ABB ACH550-UH HVAC Instruction manual

ACH550

Installation, Operation and Maintenance Manual (I, O & M)

ACH550-UH HVAC Drives (1…550 HP)

ACH550-BCR/BDR/VCR/VDR E-Clipse Bypass Drives (1…400 HP)

ACH550-PCR/PDR Packaged Drives with Disconnect (1…550 HP)

2 ACH550 Installation, Operation and Maintenance Manual

Safety

Use of warnings and notes

There are two types of safety instructions throughout this manual:

• Notes draw attention to a particular condition or fact, or give information on a

subject.

• Warnings caution you about conditions which can result in serious injury or death

and/or damage to the equipment. They also tell you how to avoid the danger. The

warning symbols are used as follows:

Electricity warning warns of hazards

from electricity which can cause

physical injury and/or damage to the

equipment.

•WARNING! The ACH550 adjustable speed

AC drive should ONLY be installed by a

qualified electrician.

•WARNING! Even when the motor is

stopped, dangerous voltage is present at the

power circuit terminals U1, V1, W1 (L1, L2,

L3) and U2, V2, W2 (T1, T2 T3) and,

depending on the frame size, UDC+ and

UDC-, or BRK+ and BRK-.

•WARNING! Dangerous voltage is present

when input power is connected. After

disconnecting the supply, wait at least 5

minutes (to let the intermediate circuit

capacitors discharge) before removing the

cover.

•WARNING! Even when power is switched

off from the input terminals of the ACH550,

there may be dangerous voltage (from

external sources) on the terminals of the

relay outputs.

•WARNING! When the control terminals of

two or more drives are connected in parallel,

the auxiliary voltage for these control

connections must be taken from a single

source which can either be one of the drives

or an external supply.

•WARNING! Disconnect the internal EMC

filter when installing the drive on an IT

system (an ungrounded power system or a

high-resistance-grounded [over 30 ohm]

power system).

•WARNING! Do not attempt to install or

remove EM1, EM3, F1 or F2 screws while

power is applied to the drive’s input

terminals.

General warning warns about

conditions, other than those caused

by electricity, which can result in

physical injury and/or damage to the

equipment.

•WARNING! Do not control the motor with

the disconnecting device (disconnecting

means); instead, use the control panel keys

or commands via the I/O board of the drive.

The maximum allowed number of charging

cycles of the DC capacitors (i.e. power-ups

by applying power) is five in ten minutes.

•WARNING! Never attempt to repair a

malfunctioning ACH550; contact the factory

or your local Authorized Service Center for

repair or replacement.

•WARNING! The ACH550 will start up

automatically after an input voltage

interruption if the external run command is

on.

•WARNING! The heat sink may reach a high

temperature.

Note: For more technical information, contact

the factory or your local ABB representative.

ACH550 Installation, Operation and Maintenance Manual 3

ACH550-UH

Contents

This manual is the Operation and Maintenance Manual for the ACH550 Drives.

Complete technical details and programming information are available in the

ACH550 User’s Manual, publication number 3AUA0000081823.

1. To determine the type of your drive, refer to its construction code on either:

• Serial number label attached on upper part of

the chokeplate between the mounting holes.

• Type code label attached on the heat sink – on

the side of the enclosure.

2. According to the construction code, proceed to your drive’s installation, operation,

diagnostics and maintenance information:

• UH – Below.

• VCR, VDR, BCR, BDR (E-Clipse Bypass) – page 39.

• PCR, PDR (Packaged Drives with Disconnect) – page 79.

ACH550-UH

Installation

Study these installation instructions carefully before proceeding. Failure to observe

the warnings and instructions may cause a malfunction or personal hazard.

WARNING! Before you begin read Safety on page 2.

Note: Keep a minimum of 50 mm (2") of free space on each side and 200 mm (8") of

free space above and below all units from non-heat producing sources. Double

these distances from heat producing sources.

S/N

ACH550-UH-059A-2

2030700001

SW:

V.2.06B

2030700001

Input

Voltage (U1)

Current (I1n)

3 PH 48…63 Hz

200…240 Vac

59.4 A

1 PH 4…63 Hz

200…240 Vac

59.4 A

Output

Voltage (U2)

Current (I2n)

3 PH 0…500 Hz

0…U1 Vac

59.4 A

3 PH 0…500 Hz

0…U1 Vac

28 A

ACH550-UH-059A-2

Power (Pn)

Mfg. Date: 01-December-2005 Org. Firmware: V.2.06B

ABB Inc.

Made in USA of foreign parts

10 HP20 HP

kAIC

S/N 2030700001

Construction

code

4 ACH550 Installation, Operation and Maintenance Manual

ACH550-UH

1. Prepare for installation

Lifting R1…R6

Lift the drive only by the metal chassis.

Lifting R7…R8

WARNING! Handle and ship floor mounted enclosures only in the upright position.

These units are not designed to be laid on their backs.

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

2. Remove the cabinet side panels for access to the cabinet/pallet mounting bolts.

(6 torx screws hold each cabinet side panel in place. Leave the side panels off until

later.)

3. Remove the 4 bolts that secure the cabinet to the shipping pallet.

WARNING! Use the lifting lugs/bars at the top of the unit to lift R7/R8 drives.

4. Use a hoist to lift the drive. (Do not place drive in final position until mounting site is

prepared.)

Unpack the drive

1. Unpack the drive.

2. Check for any damage and notify the shipper immediately if damaged components

are found.

3. Check the contents against the order and the shipping label to verify that all parts

have been received.

Tools required

To install the ACH550 you need the following:

• Screwdrivers (as appropriate for the mounting hardware used)

• Wire stripper

• Tape measure

•Drill

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

holes

• Frame sizes R7/R8: pallet truck and hoist

• For installations involving frame size R6…R8: The appropriate crimping tool for

power cable lugs.

ACH550 Installation, Operation and Maintenance Manual 5

ACH550-UH

• Mounting hardware: screws or nuts and bolts, four each. The type of hardware

depends on the mounting surface and the frame size:

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

WARNING! Before installing the ACH550, ensure the input power supply to the drive

is off.

WARNING! Metal shavings or debris in the enclosure can damage electrical

equipment and create a hazardous condition. Where parts, such as conduit plates

require cutting or drilling, first remove the part. If that is not practical, cover nearby

electrical components to protect them from all shavings or debris.

Flange Mounting Instructions

2. Prepare the mounting location

1. Mark the position of the mounting holes.

Note: Frame sizes R3 and R4 have four holes along the top. Use only two. If

possible, use the two outside holes (to allow room to remove the fan for

maintenance).

Note: ACH400 drives can be replaced using the original mounting holes. For R1 and

R2 frame sizes, the mounting holes are identical. For R3 and R4 frame sizes, the

inside mounting holes on the top of ACH550 drives match ACH400 mounts.

Frame Size Mounting Hardware Note

R1…R4 M5 #10

R5 M6 1/4 in

R6 M8 5/16 in

R7…R8 M10 7/16 Secures free standing cabinets if required.

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 ACS800-PNTG01U-EN - -

R6 AC8-FLNGMT-R6 - -

6 ACH550 Installation, Operation and Maintenance Manual

ACH550-UH

Note: Frame sizes R7 and R8 have mounting holes inside the enclosure base.

Where it is not possible to use either mounting hole at the back of the base, use an

L-bracket at the top of the enclosure to secure the cabinet to a wall or to the back of

another enclosure. Bolt the L-bracket to the enclosure using the lifting lug bolt hole

on the top of the enclosure.

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

3. Remove front cover

R1…R6, UL type 1

1. Remove the control panel, if attached.

2. Loosen the captive screw at the top.

3. Pull near the top to remove the cover.

R1…R6, UL type 12

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

2. If hood is present: Slide hood up and off of the cover.

3. Loosen the captive screws around the edge of the cover.

4. Remove the cover.

R7…R8, Cabinet Door

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

closed.

R7…R8, Side Panels

The side panels were removed to take the cabinet off the pallet. Installation access is

easier if these panels are kept off throughout the installation.

4. Mount the drive

R1…R6, UL type 1

1. Position the ACH550 onto the mounting screws

or bolts and securely tighten in all four corners.

Note: Use mounting hardware that permits fan

replacement without removal.

Note: Lift the ACH550 by its metal chassis.

2. Non-English speaking locations: Add a warning

sticker in the appropriate language over the existing warning on the top of the

module.

IP2002

ACH550 Installation, Operation and Maintenance Manual 7

ACH550-UH

R1…R6, UL type 12

For the UL type 12 enclosures, rubber plugs are required in the holes provided for

access to the drive mounting slots.

1. As required for access, remove the rubber plugs.

Push plugs out from the back of the drive.

2. R5 & R6: Align the sheet metal hood (not shown)

in front of the drive’s top mounting holes. (Attach

as part of next step.)

3. Position the ACH550 onto the mounting screws

or bolts and securely tighten in all four corners.

Note: Lift the ACH550 by its metal chassis

(frame size R6 by the lifting holes on both sides

at the top).

4. Re-install the rubber plugs.

5. Non-English speaking locations: Add a warning sticker in the appropriate language

over the existing warning on the top of the module.

R7…R8

1. Use a hoist to move the cabinet into position.

Note: If the cabinet location does not provide access to the cabinet sides, be sure to

re-mount side panels before positioning cabinet.

2. Install and tighten mounting bolts.

5. Install wiring

WARNING! Ensure the motor is compatible for use with the ACH550. The ACH550

must be installed by a competent person. If in doubt, contact your local ABB sales or

service office.

Conduit kit

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

following items:

• conduit box

•screws

• cover

The kit is included with UL type 1 Enclosures.

1, 3

8 ACH550 Installation, Operation and Maintenance Manual

ACH550-UH

Connection diagrams

The following diagrams show:

• 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.

• The R5/R6 power and ground terminals.

• The terminal layout for R7/R8.

WARNING! To avoid danger, or damage to the drive, on IT systems and corner

grounded TN systems, see section Disconnecting the internal EMC filter on

page 10.

Panel Connector

Power LED (Green)

Fault LED (Red)

Optional Module 1

X1 – Communications

Optional Module 2

GND

Power Output to Motor

Power Input

EM1

X1 – Analog Inputs and Outputs

X1 – Digital Inputs

X1 – Relay Outputs

(and 10 V Ref. Voltage Output)

(and 24 V Aux. Voltage Output)

EM3

(U1, V1, W1) (U2, V2, W2)

X0003

(RS485)

R5/R6 differ.

See next page.

Frame Sizes

R1…R4 (Diagram shows the R3 frame.)

J2 – DIP Switches

off position on position

for RS485 Termination

Terminals Not Used

J1 – DIP Switches for Analog Inputs

AI1: (in Voltage Position)

AI2: (in Current Position)

The switch is one of two types:

Alternate

Original

Illustration of available switch

positions; not default settings

Illustration of available switch

positions; not default settings

ACH550 Installation, Operation and Maintenance Manual 9

ACH550-UH

WARNING! To avoid danger, or damage to the drive, on IT systems and corner

grounded TN systems, see section Disconnecting the internal EMC filter on

page 10.

GND

Power Input

(U1, V1, W1)

X0011

Power Input

(U1, V1, W1)

X0013

Power Output to Motor

(U2, V2, W2)

GND

Power Output to Motor

(U2, V2, W2)

Terminals Not Used

10 ACH550 Installation, Operation and Maintenance Manual

ACH550-UH

Disconnecting the internal EMC filter

On certain types of systems, you must disconnect the internal EMC filter, otherwise

the system will be connected to ground potential through the EMC filter capacitors,

which might cause danger, or damage the drive.

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

The following table shows the installation rules for the EMC filter screws in order to

connect or disconnect the filter, depending on the system type and the frame size.

For more information on the different system types, see Floating networks on page

12 and Unsymmetrically grounded networks on page 11.

The locations of screws EM1 and EM3 are shown in the diagram on page 8. The

locations of screws F1 and F2 are shown in the diagram on page 9.

Frame

sizes Screw

Symmetrically

grounded TN systems

(TN-S systems)

Corner grounded

TN systems

IT systems (ungrounded

or high-resistance-

grounded [> 30 ohm])

R1…R3

EM1 x x

EM3 x

EM1 x x –

EM3 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.)

EM1 and EM3 screws are M4 x 12

F1 and F2 screws are M4 x 16

Ground Lug

Bar ACH550

R7 (R8 Similar)

Motor

Terminals

Input Power

Terminals

Control Wires

(X1)

Terminal Strip

Only on

ACH550-UH

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