’s specifications for cooling.
The motor and driven equipment are ready for start.
For IT systems and corner grounded TN systems: The internal EMC filter is disconnected
(screws EM1 & EM3 or F1 & F2 removed).
The drive is properly grounded.
The input power (mains) voltage matches the drive nominal input voltage.
The input power (mains) connections at U1, V1 and W1 are connected and tightened as
specified.
The input power (mains) fuses are installed.
The motor connections at U2, V2 and W2 are connected and tightened as specified.
The motor cable is routed away from other cables.
NO power factor compensation capacitors are in the motor cable.
The control connections are connected and tightened as specified.
NO tools or foreign objects (such as drill shavings) are inside the drive.
NO alternate power source for the motor (such as a bypass connection) is connected – no
voltage is applied to the output of the drive.
Installation
30 ACS550 User’s Manual
R6
R1…R5
Reinstall the cover
IP21 / UL type 1
1
1. Align the cover and slide it on.
2. Tighten the captive screw.
2
3. Reinstall the control panel.
4. Continue with start-up. See chapter Start-up,
control with I/O and ID Run on page 31.
IP54 / UL type 12
1. Align the cover and slide it on.
2. Tighten the captive screws around
the edge of the cover.
4
3. Slide the hood down over the top
of the cover. (Only needed for UL
type 12 installations.)
4. Install the two screws that attach
the hood. (Only needed for UL
type 12 installations.)
5. Install the control panel.
Note: The control panel window
must be closed to comply with
IP54 / UL type 12.
3
IP2009
4
3
5
6
1
2
FM
6. Optional: Add a lock (not supplied) to secure the control panel window.
7. Continue with start-up. See chapter Start-up, control with I/O and ID Run on page
31.
Installation
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