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ACH550-UH - WRP Associates, LLC

1. Service Switch Optional Output Terminals Output Ground Lug s Disconnect Switch we Output or Circuit Breaker I Ground Lug s Input Output Ground Lug Terminals Input Power H Service Switch Cable Optional arcane Terminals g BP0054 ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 41 Connection diagrams Standard E Clipse Bypass wall mounted ACH550 Standard E Clipse Bypass units are configured for wiring access from the top The following figure shows the Standard E Clipse Bypass wall mounted wiring connection points ACH550 User Power Cable Guides i Sse ao E Clipse Bypass Control Board Terminals X2 i Optional Motor Service Switch Terminals Output Ground Lug a wO Disconnect Switch ee s ay or Circuit Breaker Input Power Terminals Input Ground Lug s ACH550 E Clipse Bypass 42 ACH550 Installation Operation and
2. H l made on the E Clipse Bypass control roms a board BS O Use wire ties to permanently affix control j 8 l On communications wiring to the hooked wire Pa m EIA 485 race tie points provided maintaining a Digital I O port minimum 6 mm 1 4 spacing from power control o of control wiring terminals i is i terminals i Bi 1 l RT Drive s power connection terminals The following tables list power and motor cable terminal sizes for connections to an input circuit breaker or disconnect switch a motor terminal block and ground lugs The tables also list torque that should be applied when tightening the terminals ACH550 E Clipse Bypass 48 ACH550 Installation Operation and Maintenance Manual Vertical enclosure terminals Maximum Wire Size Capacities of Power Terminals PEREP Frame ea a A L HP Identification Size Circuit Disconnect Motor Ground Breaker Switch Termination Lugs 208 240 Volt 1 ACH550 VxR 04A6 2 R1 1 5 ACH550 VxR 06A6 2 R1 ACH550 VxR 07A5 2 R1 a E 35 in lbs 7 in lbs 6 4 ACH550 VxR 012A 2 R1 ACH550 VxR 017A 2 R1 30 in lbs 35 in lbs 7 5 ACH550 VxR 024A
3. I Li I Cable Guides Q J Ground 2 Motor Motor T Cables Cables Ground Input Power Cables Input Power Cables l e i EC l nN Standard Configuration B3 Motor Cables Input Power Cables Ground Ground i lt UL Type 3R Configuration B1 B2 Note UL Type 3R B1 B2 enclosures 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 plates to maintain 3R integrity ACH550 E Clipse Bypass 46 ACH550 Installation Operation and Maintenance Manual ACH550 to line power Follow the procedure on page 12 Before proceeding with the insulation resistance measurements check that the ACH550 is disconnected from incoming line power Failure to disconnect line power could result in death or serious injury WARNING Check the motor and motor wiring insulation before connecting the Install the control wiring Connect control wiring to terminal block X1 on the ACH550 control board and to terminal block X2 on the E Clipse Bypass control board For more information on these connections refer to the following e X1 term
4. paragraph ir t BYPASS CONTROL ENABLED ZE HAND FAVLTED 7 gt re ain er Serial Communications Termination Resistors al l sw1 Factory es l lt ON Terminated installed er OFF Not Terminated jumpers T 9 IS EERTE LO i 2 0 e fs 9 is E IOo a joo f i B Hooked wire S race tie points S m T Pr ACH550 E Clipse Bypass 60 ACH550 Installation Operation and Maintenance Manual DIP switch settings The DIP switch is used to configure the serial communications termination resistors To reduce noise on the serial communications network terminate the EIA 485 network using 120 ohm resistors at both ends of the network Use the DIP switches to connect or disconnect the on board termination resistors Both switches must be positioned in the ON or OFF position to correctly configure the termination resistors Note When using embedded protocols set SW1 in the OFF position Circuit breaker settings On some ACH550 E Clipse Bypasses the circuit breaker has adjustable settings for instantaneous current protection The factory default settings are practical for most applications Refer to the
5. i e i it So N 0o Power Input Power Output to Motor U1 V1 W1 U2 V2 W2 ag Filter Connection 1 Terminals Not Used g 0 i Terminals Not ea Nooooo O AaAaaanacona UDC i R UDC U2 V2 W2 oe Fe GND el x S t 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 corner grounded TN systems see section Disconnecting the internal EMC filter on page 70 ACH550 UH 10 ACH550 Installation Operation and Maintenance Manual R7 R8 Similar Motor Ground Lug ACH550 Control Wires Terminals Bar X1 Input Power Terminals Terminal Strip Only on ACH550 UH 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 informati
6. Fault Fault Name In eae 3 Code Panel Description and Recommended Corrective Action 35 OUTPUT WIRING Possible power wiring error detected When the drive is not running it monitors for an improper connection between the drive input power and the drive output Check for and correct e Proper input wiring line voltageis NOT connected to drive output e The fault can be erroneously declared if the input power is a delta grounded system and motor cable capacitance is large This fault can be disabled using parameter 3023 WIRING FAULT 36 INCOMP The drive cannot use the software SWTYPE e Internal Fault The loaded software is not compatible with the drive Call support representative 37 CB OVERTEMP Drive control board is overheated Check for and correct e Excessive ambient temperatures Fan failure e Obstructions in the air flow 38 USER LOAD Condition defined by parameter 3701 USER LOAD C MODE has been valid CURVE longer than the time defined by 3703 USER LOAD C TIME 101 SERF CORRUPT Error internal to the drive Contact your local ABB sales representative and 102 ea report the error number 103 SERF MACRO 104 RESERVED 105 RESERVED 201 DSP T1 Error in the system Contact your local ABB sales representative and report OVERLOAD the error number 202 DSP T2 OVERLOAD 203 DSP T3 OVERLOAD 204 DSP STACK ERROR 205 RESERVED obsolete 206 OMIO ID ERROR 207 EFB LOAD ERR 1000 PAR
7. Fault Fault Name In i x 7 Code Panel Fault Possible Cause Corrective Action 3028 EXT COMM LOSS Time between fieldbus Incorrect Check Group 51 amp 53 messages has Communication Tighten Connections exceeded timeout settings in Group 51 amp Check C o interval set with 53 Ci z AN parameter 3005 Poor Connections E Noise on Communication Line 3029 EFB CONFIG FILE Error reading Internal Startup error Cycle Power configuration file for Replace RBCU embedded fieldbus 3030 FORCE TRIP Fault trip forced by Overriding Control Check Overriding external fieldbus System tripped Control System E Clipse unit via fieldbus 3031 EFB 1 EFB 3 Fault code reserved for For Bacnet Device Check Parameters s embedded fieldbus object instances for the 5011 5017 and or 3033 drive and or bypass are 5311 5317 set greater than 4194302 in paramters 5011 5017 and or 5311 5317 respectively 3034 MTR PHASE Detects open motor Internal problem Check wiring in phase Detection is Cable problem E Clipse Unit done by current Check motor cablin transformers in bypass Motor problem 2 unit Check Motor Check if 3006 is Disabled 3037 PCB TEMP RBCU unit has reached Cabinet cooling has Stop drive and let cool 190 degrees failed down and restart ee 88 degrees ambient conditions too Add additional cooling ee high Replace RBCU Bad RBCU unit 3038 NO DRIVE DATA No drive data available Bypass not able to Proper seating of cable
8. BP0054 BP0054 If Strip and connect the individual control wires to the drive terminals ACH550 UH 16 Drive s power connection terminals ACH550 Installation Operation and Maintenance Manual The following table provides specifications for the drive s power connection terminals U1 V1 W1 Frame U2 V2 W2 Earthing PE Terminal Size BRK UDC Terminals Min Wire Size Max Wire Size Torque Max Wire Size Torque mm AWG mm AWG Nm lb ft mm AWG Nm lb ft RiNotet 9 75 18 16 6 1 3 1 16 1 3 1 R2Note1 0 75 18 16 6 1 3 1 16 1 3 1 R3Note1 25 14 25 3 2 7 2 25 2 7 R4Note1 10 8 50 1 0 5 6 4 50 1 0 5 6 R5 16 6 70 2 0 15 11 70 2 0 15 11 R6 g5Note2 3 0 185 350 MCM 40 30 185 350 MCM 40 30 R7 16 6 185 350 MCM 40 30 Attach appropriate ring lugs to R8 16 6 2x240 2x500 MCM 57 42 eel ere ae min 1 Do not use aluminum cable with frame sizes R1 R4 2 See the following section for smaller wire sizes on frame size R6 Power terminal considerations R6 Frame size WARNING For R6 power terminals if compression lugs are supplied they can only be used for wire sizes that are 95 mm 3 0 AWG or larger Smaller wires will loosen and may damage the drive and require ring lugs as described below On the R6 frame size if the cable size used is less than 95 mm 3 0 AWG or if no compression lugs are supplied u
9. Original Alternate X1 Analog Inputs and Outputs and 10 V Ref Voltage Output X1 Digital Inputs and 24 V Aux Voltage Output X1 Relay Outputs Illustration of available switch positions not default settings J2 DIP Switches for RS485 Termination J2 J2 A A ON ON off position on position Power Input U1 V1 W1 Frame Sizes R5 R6 differ See next page Illustration of available switch positions not default settings Panel Connector Power LED Green Fault LED Red Optional Module 1 X1 Communications RS485 Optional Module 2 Power Output to Motor U2 V2 W2 EM3 GND X0003 Terminals Not Used 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 ACH550 UH ACH550 Installation Operation and Maintenance Manual R5 Id Ir O 5 i Q g Bx q P q M
10. SE SOFT SOFT KEY 2 KEY 1 pom D SAA 7 AUTO P x HELP always available OFF o HAND X0201 General display features Soft key functions The soft key functions are defined by text displayed just above each key Display contrast To adjust display contrast simultaneously press u and lt a or yw as appropriate HVAC control panel modes The HVAC control panel has several different modes for configuring operating and diagnosing the drive To reach the Standard Display Mode press EXIT until the LCD display shows status information Select MENU and use UP DOWN buttons to select other modes The modes are Standard Display Mode Shows drive status information and operates the drive Parameters Mode Edits parameter values individually Start up Assistant Mode Guides the start up and configuration Changed Parameters Mode Shows changed parameters Fault Logger Mode Shows the drive fault history Drive Parameter Backup Mode Stores or uploads the parameters Clock Set Mode Sets the time and date for the drive 1 O Settings Mode Checks and edits the I O settings Alarm Mode Reporting mode triggered by drive alarms ACH550 UH 22 ACH550 Installation Operation and Maintenance Manual Operating the drive AUTO HAND The very first time the drive is powered up it is in the auto control AUTO mode and is controlled from the Control terminal block X1 To switch to hand
11. ABB SACE Instruction Sheet supplied with these units for additional information on the adjustment of these settings Operation E Clipse bypass configurations The ACH550 with E Clipse Bypass is an ACH550 AC adjustable frequency drive in an integrated UL type 1 UL type 12 or UL type 3R package with a bypass motor starter The ACH550 with E Clipse Bypass provides Disconnect switch or circuit breaker with door mounted control lever The lever can be padlocked in the OFF position padlock not supplied Bypass starter Motor overload protection Local operator panel with indicating lights and multifunction display Provisions for external control connections Embedded communications for major BMS protocols including BACnet Johnson Controls International N2 Siemens Building Technologies FLN and Modbus Optional fieldbus adapters for connection to additional BMS protocols including LonWorks and Ethernet Optional drive service switch drive input disconnect the functional equivalent of a three contactor bypass arrangement ACH550 E Clipse Bypass 61 ACH550 Installation Operation and Maintenance Manual The following shows the front view of the ACH550 E Clipse Bypass vertical configuration and identifies the major components ACH550 Drive ACH CP B ep Control Panel H H E Clipse Bypass Control Panel Operating Handle for Disconnect Switch or Circuit Breaker E Clipse Bypass BP0
12. ACH550 Input Power Motor Terminals Terminals 1 O Conduit Ground Bottom Lug Note Some UL Type 3R enclosures are designed to be mounted on a wall Mounting some of these 3R enclosures on an open rack system requires the use of the supplied 3R enclosure back plates to maintain 3R integrity ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 81 Connection diagrams standard drive with input disconnect floor mounted Floor mounted UL Type NEMA 1 amp 12 Drive with Input Disconnect units are configured for wiring access from the top and include a removable conduit mounting plate The following figure shows the wiring connection points Ground Lug ACH550 Bar Motor Terminals EE Input Power Terminals Disconnect Switch or Circuit Breaker ACH550 PCR PDR 82 ACH550 Installation Operation and Maintenance Manual Line input connections standard drive with input disconnect configurations Connect input power to the terminals of the disconnect switch or circuit breaker Connect the equipment grounding conductor to the ground lug at the top of the enclosure The figure below shows the connection points for Standard Drive with Input Disconnect configurations UL Type NEMA 1 amp 12 UL Type NEMA 1 amp 12 UL Type NEMA 1 amp 12 Vertical Construction _ Hinged Door Wall Mount Input Floor Mount Enclosures I Enclosures Power Enclosures Ground Lug ACH550 Bar Mo
13. All Every ten years See Control panel on page 38 Heatsink The heatsink fins accumulate dust from the cooling air Since a dusty heatsink is less efficient at cooling the drive overtemperature faults become more likely In a normal environment not dusty not clean check the heatsink annually in a dusty environment check more often Clean the heatsink as follows when necessary 1 Remove power from drive Remove the cooling fan see section Drive module fan replacement on page 33 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room 4 Replace the cooling fan Restore power ACH550 UH ACH550 Installation Operation and Maintenance Manual 33 Drive module fan replacement The drive module fan cools the heatsink Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from ABB Do not use other than ABB specified spare parts To monitor the running time of the cooling fan see Group 29 MAINTENANCE TRIG instructions Frame Sizes R1 R4 2 Remove d
14. 2002 OVERVOLTAGE Over voltage controller is active Check for and correct e Static or transient overvoltages in the input power supply e Insufficient deceleration time parameters 2203 DECELER TIME 1 and 2206 DECELER TIME 2 e Interaction with external input filter 2003 UNDERVOLTAGE Under voltage controller is active Check for and correct e Undervoltage on mains 2004 DIR LOCK The change in direction being attempted is not allowed Either Do not attempt to change the direction of motor rotation or e Change parameter 1003 DIRECTION to allow direction change if reverse operation is safe 2005 I O COMM Fieldbus communication has timed out Check for and correct e Fault setup 8018 COMM FAULT FUNC and 3019 COMM FAULT TIME e Communication settings Group 51 or 53 as appropriate e Poor connections and or noise on line 2006 All LOSS Analog input 1 is lost or value is less than the minimum setting Check e Input source and connections e Parameter that sets the minimum 3021 Parameter that sets the Alarm Fault operation 3001 2007 Al2 LOSS Analog input 2 is lost or value is less than the minimum setting Check e Input source and connections e Parameter that sets the minimum 3022 Parameter that sets the Alarm Fault operation 3001 ACH550 UH 30 ACH550 Installation Operation and Maintenance Manual Alarm x rare Code Display Description 2008 PANEL LOSS Panel communicat
15. Enabled LED The Enabled LED is illuminated green under the following conditions Both the Safety Interlock s and Run Enable contacts are closed e The Safety Interlock contact s are closed with no Start command present The Enabled LED flashes green if the Run Enable contact is open and when the Safety Interlock contact s are closed and a Start command is present The Enabled LED is illuminated red when the Safety Interlock contact s are open ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 63 Motor Run LED The Motor Run LED is illuminated green when the motor is running in either bypass mode or in drive mode The Motor Run LED flashes green to indicate the system has been placed in an Override condition Bypass Faulted LED The Bypass Faulted LED is illuminated or flashes red when the motor or bypass protection functions have shut down the bypass The specific nature of the fault is indicated on the bypass control display Refer to the Diagnostics section of this manual for more details Drive Selected LED The Drive Selected LED is illuminated green when the drive has been selected as the power source for the motor and no drive fault is present Bypass Selected LED The Bypass Selected LED is illuminated or flashes green when the bypass has been selected as the power source for the motor and no bypass fault is present Drive Faulted LED The Drive Faulted LED is illuminated red when t
16. To install the ACH550 you need the following e Screwdrivers as appropriate for the mounting hardware used e Wire stripper Tape measure e Drill e Frame sizes R5 R8 with UL type 12 enclosure Punch for conduit mounting holes Frame sizes R7 R8 pallet truck and hoist e For installations involving frame size R6 R8 The appropriate crimping tool for power cable lugs ACH550 UH ACH550 Installation Operation and Maintenance Manual 5 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 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 e 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 IP21 UL type 1 IP54 UL type 12 Frame size Kit Code English Kit Code English R1 FMK A R1 100000982 FMK B R1 100000990 R2 FMK A R2 100000984 FMK B R2 100000992
17. It is not possible to predict a capacitor failure Capacitor failure is usually followed by a input power fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements for frame size R5 R6 and R8 are available from ABB Do not use other than ABB specified spare parts Control panel Cleaning Use a soft damp cloth to clean the control panel Avoid harsh cleaners which could scratch the display window Battery A battery is only used in Assistant control panels that have the clock function available and enabled The battery keeps the clock operating in memory during power interruptions The expected life for the battery is greater than ten years To remove the battery use a coin to rotate the battery holder on the back of the control panel Replace the battery with type CR2032 Note The battery is NOT required for any control panel or drive function except the clock ACH550 UH ACH550 Installation Operation and Maintenance Manual 39 ACH550 E Clipse Bypass Installation drive Follow the nstallation instructions for the drive on page 3 Failure to observe the warnings and instructions may cause a malfunction or personal hazard WARNING Before you begin read Safety on page 2 Installation bypass WARNING When the ACH550 with E Clipse Bypass 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 c
18. R1 10 10 10 10 10 10 S ACHSS0PXRO6AIA RI ligg tadbe 35 inbs Findb 7 in lbs 36 in lbs 35 in lbs 5 ACH550 PxR 08A8 4 R1 7 5 ACH550 PxR 012A 4 R1 10 ACH550 PxR 015A 4 R2 6 6 6 6 15 ACH550 PxR 023A 4 R2 45 in lbs 45 in lbs 7 ise 7 oe 35 in lbs 35 in lbs 20 ACHS550 PxR 031A 4 R3 3 3 3 3 Bo Se neOUs E ane 50 in lbs 50 in lbs 4 4 50 in lbs 50 in lbs 30 ACH550 PxR 045A 4 R3 feiss Pie 40 ACHS550 PxR 059A 4 R4 50 ACHS50 PxR 072A 4 R4 E AA 50 in lbs 50 in lbs nee 50 in lbs 50 in lbs 1 1 Refer to 60 ACH550 PxR 078A 4 R4 50 in lbs 62 in lbs Drive s 1 0 1 0 Aneel connection 75 ACH550 PxR 097A 4 R4 70 in lbs 70 in Ibs terminals 2 50 in lbs 100 ACH550 PxR 125A 4 R5 350 MCM 300 MCM 125 ACHS550 PxR 157A 4 Re 2 4 nlbs 200in lbs 300 MCM 300 MCM 3 x 3 0 2 0 275 in lbs 200 in lbs 250 in lbs 375 in lbs 150 ACH550 PxR 180A 4 R6 2x500 2x 500 350 MCM 200 ACH550 PxR 246A 4 R6 MCM MOM 2 ei 2 A sees 100 in lbs 274 in lbs 274 in lbs Ineps nee 250 ACH550 PxR 316A 4 R8 2 x 500 300 ACH550 PxR 368A 4 R8 MCM 2 x 500 MCM 350 ACH550 PxR 414A 4 Ra 274 in lbs 274 in lbs 5 Bus Bar 400 ACH550 PxR 486A 4 R8 Holes 450 ACH550 PxR 526A 4 R8 pe ee x 500 ACH550 PxR 602A 4 R8 MCM s ses Ha 375 in lbs ips 550 ACH550 PxR 645A 4 R8 1 PxR represents both PC
19. 2 R2 He 40 in lbs 8 7 in lbs 2 10 ACH550 VxR 031A 2 R2 2 50 in lbs 15 ACH550 VxR 046A 2 R3 50 in lbs 4 2 20 ACH550 VxR 059A 2 R3 18 in lbs 2 0 50 in lbs 1 1 120 in lbs 25 ACH550 VxR 075A 2 R4 50 in lbs 55 in lbs 380 480 Volt 1 1 5 ACH550 VxR 03A3 4 R1 2 ACH550 VxR 04A1 4 R1 3 ACH550 VxR 06A9 4 R1 0 4 0 35 in lbs 7 in lbs 6 4 5 ACH550 VxR 08A8 4 R1 7 5 ACH550 VxR 012A 4 R1 10 ACH550 VxR 015A 4 R2 8 30 in lbs 35 in lbs 15 ACH550 VxR 023A 4 R2 40 in lbs gt sm 20 ACH550 VxR 031A 4 R3 25 ACH550 VxR 038A 4 R3 Ha i 50 in Ibs 4 50 in lbs 30 ACH550 VxR 045A 4 R3 18 in lbs 40 ACH550 VxR 059A 4 R4 2 ra 50 in lbs 50 ACH550 VxR 072A 4 R4 1 pers 2 0 0 inlbs LTS 120 in bs 60 ACH550 VxR 078A 4 R4 a 70 in lbs ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 49 Frame Maximum Wire Size Capacities of Power Terminals AP Identification Size Circuit Disconnect Motor Ground Breaker Switch Termination Lugs 500 600 Volt 2 ACH550 VxR 02A7 6 R2 3 ACH550 VxR 03A9 6 R2 5 ACH550 VxR 06A1 6 R2 8 6 4 7 5 ACH550 VxR 09A0 6 R2 62 in lbs 8 30 in lbs 35 in lbs 10 ACH550 VxR 011A 6 R2 7 in lbs 15 ACH550 VxR 017A 6 R2 20 ACH550 VxR 022A 6 R3 4 2 25 ACH550 VxR 027A 6 R3 62 in lbs 50 in lbs 30 ACH550 VxR 032A 6 R4 4 40 ACH550 VxR 041A 6 R4 18 in lbs 2 1 1 2 0 5
20. 20 RO1A Maximum 250 VAC 30 VDC 2 A EE Minimum 500 mW 12 V 10 mA a 21 RO1B _ Z 22 RO2C Relay output 2 programmable Default Running gt Maximum 250 VAC 30 VDC 2A 23 RO2A 2 oer Minimum 500 mW 12 V 10 mA amp 24 RO2B _ o 25 RO3C Relay output 3 programmable Default Fault 1 26 RO3A Maximum 250 VAC 30 VDC 2 A TNH Minimum 500 mW 12 V 10 mA 27 RO3B _4 1 Digital input impedance 1 5 kQ Maximum voltage for digital inputs is 30 V 2 Default values depend on the macro used Values specified are for the HVAC default macro ACH550 UH 18 ACH550 Installation Operation and Maintenance Manual You can wire the digital input terminals in either a PNP or NPN configuration PNP connection source NPN connection sink x1 X1 10 24V Mol 24V 1 11 GND 2 147 GND L_112 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 Serial communications Terminals 28 32 provide RS485 serial communication connections used to control or monitor the drive from a fieldbus controller 6 Check installation Before applying power perform the following checks Check Installation environment conforms to the drive s specifications for ambient conditi
21. 25 FBA PAR 26 REFRESH FBA PAR 28 FBA PAR 29 FBA PAR 30 FBA STATUS FBA PAR 32 FBA PAR 33 GROUP 53 DRIVE EFB 5301 5302 5303 5304 5305 5306 DV PROT ID DV MAC ID BAUD RATE EFB PARITY PROFILE DV OK MSG DV CRC ERR UART ERROR DV STATUS DV PAR 10 DV PAR 11 DV PAR 12 DV PAR 13 DV PAR 14 DV PAR 15 DV PAR 16 DV PAR 17 DV PAR 18 DV PAR 19 DV PAR 20 GROUP 54 FBA DATA IN 5401 5402 5403 5404 5405 5406 5407 5408 5409 DATA IN DATA IN DATA IN DATA IN N N N DATA IN 9 GROUP 55 FBA DATA OUT 5501 5502 5503 5504 5505 5506 5507 5508 5509 5510 DATA OUT 1 DATA OUT 2 DATA OUT 3 DATA OUT 4 DATA OUT 5 DATA OUT 6 DATA OUT 7 DATA OUT 8 DATA OUT 9 DATA OUT10 GROUP 98 OPTIONS 9802 COMM PROT SEL GROUP 99 STARTUP DATA 9902 B P MACRO ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 93 ACH550 PCR PDR 94 ACH550 Installation Operation and Maintenance Manual AA ER ED FPREDIEIP ABB Inc 16250 West Glendale Drive New Berlin WI 53151 3AUA0000081824 REV B Effective 04 15 2012 USA Telephone 1 800 752 0696 Fax 1 262 785 0397 Internet www abb us drives
22. 30 ACH550 BxR 032A 6 R4 4 4 40 ACH550 BxR 041A 6 R4 1 1 18 in lbs 18 in lbs 2 62 in lbs 62 in lbs F rA 210 210 50 in lbs 2 50 ACHS550 BxR 052A 6 R4 55 in lbs 55 in lbs 120 in lbs 120 in lbs 50 in lbs 60 ACHS550 BxR 062A 6 R4 espe bel a 75 ACH550 BxR 077A 6 R6 1 0 1 0 1 1 100 ACH550 BxR 099A 6 R6 prow mew 70inlbs 70in tbs 53in lbs S3in tbs 3 43 0 125 ACH550 BxR 125A 6 Re 274 27 300MCM 300 mom 250 mom 250 mem 20 intos 42 0 150 ACH550 Bx R144A 6 R6 275 in lbs 275 in lbs 300 in lbs 300 in lbs 375 in lbs 1 BxR represents both BCR and BDR 2 Torque values shown relate to current production Check component labels on previously installed units for required tightening torque ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual Basic control connections for E Clipse HVAC Default E Clipss HVAC Default Terminal for Signal Cable Snieid Analog Input 1 Analog Input Common 10V 10mA Reference Voltage for Potentiometer Analog Input 2 Analog Input Common Speed Reference Process Setpoint Process Feedback Signal Customer Auto Start Parameter 1601 START STOP Digital input2 Parameter 1602 06 NOT SEL Digital Input3 Parameter 1603 START EN 1 Safety Interiock 1 Digital input4 Parameter 1604 07 NOT SEL Digital inputS Parameter 1605 1701 NOT SEL Digital inpute
23. 3nd bracket overlapping the center bracket by 1 2 to the right CLL 1st filter retaining bracket 1st and 2nd filter retaining brackets All 3 filter retaining brackets Install the filter frame back to the cabinet door Carefully align the mounting hooks to the slots in the cabinet door The hooks should be pointing down Press in at the center of the filter frame with your knee and gently press down with your hands at the top of the frame The filter frame will slide down approximately 3 4 inch and should be sealed securely to the door around the entire filter frame ACH550 UH ACH550 Installation Operation and Maintenance Manual 37 Frame Sizes R7 R8 UL type 12 enclosure exhaust filters The exhaust filters in the R7 R8 UL type 12 enclosure are located in the exhaust box at the top of the enclosure There are 2 filter frames attached to the exhaust box 1 Remove each filter frame e Lift up on the filter frame until it slides approximately 3 4 inch WANN CIII Pull away from the exhaust box to remove PC00021 2 For each filter frame remove the wire retainers that hold the filters in place y RN e Lay the filter frames on a flat work surface e The wire retainers have a A square U shape Remove by squeezing the open end of the U towards the middle of the square until the retainer top open end of U clears the filter frame PCo0001 PC00019 e
24. 4203 DERIVATION TIME 4204 PID DERIV FILTER 4205 ERROR VALUE INV 4206 UNITS 4207 DSP FORMAT 4208 0 VALUE 4209 100 VALUE 4210 SET POINT SEL 4211 INTERNAL SETPNT 4212 SETPOINT MIN 4213 SETPOINT MAX 4214 FBK SEL 4215 FBK MULTIPLIER 4216 ACT1 INPUT 4217 ACT2 INPUT 4218 ACT1 MINIMUM 4219 ACT1 MAXIMUM 4220 ACT2 MINIMUM 4221 ACT2 MAXIMUM 4228 ACTIVATE 4229 OFFSET 4230 TRIM MODE 4231 TRIM SCALE 4232 CORRECTION SRC GROUP 45 ENERGY SAVING 4502 ENERGY PRICE 4507 CO2 CONV FACTOR 4508 PUMP POWER 4509 ENERGY RESET GROUP 51 EXT COMM MODULE 5101 FBA TYPE 5102 FBA PAR 2 26 5127 FBA PAR REFRESH 5128 FILE CPI FW REV 5129 FILE CONFIG ID 2130 FILE CONFIG REV 5131 FBA STATUS 5132 FBA CPI FW REV 5133 FBA APPL FW REV GROUP 52 PANEL COMM 5201 STATION ID 5202 BAUD RATE 5203 PARITY 5204 OK MESSAGES 5205 PARITY ERRORS 5206 FRAME ERRORS 5207 BUFFER OVERRUNS 5208 CRC ERRORS GROUP 53 EFB PROTOCOL 5301 EFB PROTOCOL ID 5302 EFB STATION ID 5303 EFB BAUD RATE 5304 EFB PARITY 5305 EFB CTRL PROFILE 5306 EFB OK MESSAGES 5307 EFB CRC ERRORS 5308 EFB UART ERRORS 5309 EFB STATUS 5310 EFB PAR 10 18 5319 EFB PAR 19 20 GROUP 64 LOAD ANALYZER 6401 PVL SIGNAL 6402 PVL FILTER TIME 6403 LOGGERS RESET 6404 AL2 SIGNAL 6405 AL2 SIGNAL BASE 6406 PEAK VALUE 6407 PEAK TIME 1 6408 PEAK TIME 2 6409 CURRENT AT PEAK 6410 UDC AT PEAK 6411 FREQ AT PEAK 6412 TIME OF RESET
25. Board Terminals x2 ee Disconnect Switch ACH550 Drive TM ly SOA ooo T ft y os fl o non oo ifi ifo ifi ifo HH Doe hotrod oo or Circuit Breaker j Service m Ok 7 optional ACH550 Control Board Terminals x1 EI El B4 ACH550 E Clipse Bypass 44 ACH550 Installation Operation and Maintenance Manual Power connections Vertical E Clipse Bypass configurations Line input connections I Connect the input power to the terminals A at the bottom of the disconnect switch or f circuit breaker as shown below Also see Connection diagrams Vertical E Clipse Bypass on page 40 Connect the equipment grounding conductor to the ground lug near the input power connection point Motor Ground if k Motor connections i Cables Connect the motor cables to the terminals input Power at the bottom of the bypass section as Cables shown in the figure Also see Connection a s Nra diagrams Vertical E Clipse Bypass on NYJ page 43 Connect the motor grounding conductor to the ground l
26. E Clipse Bypass will not function properly Parameter 9802 must be set to STD MODBUS e Parameter 1001 must be set to Comm e Parameter 1002 must be set to Comm e Parameter 1601 must be set to Comm e Parameter 1608 must be set to Comm e Parameter 5303 must be set to 76 8 kb s Parameter 5304 must be set to 8 EVEN 1 e Parameter 5305 must be set to DCU PROFILE e Parameter 5310 must be set to 103 Parameter 5311 must be set to 104 Power must be cycled Refer to the ACH550 UH User s Manual for programming instructions Note Run motor from drive before attempting bypass operation System check motor disconnected from the ACH550 with E Clipse Bypass If you are familiar with the E Clipse Bypass operation you may skip the following section Otherwise after performing the system checks and setting the ACH550 Drive Start up Data parameters become familiar with the operation of the ACH550 Drive with E Clipse Bypass without the motor connected as follows 1 Disconnect and lock out power to the E Clipse Bypass unit wait at least five minutes after disconnecting power 2 Disconnect the motor from the E Clipse Bypass unit 3 Apply power to the E Clipse Bypass unit by turning on the branch circuit disconnect device and the bypass disconnect switch or circuit breaker 4 The ACH550 Control Panel display should be illuminated On the E Clipse Bypass control panel
27. Fixed SMOKE CONTROL Override 1 Firestat Freezestat High Static Switen Relay Output 1 Parameter 1401 BYP NOT FLT Default Operation Sypass Not Faulted 11 connected to 13 Bypass Faulted 11 connected to 12 Relay Oulput2 Parameter 1404 SYS RUNNING Default Operation System Running 14 connected to 16 Relay Oulput3 Parameter 1407 SYS STARTED Default Operation System Started 17 connected to 19 Relay Outputs Parameter 1410 BYPASS SEL Default Operation Sypass Selected 20 connected to 22 Relay OutputS Parameter 1413 BYPASS AUTO Default Operation Sypass in Auto 23 connected to 25 Parameters Changed Relative to E Clipse HVAC Default Parameter Number Description Setting Smoke Control Override1 documentation 53 Smoke Control Override1 is a fixed input Closing Digital Input 6 will place the E Clipse Bypass in Smoke Control mode which may reassign the function of the other Digital Inputs Refer to the ACH550 E Clipse Bypass 54 ACH550 Installation Operation and Maintenance Manual 2 Check installation bypass Control panel settings and checks Apply power to the E Clipse Bypass unit The ACH550 Control Panel should show the operating status of the drive If the E Clipse Bypass Control Panel displays a PHASE SEQ Phase Sequence fault remove power wait at least 5 minutes and then swap any two input phas
28. HZRPM Parameter values are inconsistent Check for any of the following LIMITS e 2001 MINIMUM SPEED gt 2002 MAXIMUM SPEED e 2007 MINIMUM FREQ gt 2008 MAXIMUM FREQ e 2001 MINIMUM SPEED 9908 MOTOR NOM SPEED is outside proper range gt 50 e 2002 MAXIMUM SPEED 9908 MOTOR NOM SPEED is outside proper range gt 50 2007 MINIMUM FREQ 9907 MOTOR NOM FREQ is outside proper range gt 50 e 2008 MAXIMUM FREQ 9907 MOTOR NOM FREQ is outside proper range gt 50 1001 PAR PFAREFNG Parameter values are inconsistent Check for the following e 2007 MINIMUM FREQ is negative when 8123 PFA ENABLE is active ACH550 UH 28 ACH550 Installation Operation and Maintenance Manual Fault Fault Name In a Code Panel Description and Recommended Corrective Action 1002 RESERVED Obsolete 1003 PAR Al SCALE Parameter values are inconsistent Check for any of the following e 1301 Al 1 MIN gt 1302 Al 1 MAX e 1304 Al 2 MIN gt 1305 Al 2 MAX 1004 PARAOSCALE Parameter values are inconsistent Check for any of the following e 1504 AO 1 MIN gt 1505 AO 1 MAX e 1510 AO 2 MIN gt 1511 AO 2 MAX 1005 PAR PCU 2 Parameter values for power control are inconsistent Improper motor nominal kVA or motor nominal power Check for the following e 1 1 lt 9906 MOTOR NOM CURR 9905 MOTOR NOM VOLT 1 73 Py lt 3 0 e Where Py 1000 9909 MOTOR NOM POWER i
29. J7 connector on Check that J7 drive is controlling the RBCU unit connector is firmly motor and the power to Loose input wiring seated in RBCU the bypass is removed Check tigh f Incoming power eck tightness o before the drive phases Seba incoming connections back Message will Check P 0413 appear in the fault log ec arameter This message will only to view voltage level at appear when drive time of trip contactor opens when Check upstream drive is operating protection 3008 DRIVE Al2 LOSS Only displayed when in Check ACH550 manual Check ACH550 manual Supervisory mode for Al2 loss for Al2 loss Indicates that Al2 on the drive has failed 3009 MTR OVERLOAD Bypass opens on motor Drive Mode Check if overload overload conditions Bad Motor condition exists defined in the drive Bad CT s Drive Mode Bad RBCU Refer to 550 manual B de for proper ypass Moge troubleshooting Bad motor techniques Bad CT s Bypass Mode Bad RBCU Check that J2 Either mode connector is firmly low input voltage Sea nee Use clamp meter to verify mtr current vs display in parameter 0101 Check input voltage ACH550 E Clipse Bypass 68 ACH550 Installation Operation and Maintenance Manual Fault Fault Name In f Code Panel Fault Possible Cause Corrective Action 3010 INP PHASE A Fault will be generated Loose J7 connector Check J7 connector LOSS only when trying to Loose wiring on Check yellow wire on close the bypass Contacto
30. LOSS Analog input 2 loss Analog input value is less than AI2FLT LIMIT 3022 Check for and correct e Source and connection for analog input e Parameter settings for AI2FLT LIMIT 3022 and 3001 AIl lt MIN FUNCTION MOT TEMP Motor is too hot based on either the drive s estimate or on temperature feedback e Check for overloaded motor e Adjust the parameters used for the estimate 3005 3009 e Check the temperature sensors and Group 35 parameters ACH550 UH ACH550 Installation Operation and Maintenance Manual 25 Fault Code Fault Name In Panel Description and Recommended Corrective Action 10 PANEL LOSS Panel communication is lost and either Drive is in local control mode the control panel displays HAND or OFF or e Drive is in remote control mode AUTO and is parameterized to accept start stop direction or reference from the control panel To correct check e Communication lines and connections e Parameter 3002 PANEL COMM ERROR e Parameters in Group 10 START STOP DIR and Group 11 REFERENCE SELECT if drive operation is AUTO 11 ID RUN FAIL The motor ID run was not completed successfully Check for and correct e Motor connections e Motor parameters 9905 9909 do not match motor nameplate 12 MOTOR STALL Motor or process stall Motor is operating in the stall region Check for and correct Excessive load e Insufficient motor powe
31. Link Fault Drive Link Error or Drive Setup alarm check the following parameter settings to ensure they have been recovered If necessary individually set the correct parameter settings as indicated below and cycle power The only ACH550 Drive macro that provides the proper configuration settings by default is the E Clipse Bypass macro If any other ACH550 Drive macro is used that macro should be selected after completing the initial tests When using any other macro the following ACH550 Drive parameter values must be set and power cycled or the E Clipse Bypass will not function properly Parameter 9802 must be set to STD MODBUS e Parameter 1001 must be set to Comm e Parameter 1002 must be set to Comm e Parameter 1601 must be set to Comm ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 55 e Parameter 1608 must be set to Comm e Parameter 5303 must be set to 76 8 kb s Parameter 5304 must be set to 8 EVEN 1 Parameter 5305 must be set to DCU PROFILE e Parameter 5310 must be set to 103 e Parameter 5311 must be set to 104 Power must be cycled Refer to the ACH550 UH User s Manual for additional information Note Run motor from drive before attempting bypass operation System check motor connected to ACH550 with E Clipse Bypass After performing the control panel checks and setting the ACH550 Drive Start up
32. 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 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 ACH550 UH 2 ACH550 Installation Operation and Maintenance Manual 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 Drill holes of appropriate size in the mounting location 3 Remove front cover R1 1 R6 UL type 1 Remove the control panel if attached 2 Loosen the captive screw at the top 3 Pull near the top to remove the cover R7 R6 UL type 12 If hood is present Remove screws 2 holding the hood in place If hood is present Slide hood up and of
33. Save the retainers for reinstallation 3 Remove and inspect the filter 4 Install clean filters Note When installing DUSTLOK filter media the white side must face to outside of the cabinet and the orange side faces in Be sure to tuck the filter edges into the groove around the entire filter frame This detail is very important for proper operation PC00022 5 Reinstall the filter restrainers Insert the base of a retainer bottom of U shape into a filter frame channel e Squeeze the open end of the U until it clears the filter frame e Seat the open end of the U Pcoaors PC0000 in the filter frame channel e Release the retainer to its relaxed square shape ACH550 UH 38 Install each filter frame to the bonnet on top ACH550 Installation Operation and Maintenance Manual of the cabinet e Carefully align the frame s mounting hooks with the slots in the bonnet The hooks should be pointing down e Press down at the top of the filter frame The filter frame slides down approximately 3 4 inch amp D am BCOOOTD PC00011 e Check all around the filter frame for a secure seal to the exhaust box Capacitors The drive intermediate circuit employs several electrolytic capacitors Their life span is from 35 000 90 000 hours depending on drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature
34. both the display and Enabled LED should be illuminated If the Enabled LED is not illuminated solid green check to see that closed contacts or jumpers connect terminal X2 3 to X2 4 and X2 2 to X2 7 on the bypass control board ACH550 E Clipse Bypass 58 ACH550 Installation Operation and Maintenance Manual 5 On the E Clipse Bypass control panel either the Drive Selected or Bypass Selected 10 11 12 13 14 LED should be illuminated Pressing the Drive Select or Bypass Select key should switch the bypass back and forth between the Drive mode and the Bypass mode as indicated by the LEDs above each button Check that the bypass control panel switches the system between modes Leave the system in the Bypass mode when proceeding to the next step Check to see that pressing the e Auto key on the bypass control panel causes the bottom line on the E Clipse Bypass display to indicate Bypass in Auto Hand key on the bypass control panel generates a Motor Phase Fault e Under normal conditions motor connected pressing the Hand key on the bypass control panel causes the bottom line on the E Clipse Bypass display to indicate Hand A Run OFF key on the bypass control panel causes the bottom line on the E Clipse Bypass display to indicate Off Stop For Steps 8 through 14 ACH550 Drive Parameter 9904 must be set to Scalar Freq After successful completion of Step 13 Parameter 9904 may be set
35. control HAND and control the drive using the control panel press and hold the gt or pp button e Pressing the HAND button switches the drive to hand control while keeping the drive running e Pressing the OFF button switches to hand control and stops the drive To switch back to auto control AUTO press and hold the button Hand Auto Off To start the drive press the HAND or AUTO buttons to stop the drive press the OFF button Reference To modify the reference only possible if the display in the upper right corner is in reverse video press the UP or DOWN buttons the reference changes immediately The reference can be modified in the local control mode HAND OFF and can be parameterized using Group 11 reference select to also allow modification in the remote control mode Note The Start Stop Shaft direction and Reference functions are only valid in local control HAND OFF mode Start up by using the Start Up Assistant To start the Start Up Assistant follow these steps Select MENU to enter the main menu GE 1 Select ASSISTANTS with the Up Down buttons and select ENTER S 2 b u Scroll to COMMISSION DRIVE with the Up Down buttons cA 3 a Change the values suggested by the assistant to your preferences and then SE 4 press SAVE after every change The Start Up Assistant will guide you through the start up ACH550 UH ACH550 Installation Ope
36. drive contol panel display indicates Off ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 59 If the ACH550 Drive and E Clipse Bypass operate according to these steps and you have familiarized yourself with their operation disconnect and lock out power to prepare for the next test A WARNING Wait at least five minutes after disconnecting power from the drive before you attempt to service the drive Bus capacitors in the intermediate DC circuit must discharge before servicing the drive Using a meter rated for 1000 VDC check for zero volts at e Terminals BRK to GND and BRK to GND frame size R1 R2 e Terminals UC and UC frame size R3 R8 If the drive does not operate according to these steps refer to the ACH550 UH User s Manual 3 Check jumpers and switches The settings described in this section are factory set and for most situations do not require adjustment However it is a good practice to review these settings to confirm that they are appropriate for the configuration installed Jumper and switch locations The figure below shows the locations of the SW1 DIP switch on the E Clipse Bypass control board The function and setting of this switch is explained in the following
37. fault declared 3017 MTR UNDERLOAD If motor power level Broken belt Check load falls below minimum Reset bypass keypad power level establish in Check fault code 17 parameter 3003 for the eG ey a on time s set in a pa 1uriner parameter 3002 fault acuon will be generated Parameter 3003 is a percentage of motor power as defined in the drive via parameter 9909 Fault only applies to bypass mode ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 69 Fault Fault Name In g Code Panel Fault Possible Cause Corrective Action 3018 MAX CYCLE Supervisory Mode only High and low levels of Check parameters FAULT Declared if bypass hysteresis band are too 3202 3205 Increase contactor is closed by tight time delays on supervisory control 16 parameters 3204 and times within a 1 hour 3205 period 3019 DRIVE LINK FAULT Supervisory Mode Bad cable connection Proper seating of cable Only Fault generated if between drive and in drive and RS 485 link between bypass RBCU connector J3 drive and bypass stops Communication Check drive parameter communicating improperly set in drive 9802 Modbus and Parameter 9802 9902 E Clipse PE en Check drive Group 53 improperly set in drive ener parameter 9902 Follow DriveLink recovery procedure 3020 PHASE SEQ Sequence of 3 phase Phase sequence Swap any two of the voltage input is such unknown at time
38. lbs 150 ACH550 PxR 144A 6 R6 275 in Ibs 200 in Ibs 1 PxR represents both PCR and PDR 2 Torque values shown relate to current production Check component labels on previously installed units for required tightening torque ACH550 PCR PDR 86 ACH550 Installation Operation and Maintenance Manual UL Type NEMA 3R Enclosures Input oe Power WARNING Check the motor and motor wiring insulation before connecting the ACH550 to line power Follow the procedure on page 72 Before proceeding with the insulation resistance measurements check that the ACH550 is disconnected from incoming line power Failure to disconnect line power could result in death or serious injury Note For the remainder of the wiring motor and control wiring refer to page 7 ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual Operation 87 This information is unique to ACH550 input disconnect configurations PCR or PDR Refer to the Operation instructions on page 27 for all other information Input disconnect configuration The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive packaged with an input disconnect switch or circuit breaker and with a door interlocked external operating handle The operating handle can be padiocked in the OFF position padlock not supplied Enclosure options are UL Type 1 UL Type 12 and UL Type 3R NEMA 1 N
39. on Frame Size e Frame Sizes 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 1P5013 e Frame Sizes R4 and R5 Use punch to create holes for conduit connections as needed 7 1P5023 For each conduit run input power motor and control wiring must be separate install liquid tight conduit connectors not supplied Sie 6 iced 4 Route the motor wiring through conduit not the aS same conduit as input power wiring run a 5 Strip the wires K A 6 Connect the power motor and ground wires to 3 1 J 4 10 11 12 13 the drive terminals IP5007 Note For R5 frame size the minimum power cable size is 25 mm 4 AWG For R6 frame size refer to Power terminal considerations R6 Frame size on page 16 Route the control cables through the conduit not 2 A the same conduit as either input power or motor wiring runs Use available secure points and tie strap landings to 9 11 permanently secure control wiring at a minimum distance of 6 mm 1 4 from power wiring Strip the control cable sheathing and twist the copper screen into a pig tail Connect the ground screen pig tail for digital and analog I O cables at X1 1 Ground only at drive end Connect the ground screen pig tail for RS485 ca
40. 0 in lbs 50 ACH550 VxR 052A 6 R4 62 in Ibs 55 in lbs 120 in lbs 1 60 ACH550 VxR 062A 6 R4 70 in lbs ACH550 E Clipse Bypass 50 ACH550 Installation Operation and Maintenance Manual Standard enclosure terminals Power Wiring Data pase Circuit Circuit Disconnect Disconnect Motor Motor Ground Ground HP Type Code Frame Breaker Breaker Switch Switch Terminals Terminals Lugs Lugs Size UL Type UL Type UL Type UL Type UL Type UL Type UL Type UL Type NEMA NEMA NEMA NEMA NEMA NEMA NEMA NEMA 1 amp 12 3R 1 amp 12 3R 1 amp 2 3R 1 amp 2 3R 208 240 Volt 1 ACH550 BxR 04A6 2 R1 1 5 ACH550 BxR 06A6 2 R1 2 ACH550 BxR 07A5 2 R1 8 8 6 6 4 4 3 ACH550 BxR 012A 2 R1 40 in lbs 40 in lbs 8 8 30 in lbs 30 in lbs 35 in lbs 35 in lbs 5 ACHS550 BxR 017A 2 R1 Aiibs Zinips 7 5 ACH550 BxR 024A 2 R2 10 ACH550 BxR 031A 2 R2 50 AN 50 ie 15 ACH550 BxR 046A 2 R3 4 4 2 20 ACH550 BxR 059A 2 R3 50in lbs 50 in lbs 18 in lbs 18 in lbs 2 0 2 0 50 in lbs 25 ACH550 BxR 075A 2 R4 1 r E 50 m 55 in lbs 55 in lbs 1 0 1 0 1 1 S07 AS HASO BAR OBEA E H RA 70in tbs 70in lbs 53 in lbs 53 in Ibs 40 ACH550 BxR 114A 2 R4 Gon EN 350 MCM 250 MCM 50 ACH550 BxR 143A 2 R6 reat eae 300 MCM 300 MCM 300 in lbs 300 in lbs 275 in lbs 275 in lbs 2x 3 0 2 0 400 MCM 400 MCM 250 in I
41. 091 The following shows the front view of the ACH550 E Clipse Bypass standard ACH550 Drive with E Clipse Bypass TNT ACH CP B Control Panel E Clipse Bypass Control Panel configurations and identifies the major components TTT oo ai ll TU Operating Handle for Disconnect Switch or Circuit Breaker ACH550 E Clipse Bypass 62 ACH550 Installation Operation and Maintenance Manual The following is a typical power diagram Disconnect Switch Drive with E Clipse Bypass Drive Output rape Bypass or Circuit Breaker r ml d Contactor 3 Phase i Input Power 3 Service Switch Optional L l _ ______ Bypass Contactor Drive Input Fuse Bypass control The bypass control panel features Ready Indication Display Illuminated i ey LCD Display Display ee Downs Up Fees Mag La ooo i tm GE Drive and Bypass Selected Faulted LEDs ON Hand Key OFF Reset Key Drive Bypass Select Keys wee Motor Run LED Ready Power On Indication The Ready Power On indication is provided by the bypass control panel The bypass control panel display will be illuminated and text will be displayed when the disconnect switch or circuit breaker is closed and control power is applied to the bypass
42. 1 5 ALARM or 16 FLT ALARM this alarm is not indicated by a relay output Maintenance Warning Read Safety on page 2 before performing any maintenance on the equipment Ignoring the safety instructions can cause injury or death ACH550 UH 32 Maintenance intervals ACH550 Installation Operation and Maintenance Manual If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB needed Maintenance Application Interval Instruction Check replace R7 R8 R7 R8 UL type 12 Check every 3 Frame Sizes R7 R8 UL enclosure inlet air filter enclosures months Replace as type 12 enclosure inlet air filter on page 35 Check replace R7 R8 R7 R8 UL type 12 Check every 6 Frame Sizes R7 R8 UL enclosure exhaust air enclosures months Replace as type 12 enclosure exhaust filter needed filters on page 37 Check and clean All Depends on the See Heatsink below heatsink dustiness of the environment every 6 12 months Replace drive module All Every six years See Drive module fan fan replacement on page 33 Replace enclosure fan UL type 12 Every three years See Enclosure fan enclosures replacement UL Type 12 enclosures on page 34 Change capacitor Frame sizes R5 R6 and R8 Every ten years See Capacitors on page 38 Replace battery in the Assistant control panel
43. 1 6413 TIME OF RESET 2 6414 AL1RANGEOTO10 6415 AL1RANGE10TO20 6416 AL1RANGE20TO30 6417 AL1RANGE30TO40 6418 AL1RANGE40TO50 6419 AL1RANGESOTO60 6420 AL1RANGE60TO70 6421 AL1RANGE70TO80 6422 AL1RANGE80TO90 6423 AL1RANGE90TO 6424 AL2RANGEOTO10 6425 AL2RANGE10TO20 6426 AL2RANGE20TO30 6427 AL2RANGE30TO40 6428 AL2RANGE40TOSO 6429 AL2RANGESOTO60 6430 AL2RANGE60TO70 6431 AL2RANGE70TO80 6432 AL2RANGE80TO90 6433 AL2RANGE90TO GROUP 81 PFA CONTROL 8103 REFERENCE STEP 1 8104 REFERENCE STEP 2 8105 REFERENCE STEP 3 8109 START FREQ 1 8110 START FREQ 2 8111 START FREQ 3 8112 LOW FREQ 1 8113 LOW FREQ 2 8114 LOW FREQ 3 8115 AUX MOT START D 8116 AUX MOT STOP D 8117 NR OF AUX MOT 8118 AUTOCHNG INTERV 8119 AUTOCHNG LEVEL 8120 INTERLOCKS 8121 REG BYPASS CTRL 8122 PFA START DELAY 8123 PFA ENABLE 8124 ACC IN AUX STOP 8125 DEC IN AUX START 8126 TIMED AUTOCHNG 8127 MOTORS 8128 AUX START ORDER GROUP 98 OPTIONS 9802 COMM PROT SEL GROUP 99 START UP DATA 9901 LANGUAGE 9902 APPLIC MACRO 9904 MOTOR CTRL MODE 9905 MOTOR NOM VOLT 9906 MOTOR NOM CURR 9907 MOTOR NOM FREQ 9908 MOTOR NOM SPEED 9909 MOTOR NOM POWER 9915 MOTOR COSPHI For E Clipse Bypass Drive GROUP 01 ACTUAL DATA 0101 MOTOR CURR 0102 INPUT VOLT 0103 DI STATUS 0104 RO STATUS 0105 PCB TEMP 0106 KW HOURS 0107 COMM RO 0108 RUN TIME 0109 ONTIME 1 0110 ONTIME2 0111 A B VOLT 0112 B C VOLT 0113 C A VOLT 0114 MWH SAVED 0115 COST S
44. 2 RO1 3 STATUS GROUP 13 2104 DC HOLD CTL 3101 NR OF TRIALS 3701 USER LOAD C 123 RO 4 6 STATUS ANALOG INPUTS 2105 DC HOLD SPEED 3102 TRIAL TIME MODE 124 AO1 1301 MINIMUN Ali 2106 DC CURR REF 3103 DELAY TIME 3702 USER LOAD C 125 AO2 1302 MAXIMUM Ali 2107 DC BRAKE TIME 3104 AR OVERCURRENT FUNC 126 PID 1 OUTPUT 1303 FILTER Alt 2108 START INHIBIT 3105 AR OVERVOLTAGE 3703 USER LOAD C TIME 127 PID 2 OUTPUT 1304 MINIMUM Al2 2109 EM STOP SEL 3106 AR 3704 LOAD FREQ 1 128 PID 1 SETPNT 1305 MAXIMUM Al2 2110 TORQ BOOST UNDERVOLTAGE 3705 LOAD TORQ LOW 1 129 PID 2 SETPNT 1306 FILTER Al2 CURR 3107 AR AleMIN 3706 LOAD TORQ HIGH 1 130 PID1FBK GROUP 14 2113 START DELAY 3108 AR EXTERNAL FLT 3707 LOAD FREQ 2 131 PID 2 FBK RELAY OUTPUTS GROUP 22 GROUP 32 3708 LOAD TORQ LOW 2 132 PID 1 DEVIATION 1401 RELAY OUTPUT 1 ACCEL DECEL SUPERVISION 3709 LOAD TORQ HIGH 2 133 PID 2 DEVIATION 1402 RELAY OUTPUT 2 2201 ACC DEC 1 2 SEL 3201 SUPERV 1 PARAM 3710 LOAD FREQ 3 134 COMM RO WORD 1403 RELAY OUTPUT 3 2202 ACCELER TIME 1 3202 SUPERV 1 LIM LO 3711 LOAD TORQ LOW 3 135 COMM VALUE 1 1404 RO 1 ON DELAY 2203 DECELER TIME 1 3203 SUPERV 1 LIM HI 3712 LOAD TORQ HIGH 3 136 COMM VALUE 2 1405 RO 1 OFF DELAY 2204 RAMP SHAPE 1 3204 SUPERV 2 PARAM 3713 LOAD FREQ 4 137 PROCESS VAR 1 1406 RO 2 ON DELAY 2205 ACCELER TIME 2 3205 SUPERV 2 LIM LO 3714 LOAD TORQ LOW 4 138 PROCESS VAR 2 1407 R 2 OFF DELAY 2206 DECELER TIME 2 3206 SUPERV 2 LIM HI 3715 LOAD TORQ HIGH 4 139 PROCESS VAR 3 1408 RO 3 ON DELAY 2207 R
45. ACH550 Installation Operation and Maintenance Manual I O amp 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 Safety Use of warnings and notes ACH550 Installation Operation and Maintenance Manual There are two types of safety instructions throughout this manual e Notes draw attention to a particular condition or fact or give information on a subject e 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 AN 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 e 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 e WARNING Even when power is switched off from the input terminals of the ACH550 there may be dangero
46. AMP SHAPE 2 3207 SUPERV 3 PARAM 3716 LOAD FREQ5 140 RUNTIME 1409 RO 3 OFF DELAY 2208 EM DEC TIME 3208 SUPERV 3 LIM LO 3717 LOAD TORQ LOW 5 141 MWH COUNTER 1410 RELAY OUTPUT 4 2209 RAMP INPUT 0 3209 SUPERV 3 LIM HI 3718 LOAD TORQ HIGH 5 142 REVOLUTION 1411 RELAY OUTPUT 5 GROUP 23 GROUP 33 GROUP 40 CNTR 1412 RELAY OUTPUT 6 SPEED CONTROL INFORMATION PROCESS PID SET 1 143 DRIVEONTIMEHI 1413 RO 4 ON DELAY 2301 PROP GAIN 3301 FW VERSION 4001 GAIN 144 DRIVE ON TIME LO 1414 RO 4 OFF DELAY 2302 INTEGRATION TIME 3302 LP VERSION 4002 INTEGRATION TIME 145 MOTOR TEMP 1415 RO5 ON DELAY 2303 DERIVATION TIME 3303 TEST DATE 4003 DERIVATION TIME 150 CB TEMP 1416 RO 5 OFF DELAY 2304 ACC 3304 DRIVE RATING 4004 PID DERIV FILTER 153 MOT THERM 1417 RO 6 ON DELAY COMPENSATION 3305 PARTABLE 4005 ERROR VALUE INV STRESS 1418 RO 6 OFF DELAY 2305 AUTOTUNE RUN VERSION 4006 UNITS 158 PID COMM VALUE 1 GROUP 15 GROUP 25 GROUP 34 4007 DSP FORMAT 159 PID COMM VALUE 2 ANALOG OUTPUTS CRITICAL SPEEDS PANEL DISPLAY 4008 0 VALUE 174 SAVED KWH 1501 AO1 CONTENT 2501 CRIT SPEED SEL 3401 SIGNAL 1 PARAM 4009 100 VALUE 175 SAVED MWH 1502 AO1 CONTENT MIN 2502 CRITSPEED1LO 3402 SIGNAL 1 MIN 4010 SET POINT SEL 176 SAVED AMOUNT 1 1503 AO1 CONTENT 2503 CRIT SPEED 1 HI 3403 SIGNAL 1 MAX 4011 INTERNAL SETPNT 177 SAVED AMOUNT 2 MAX 2504 CRITSPEED2LO 3404 OUTPUT 1 DSP 4012 SETPOINT MIN 178 SAVED CO2 1504 MINIMUM AO1 2505 CRIT SPEED 2 HI FORM 4013 SETPOINT MAX GROUP 03 1505 MAXIMUM AO1 2506
47. AVED 0116 CO2 SAVED 0117 KWH SAVEL 0118 KWH SAVE H GROUP 03 STATUS 0301 FBUS CW 1 0303 FBUS SW 1 0305 FLT WORD 1 0306 FLT WORD 2 0307 FLT WORD 3 0308 ALR WORD 1 0309 ALR WORD 2 GROUP 04 FAULT LOG 0401 LAST FAULT 0402 F1 TIME 1 0403 F1 TIME 2 0404 F1 VOLTAGE 0405 F1 CURRENT 0406 F1 EVENT 1 0407 F1 E1 TIME 0408 F1 EVENT 2 0409 F1 E2 TIME 0410 FAULT 2 0411 F2TIME 1 0412 F2 TIME 2 0413 F2 VOLTAGE 0414 F2 CURRENT 0415 F2 EVENT 1 0416 F2 E1 TIME 0417 F2 EVENT 2 0418 F2 E2 TIME 0419 FAULT 3 0420 FAULT 4 0421 FAULT 5 GROUP 05 EVENT LOG 0501 LAST EVENT 0502 E1 TIME 1 0503 E1 TIME 2 0504 EVENT 2 0505 E2 TIME 1 0506 E2 TIME 2 0507 EVENT 3 0508 E3 TIME 1 0509 E3 TIME 2 0510 EVENT 4 0511 E4TIME 1 0512 E4 TIME 2 GROUP 14 RELAY OUT 1401 RO1 SELECT 1402 R1 ON DLY 1403 R1 OFF DLY 1404 RO2 SELECT 1405 R2 ON DLY 1406 R2 OFF DLY 1407 RO3 SELECT 1408 R3 ON DLY 1409 R3 OFF DLY 1410 RO4 SELECT 1411 R40ONDLY 1412 R4 OFF DLY 1413 ROS SELECT 1414 R5 ON DLY 1415 R5 OFF DLY GROUP 16 SYSTEM CTRL 1601 START STOP 1602 RUN ENABLE 1603 START EN 1 1604 START EN 2 1605 START EN 3 1606 START EN 4 1607 RESET SRC 1608 AUTO XFR 1609 OC TRANSFR 1610 OV TRANSFR 1611 UV TRANSFR 1612 Al TRANSFR 1613 BP DISABLE 1614 BP RUN DLY 1615 SAVE PARAM 1616 DISP ALRMS 1617 DRIVE TEST 1618 PASS CODE 1619 PAR LOCK 1620 RUN EN TXT 1621 ST EN1 TXT 1622 ST EN2 TXT 1623 ST EN3 TXT 1624 ST EN4 TXT 1625 COMM CTRL 1626 MODE L
48. CRIT SPEED 3 LO 3405 OUTPUT 1 UNIT 4014 FBK SEL FB ACTUAL SIGNALS 1506 FILTER AO1 2507 CRIT SPEED 3 HI 3406 OUTPUT 1 MIN 4015 FBK MULTIPLIER 301 FB CMD WORD 1 1507 AO2 CONTENT GROUP 26 3407 OUTPUT 1 MAX 4016 ACT1 INPUT 302 FB CMD WORD 2 1508 AO2 CONTENT MIN MOTOR CONTROL 3408 SIGNAL 2 PARAM 4017 ACT2 INPUT 303 FB STS WORD 1 1509 AO2 CONTENT 2601 FLUX OPT ENABLE 3409 SIGNAL 2 MIN 4018 ACT1 MINIMUM 304 FB STS WORD 2 MAX 2602 FLUX BRAKING 3410 SIGNAL 2 MAX 4019 ACT1 MAXIMUM 305 FAULT WORD 1 1510 MINIMUM AO2 2603 IR COMP VOLT 3411 OUTPUT 2 DSP 4020 ACT2 MINIMUM 306 FAULT WORD 2 1511 MAXIMUM AO2 2604 IR COMP FREQ FORM 4021 ACT2 MAXIMUM 307 FAULT WORD 3 1512 FILTER AO2 2605 U F RATIO 3412 OUTPUT 2 UNIT 4022 SLEEP SELECTION 308 ALARM WORD 1 GROUP 16 2606 SWITCHING FREQ 3413 OUTPUT 2 MIN 4023 PID SLEEP LEVEL 309 ALARM WORD 2 SYSTEM CONTROLS 2607 SW FREQ CTRL 3414 OUTPUT 2 MAX 4024 PID SLEEP DELAY GROUP 04 1601 RUN ENABLE 2608 SLIP COMP RATIO 3415 SIGNAL3PARAM 4025 WAKE UP DEV FAULT HISTORY 1602 PARAMETERLOCK 2609 NOISE 3416 SIGNAL 3 MIN 4026 WAKE UP DELAY 401 LAST FAULT 1603 PASS CODE SMOOTHING 3417 SIGNAL 3 MAX 4027 PID 1 PARAM SET 402 FAULT TIME 1 1604 FAULT RESET SEL 2619 DC STABILIZER 3418 OUTPUT 3 DSP GROUP 41 403 FAULT TIME 2 1605 USER PAR SET GROUP 29 FORM PROCESS PID SET 2 404 SPEED AT FLT CHG MAINTENANCE TRIG 3419 OUTPUT 3 UNIT 4101 GAIN 405 FREQ AT FLT 1606 LOCAL LOCK 2901 COOLING FAN 3420 OUTPUT 3 MIN 4102 INTEGRATION TIME 406 VOLTAGE AT
49. D if parameter 1613 is set to Disable 4013 DRIVE LINK Same as Fault 3019 Bad cable between Proper seating of cable ERROR however will occur drive and bypass in drive and when notin supervisory Communication RBCU connector J3 mode improperly set in drive Check drive parameter Parameter 98 02 and 99 02 98 02 Modbus Check drive Group 53 Application Macro in Follow DriveLink 99 02 set to 15 text OTOW Svein recovery procedure 4014 DRIVE TEST Alarm is generated NA NA when bypass parameter 1617 is set to enable 4015 START DRIVE 1ST Message displayed on NA Run drive in Hand initial out of box power up sequence ACH550 E Clipse Bypass 74 ACH550 Installation Operation and Maintenance Manual START ENABLE 1 VIBRATION SWITCH FIRESTAT FREEZESTAT OVERPRESSURE VIBRATION TRIP SMOKE ALARM SAFETY OPEN LOW SUCTION PRES the RUN Enable is not present Bad 24v supply Bad digital input 24 V common is not tied to Digital input common on bypass when using external 24 v supply Alarm Alarm Name In F A Code Panel Alarm Possible Cause Corrective Action 4016 INP VOLTAGE 3 Phase input voltage NA Loose J7 connector LOW has not reached a Low input voltage sufficient level to Incoming voltage has enable editing of not reached at least parameters via the 155 VAC within a few keypad This message seconds of powerup is generated within a few seconds of power up 4019 OVERRIDE 1 Ala
50. Data parameters check the operation of the ACH550 Drive with E Clipse Bypass with the motor connected as follows 1 Disconnect and lock out power to the E Clipse Bypass unit wait at least five minutes before disconnecting power 2 Connect the motor to the output terminals CAUTION If the Bypass Override Override 2 input contact is closed the motor will start across the line as soon as power is applied If the Safety Interlock and Run Enable input contacts are closed and the Smoke Control Override 1 input contact is closed the motor will start across the line as soon as power is applied If the Start Stop Safety Interlock and Run Enable input contacts are closed and the system is in the Bypass mode and in either Hand or Auto the motor will start across the line as soon as power is applied If the Start Stop Safety Interlock and Run Enable input contacts are closed and the system is in the Drive mode with the drive in either Hand or Auto mode the motor will start on the drive as soon as power is applied In order to prevent the motor from starting the system should be in the Drive mode and the drive should be OFF when the power is disconnected at the end of the previous series of control panel settings and checks In order to prevent the motor from running without disconnecting the motor open the Run Enable and Safety Interlock contacts on bypass control board terminals X2 2 X2 3 and X2 4 before applying power Set the b
51. ED 1102 EXT1 EXT2 SEL LIMITS 3007 MOT LOAD CURVE 3608 START DAY 2 103 OUTPUT FREQ 1103 REF1 SELECT 2001 MINIMUM SPEED 3008 ZERO SPEED LOAD 3609 STOP DAY 2 104 CURRENT 1104 REF 1 MIN 2002 MAXIMUM SPEED 3009 BREAK POINT 3610 START TIME 3 105 TORQUE 1105 REF 1 MAX 2003 MAX CURRENT FREQ 3611 STOP TIME 3 106 POWER 1106 REF2 SELECT 2006 UNDERVOLT CTRL 3010 STALL FUNCTION 3612 START DAY 3 107 DC BUS VOLTAGE 1107 REF 2 MIN 2007 MINIMUM FREQ 3011 STALL 3613 STOP DAY 3 109 OUTPUT VOLTAGE 1108 REF 2 MAX 2008 MAXIMUM FREQ FREQUENCY 3614 START TIME 4 110 DRIVE TEMP GROUP 12 2013 MIN TORQUE SEL 3012 STALL TIME 3615 STOP TIME 4 111 EXTERNAL REF 1 CONSTANT SPEEDS 2014 MAX TORQUE SEL 3017 EARTH FAULT 3616 START DAY 4 112 EXTERNAL REF 2 1201 CONST SPEED SEL 2015 MIN TORQUE 1 3018 COMM FAULT 3617 STOP DAY 4 113 CTRL LOCATION 1202 CONST SPEED 1 2016 MIN TORQUE 2 FUNC 3622 BOOST SEL 114 RUNTIME R 1203 CONST SPEED 2 2017 MAX TORQUE 1 3019 COMM FAULT TIME 3623 BOOST TIME 115 KWH COUNTER R 1204 CONST SPEED 3 2018 MAX TORQUE 2 3021 Al FAULT LIMIT 3626 TIMER 1 SRC 116 APPLBLK OUTPUT 1205 CONST SPEED 4 GROUP 21 3022 Al2 FAULT LIMIT 3627 TIMER 2 SRC 118 DI 1 3 STATUS 1206 CONST SPEED 5 START STOP 3023 WIRING FAULT 3628 TIMER 3 SRC 119 DI 4 6 STATUS 1207 CONST SPEED 6 2101 START FUNCTION 3024 CB TEMP FAULT 3629 TIMER 4 SRC 120 Al1 1208 CONST SPEED 7 2102 STOP FUNCTION GROUP 31 GROUP 37 121 Al2 1209 TIMED MODE SEL 2103 DC MAGN TIME AUTOMATIC RESET USER LOAD CURVE 12
52. EMA 12 and NEMA 3R The following is a typical power diagram Disconnect Switch or Circuit Breaker aN Drive with Input Disconnect 3 Phase ACH550 Input Power 3 Drive 3 ACH550 PCR PDR 88 ACH550 Installation Operation and Maintenance Manual The following shows the front view of the ACH550 Drive with Input Disconnect standard configurations and identifies the major components UL Type NEMA 1 amp 12 Vertical Construction Enclosures UL Type NEMA 1 amp 12 Hinged Door Wall Mount Enclosures UL Type NEMA 1 amp 12 Floor Mount Enclosures ACH550 Drive Control Panel l I OLOGICAL Operating Handle for Disconnect Switch or Circuit Breaker UL Type NEMA 3R Enclosures ACH550 Drive Control Panel with Hinged Cover ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 89 Maintenance Maintenance intervals If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB for ACH550 enclosures in addition to the intervals on page 37 Maintenance Configuration Interval Instruction Check replace hinged Hinged door wall Check every 3 Enclosure air filter replacement door wall mount mount UL Type months Replace UL Type NEMA 12 hinged door enclosure inlet air filter NEMA 12 as needed wall mount enclo
53. FA IO 2 IO configuration is not complete the actual number of PFA motors parameter 8127 MOTORS does not match the PFA motors in Group 14 and parameter 8118 AUTOCHNG INTERV 1014 PAR PFA IO 3 IO configuration is not complete the drive is unable to allocate a digital input interlock for each PFA motor parameters 8120 INTERLOCKS and 8127 MOTORS Fault history For reference the last three fault codes are stored into parameters 0401 0412 0413 For the most recent fault identified by parameter 0401 the drive stores additional data in parameters 0402 0411 to aid in troubleshooting a problem For example parameter 0404 stores the motor speed at the time of the fault ACH550 UH ACH550 Installation Operation and Maintenance Manual 29 To clear the fault history all of the Group 04 Fault History parameters 1 Using the control panel in Parameters mode select parameter 0401 2 Press EDIT 3 Press UP and Down simultaneously 4 Press SAVE Alarm listing The following table lists the alarms by code number and describes each pol Display Description 2001 OVERCURRENT Current limiting controller is active Check for and correct e Excessive motor load e Insufficient acceleration time parameters 2202 ACCELER TIME 1 and 2205 ACCELER TIME 2 Faulty motor motor cables or connections Output disconnect device not interlocked e Interaction with external input filter
54. FLT 1607 PARAM SAVE TRIG 3421 OUTPUT 3 MAX 4103 DERIVATION TIME 407 CURRENT AT FLT 1608 START ENABLE 1 2902 COOLING FAN ACT GROUP 35 4104 PID DERIV FILTER 408 TORQUE AT FLT 1609 STARTENABLE2 2903 REVOLUTION TRIG MOTOR TEMP MEAS 4105 ERROR VALUE INV 409 STATUS AT FLT 1610 DISPLAY ALARMS 2904 REVOLUTION ACT 3501 SENSOR TYPE 4106 UNITS 410 DI 1 3 AT FLT 1611 PARAMETER VIEW 2905 RUN TIME TRIG 3202 INPUTSELECTION 4107 UNIT SCALE 411 DI 4 6 AT FLT GROUP 17 2906 RUN TIME ACT 3503 ALARM LIMIT 4108 0 VALUE 412 PREVIOUS FAULT 1 OVERRIDE 2907 USER MWH TRIG 3504 FAULT LIMIT 4109 100 VALUE 413 PREVIOUS FAULT 2 1701 OVERRIDE SEL 2908 USER MWH ACT GROUP 36 4110 SET POINT SEL GROUP 10 1702 OVERRIDE FREQ GROUP 30 TIMED FUNCTIONS 4111 INTERNAL SETPNT START STOP DIR 1703 OVERRIDE SPEED FAULT FUNCTIONS 3601 TIMERS ENABLE 4112 SETPOINT MIN 1001 EXT COMMANDS 1704 OVERR PASS 3001 AI lt MIN FUNCTION 3602 START TIME 1 4113 SETPOINT MAX 1002 EXT2 COMMANDS CODE 3002 PANEL COMMERR 3603 STOP TIME 4114 FBK SEL 1003 DIRECTION 1705 OVERRIDE 3003 EXTERNAL FAULT 1 3604 START DAY 1 a PREMU sh a ACH550 PCR PDR 92 ACH550 Installation Operation and Maintenance Manual 4117 ACT2 INPUT 4118 ACT1 MINIMUM 4119 ACT1 MAXIMUM 4120 ACT2 MINIMUM 4121 ACT2 MAXIMUM 4122 SLEEP SELECTION 4123 PID SLEEP LEVEL 4124 PID SLEEP DELAY 4125 WAKE UP DEV 4126 WAKE UP DELAY GROUP 42 EXT TRIM PID 4201 GAIN 4202 INTEGRATION TIME
55. Group 112 extract drive data on in drive and RBCU initial power up due to connector J3 Bad cable connection Check drive parameter between drive and 9802 Modbus and bypass 9902 E Clipse Communication Check drive Group 53 improperly set in drive Follow DriveLink Parameter 9802 recovery procedure Application Macro _ then cycle power to improperly set in drive bypass parameter 9902 3039 FBA PAR CONF Non embedded Incorrect settings in Verify Group 51 fieldbus has detected Group 51 parameters an error in Group 51 parameters 3101 SFLASH Internal checksum error NA Cycle power CORRUPT Replace RBCU Upgrade firmware ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 71 Fault Code 3102 Fault Name In Panel PMAP FILE Fault Parameter file is corrupt Possible Cause Corrective Action Cycle Power Contact ABB with information that preceeded fault 3201 T1 OVERLOAD T1 program cycle is overloaded NA Contact ABB with information that proceeded fault Cycle Power Replace RBCU 3202 T2 OVERLOAD T2 program cycle is overloaded NA Contact ABB with information that proceeded fault Cycle Power Replace RBCU 3203 T3 OVERLOAD T3 program cycle is overloaded NA Contact ABB with information that proceeded fault Cycle Power Replace RBCU 3204 STACK OVERFLOW Program cycle is overloaded NA Contact ABB with i
56. Maintenance Manual User Power Cable Guides ACH550 Drive Clipse Bypass Control Board Terminals X2 Disconnect Switch or Circuit Breaker nput Ground Lug Pa Beli a Input Power Terminals Motor Terminals x P ri A 2 Hs HHEH TI R z a Output Ground Lug Service Switch optional ACH550 Drive Output Ground Lug Input Ground Lug Motor Terminals Input Power Terminals Terminals X2 a ees j Service Switch optional B3 ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 43 Connection diagrams Standard E Clipse Bypass R8 floor mounted ACH550 Standard E Clipse Bypass units are configured for wiring access from the top The following figure shows the Standard E Clipse Bypass floor mounted wiring connection points Ground Lug Bar Motor Terminals Input Power Terminals E Clipse Bypass Control
57. OCK 1627 COST KWH 1628 LEARN MODE 1629 LEARN TIME 1630 REVERSE REQ 1631 DRV BYPASS GROUP 17 OVERRIDE 2 1701 OVERRIDE 2 1702 RUN EN OVR 1703 ST EN1 OVR 1704 ST EN2 OVR 1706 ST EN4 OVR 1707 FAULTS OVR GROUP 30 FLT FUNCTION 3001 UL ACTION 3002 ULTIME 3003 UL TRIP 3004 COMM LOSS 3005 COMM TIME 3006 PHASE LOSS 3007 PHASE SEQ GROUP 32 SUPERV CTRL 3201 SUPER CTRL 3202 START LVL 3203 STOP LEVEL 3204 START DLY 3205 STOP DLY 3206 FBKLOSS GROUP 33 INFORMATION 3301 FW VERSION 3302 PT VERSION 3303 LP VERSION 3304 CB VERSION 3305 TEST DATE 3306 DRIVE TYPE 3307 SUB ASMBLY 3308 PLANT CODE 3309 MFG DATE 3310 UNIT NUM GROUP 50 BYPASS EFB 5001 BP PROT ID 5002 BP MAC ID 5003 BAUD RATE 5004 EFB PARITY 5005 PROFILE 5006 BP OK MSG 5007 BP CRC ERR 5008 UART ERROR 5009 BP STATUS 5010 BP PAR 10 5011 BP PAR 11 5012 BP PAR 12 5013 BP PAR 13 5014 BP PAR 14 5015 BP PAR 15 5016 BP PAR 16 5017 BP PAR 17 5018 BP PAR 18 5019 BP PAR 19 5020 BP PAR 20 GROUP 51 EXT COMM MOD 5101 FBA TYPE 5102 FBA PAR 2 5103 FBA PAR3 5104 FBA PAR 4 5105 FBA PAR5 5106 FBA PAR 6 5107 FBA PAR7 5108 FBA PAR 8 5109 FBA PAR 9 5110 FBA PAR 10 5111 FBA PAR 11 5112 FBA PAR 12 5113 FBA PAR 13 5114 FBA PAR 14 5115 FBA PAR 15 5116 FBA PAR 16 5117 FBA PAR 17 5118 FBA PAR 18 5119 FBA PAR 19 5120 5121 5122 5123 5124 5125 5126 5127 5128 5129 5130 5131 5132 5133 FBA PAR 20 FBA PAR 21 FBA PAR 22 FBA PAR 23 FBA PAR 24 FBA PAR
58. R and PDR 2 Torque values shown relate to current production Check component labels on previously installed units for required tightening torque ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 85 600 Volt Power Wiring Data Circuit Circuit Disconnect Disconnect Ground Ground Frame Breaker Breaker Switch Switch EM Lugs Lugs HP Type Code Size UL Type UL Type ULType ULType terminals UL Type UL Type NEMA NEMA NEMA NEMA NEMA NEMA 1 amp 12 3R 1 amp 12 3R 1 amp 12 3R 2 ACH550 PxR 02A7 6 R2 3 ACH550 PxR 03A9 6 R2 ACH550 PxR 06A1 6 R2 6 46 6 6 7 5 ACH550 PxR 09A0 6 R2 62 in lbs 62 in lbs 48 48 35 in lbs 35 in lbs 10 ACH550 PxR 011A 6 R2 7 in lbs 7 in lbs 15 ACH550 PxR 017A 6 R2 20 ACH550 PxR 022A 6 R3 3 3 3 3 25 ACH550 PxR 027A 6 R3 62in lbs 62 in lbs Sees SERIA IDS SOINS 30 ACH550 PxR 032A 6 R4 4 4 Drive s i power 40 ACH550 PxR 041A 6 R4 18 in Ibs 18 in lbs connection terminals 1 1 2 50 ACH550 PxR 052A 6 R4 62in lbs 62in lbs 55 in Ibs 55 in lbs 50 in lbs p5 1 1 50 in lbs 60 ACH550 PxR 062A 6 R4 Bot ise 62 in Ibs 75 ACH550 PxR 077A 6 R6 1 0 1 0 1 ACH PxR A 70 in lbs 70 in lbs 00 ACH550 PxR 099A 6 Re earch ZOO NCN 3x 370 125 ACH550 PxR 125A 6 R6 274 in lbs 275 in lbs 355 MCM Signet 250 in lbs 2 0 375 in
59. R4 Sire 70indbs e nabs 53 in lbs 350 350 100 ACH550 BxR 125A 4 R5 MCM MCM 250 MCM 250 MCM 125 ACH550 BxR 157A 4 R6 Lane rae 300 MCM 300 MCM 300 in lbs 300 in lbs i 7 275 in lbs 275 in lbs 2 x 3 0 2 0 _BxR 180A 400 MOM 400 MCM 250 in Ibs 375 in lbs 150 ACH550 BxR 180A 4 R6 aoe ine 37E nabs See 2x500 2x500 2x500 beatae 200 ACH550 BxR 246A 4 R6 574 MCM MCM MCM sf sates 274 in lbs 375 in lbs 375 in lbs in Ibs 2 x 500 MCM 2 x 500 250 ACH550 BxR 316A 4 R8 ao MCM 300 ACHS50 BxR 368A 4 R8 in lbs BU UES mtn ay 350 ACHS550 BxR 414A 4 R8 500 in Ibs T 400 ACH550 BxR 486A 4 R8 ACH550 E Clipse Bypass 52 ACH550 Installation Operation and Maintenance Manual Power Wiring Data Bese Circuit Circuit Disconnect Disconnect Motor Motor Ground Ground di PA Frame UL Type UL type UL Type UL Type ULType UL type UL Type UL Type e NEMA NEMA NEMA NEMA NEMA NEMA NEMA NEMA 1 amp 12 3R 1 amp 12 3R 1 amp 2 3R 1 amp 2 3R 600 Volt 2 ACH550 BxR 02A7 6 R2 3 ACH550 BxR 03A9 6 R2 5 ACH550 BxR 06A1 6 R2 8 8 6 6 4 4 7 5 ACH550 BxR 09A0 6 R2 62 in lbs 62 in lbs 8 8 30 in lbs 30 in lbs 35in lbs 35 in lbs 10 ACH550 BxR 011A 6 R2 7in lbs 7 in lbs 15 ACH550 BxR 017A 6 R2 20 ACH550 BxR 022A 6 R3 2 2 25 ACH550 BxR 027A 6 R3 50 in lbs 50 in Ibs
60. READ ONLY only parameter E g try to change value PAR 01 02 INPUT VOLT 2 CAN T EDIT Try to change value of a parameter which is allowed to be changed only when WHEN STARTED system is not started E g PAR 16 02 RUN ENABLE 3 CAN T EDIT Try to change value of a reset only parameter other than zero UP DOWN UP DOWN ONLY buttons must be pressed simultaneoulsy for requesting default value of the PAR on the display value zero and after that ENTER pressed for saving it reset the parameter E g PAR 04 01 LAST FAULT 4 CAN T EDIT Input voltage too low Changing of parameters prohibited since system cannot INP VOLTAGE LOW save values to nv mem w insufficient voltage 5 CAN T EDIT Try to save value press the ENTER key in Parameter Edit State of a hidden PAR IS HIDDEN parameter Should not be possible If hidden parameters are turned visible this message is not given 6 CAN T EDIT Try to save value which is over LO LIMIT of the parameter Should not be UNDER LO LIMIT possible when changing parameters from control panel 7 CAN T EDIT Try to save value which is over HI LIMIT of the parameter Should not be UNDER HI LIMIT possible when changing parameters from control panel 8 CAN T EDIT Try to save value which is out of enumerated value list Should not be possible ENUM VAL ONLY when changing parameters from control panel 9 CAN T EDIT Try to request default value press UP and DOWN buttons simultaneously for NO DEFAULT a parameter which is defined no
61. RNING e 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 Do not connect or disconnect input or output power wiring or control wires when power is applied Never connect line voltage to drive output Terminals T1 T2 and T3 Do not make any voltage tolerance tests Hi Pot or Megger on any part of the unit Disconnect motor wires before taking any measurements in the motor or motor wires e Make sure that power factor correction capacitors are not connected between the drive and the motor ACH550 PCR PDR 80 ACH550 Installation Operation and Maintenance Manual Connection diagrams standard drive with input disconnect wall mounted The following figure shows the Standard Drive with Input Disconnect wall mounted wiring connection points UL Type NEMA 1 amp 12 UL Type NEMA 1 amp 12 Vertical Construction ACH550 Hinged Door Wall Mount 1 0 Conduit Enclosures Enclosures Top Terminals Motor Disconnect Switch lt Hea o s Terminals or Circuit Breaker Input Power Terminals O Conduit Bottom UL Type NEMA 3R Enclosures Fan Space Heater Power Supply amp Control Assembly Disconnect Switch or Circuit Breaker
62. ally once the drive is commissioned the welcome screen and this option no longer appear Motor data The motor data on the ratings plate may differ from the defaults in the ACH550 The drive provides more precise control and better thermal protection if you enter the rating plate data 1 Gather the following from the motor ratings plate e Voltage e Nominal motor current e Nominal frequency e Nominal speed e Nominal power 2 Edit parameters 9905 9909 to the correct values e Assistant Control Panel The Start Up Assistant walks you through this data entry e Basic Control Panel Refer to ACH550 User s Manual for parameter editing instructions Fault and alarm adjustments The ACH550 can detect a wide variety of potential system problems For example initial system operation may generate faults or alarms that indicate set up problems 1 Faults and alarms are reported on the control panel with a number Note the number reported 2 Review the description provided for the reported fault alarm Use the fault and alarm listings on pages 24 and 29 respectively or e Press the help key Assistant Control Panel only while fault or alarm is displayed 3 Adjust the system or parameters as appropriate ACH550 UH ACH550 Installation Operation and Maintenance Manual 21 Operation The ACH550 HVAC control panel ACS CP B features n Status LED Green when normal if flashing or red see Diagnostics
63. bles at X1 28 or X1 32 Ground only at drive end Strip and connect the individual control wires to the drive terminals Install the conduit box cover 1 screw IP5008 ACH550 UH ACH550 Installation Operation and Maintenance Manual R7 R8 wiring both enclosure types 15 The figures show connections in the R7 cabinet the R8 cabinet is similar Route the input power motor and control cables to the top of the cabinet Each cable type input power motor and control must be in separate conduit Use punch to create holes for conduit connections as needed UL type 12 Enclosure For each conduit run input power motor and control wiring must be separate install liquid tight conduit connectors not supplied Connect input power and motor cables to the bus terminals 6 Connect grounds to ground bar 7 Use available secure points and tie strap 10 landings to permanently secure control wiring at a minimum distance of 6 mm 1 4 from power wiring Strip the control cable sheathing and twist the copper screen into a pig tail Connect the ground screen pig tail for digital and analog I O cables at X1 1 Ground only at drive end Connect the ground screen pig tail for RS485 cables at X1 28 or X1 32 Ground only at drive end Remove the conduit connection plate from the top of the left bay Input Power Cable Terminal Strip Only on ACH550 UH
64. bs 375 in lbs 60 ACHS550 BxR 178A 2 R6 Pee ike oceans 75 ACH550 BxR 221A 2 R6 2x500 2x 500 100 ACHS50 BxR 248A 2 Re 274 208 974 in tbs 274 in lbs 375 in lbs 375 in Ibs a ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 51 Power Wiring Data Base Circuit Circuit Disconnect Disconnect Motor Motor Ground Ground HP Type Code Frame Breaker Breaker Switch Switch Terminals Terminals Lugs Lugs Siz UL Type UL Type UL Type UL Type UL Type UL Type UL Type UL Type e NEMA NEMA NEMA NEMA NEMA NEMA NEMA NEMA 1 amp 12 3R 1 amp 12 3R 1 amp 2 3R 1 amp 2 3R 480 Volt 15 ACHS50 BxR 03A3 4 R1 2 ACH550 BxR 04A1 4 R1 3 ACH550 BxR 06A9 4 R1 8 8 6 6 4 4 5 ACH550 BxR 08A8 4 R1 40 in lbs 40 in Ibs 8 8 30 in lbs 30 in lbs 35 in lbs 35 in Ibs 7 in lbs 7 in lbs 7 5 ACH550 BxR 012A 4 R1 10 ACH550 BxR 015A 4 R2 15 ACH550 BxR 023A 4 R2 20 ACH550 BxR 031A 4 R3 25 ACH550 BxR 038A 4 R3 30 ACH550 BxR 045A 4 R3 2 2 50 in lbs 50 in lbs 4 4 18 in lbs 18 in lbs 40 ACH550 BxR 059A 4 R4 1 1 2 50 in lbs 50 in lbs 50 in lbs 50 ACH550 BxR 072A 4 R4 b Hi i5 E 2 0 2 0 2 120 in lbs 120 in Ibs 50 in lbs 1 1 60 ACH550 BxR 078A 4 R4 e AE are 1 0 1 0 1 1 75 ACH550 BxR 097A 4
65. ck Resolution 0 1 D accuracy 1 g J1 Al2 OFF 0 2 10 V Ri 312 kQ 2 gt BY aon lt F or for OFF for ON J1 Al2 ON 0 4 20 mA R 100 Q o gt hor ate AGND Analog input circuit common connected internally to chassis gnd through 1 MQ AO1 Analog output programmable Default frequency 0 20 mA load lt 500 9 Accuracy 3 full scale 8 AO2 Analog output programmable Default current 0 20 mA load lt 500 Q Accuracy 3 full scale 9 AGND Analog output circuit common connected internally to chassis gnd through 1 MQ 10 24V Auxiliary voltage output 24 VDC 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 gt 10 V or lt 10 V between that input and DCOM The 24 V may be provided by the y ACH550 X1 10 or by an external 12 24 V source of either polarity gt 2 13 DH Digital input 1 programmable Default start stop 14 DI2 Digital input 2 programmable Default not configured 15 DIS Digital input 3 programmable Default constant preset speed 16 DI4 Digital input 4 programmable Default safety interlock 17 DI5 Digital input 5 programmable Default not configured 18 DIG Digital input 6 programmable Default not configured 19 RO1C Relay output 1 programmable Default Ready
66. ck Parameter 0103 For status of digital input ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 75 Alarm Alarm Name In n A Code Panel Alarm Possible Cause Corrective Action 4024 Selected by PAR Alarm will occur when Run Enable condition is Check 24 Volts on 1624 start order is given and not satisfied RBCU unit START ENABLE 4 the iy Enable is not Bad 24v supply Check for 24 volts on VIBRATION Perce Bad digital input respective DI when SWITCH DAN common is hoi condition is satisfie Ma tied to Digital input Check Parameter 0103 LOW SUCTION common on bypass For status of digital PRES when using external 24 nput v supply 4025 LOCAL DISABLED Alarm is displayed if MODE LOCK 16 29 is set to AUTO MODE and the Hand or Off key is pressed 4026 AUTO DISABLED This alarm is displayed if MODE LOCK 1629 is set to LOCAL MODE and the Auto key is pressed 4027 COMM CONFIG Alarm is displayed if the E Clipse parameters Change MAC address ERR drive and bypass MAC 5002 BP MAC ID amp to unique values addresses are equal or 5302 DV MAC ID are invalid set to the same value 4028 FBA PAR CONF Non embedded Verify Group 51 fieldbus has detected parameters an error in Group 51 parameters 4029 DRIVE FAULTED The drive is faulted Reset drive ACH550 E Clipse Bypass 76 Bypass status listing ACH550 Installation Operation and Maintenance Manual B
67. e is an active bypass fault the control panel will flash the fault number and fault diagnostic indication in English Bypass Alarm Display mode If there is an active bypass alarm the control panel will flash the alarm number and alarm diagnostic indication in English Start up by changing the parameters from the start up list To change the parameters follow these steps 1 The Default Display indicates the Bypass Control mode ENTER 2 Press ENTER to enter the Main Menu bie ACH550 E Clipse Bypass Qn ACH550 Installation Operation and Maintenance Manual 3 Select the Startup Params with the Up Down arrows and press ENTER VA ENTER 4 Select the appropriate Parameter with the Up Down arrows and press ENTER VA Erm 5 Press the Up Down arrows to change the Parameter Value VA 6 Press ENTER to store the modified value or press ESC to leave the ENTER Parameter Edit mode 7 Press ESC to return to the Main Menu and again to return to the Default Display ESC ii Start up by changing the parameters individually from the parameter list To change the parameters follow these steps 1 The Default Display indicates the Bypass Control mode 2 Press ENTER to enter the Main Menu ENTER 3 Select the Parameter List with the Up Down arrows and press ENTER V A ENTER 4 Select the appropriate Parameter Group with the Up D
68. e wires If the motor is a standard 208 V 60 Hz motor connected to a 208 V drive or a 460 V 60 Hz motor connected to a 480 V drive the default parameter settings should be suitable for the initial tests described below If the motor s rating is not 208 V or 460 V 60 Hz the MOTOR NOM VOLT and MOTOR NOM FREQ parameters will need to be properly set before proceeding Refer to the ACH550 UH User s Manual and set the parameters as required Note The settings for ALL external serial communication between the ACH550 with E Clipse Bypass and any Building Automation System are configured using the E Clipse Bypass operator panel DO NOT attempt to configure the external serial communication connection using the ACH550 operator panel The settings for internal communication between the ACH550 and the E Clipse Bypass are configured at the factory and require no adjustment Drive Link recovery procedure If the ACH550 Drive communication settings are unintentionally changed during setup a Drive Link Fault Drive Link Error or Drive Setup alarm may be displayed Should this occur accomplish the following steps in order Using the ACH550 Drive Keypad 1 Set Parameter 9802 to STD MODBUS 2 Set Parameter 9902 to E CLIPSE 3 Cycle Power Following the above steps in order should restore proper communications between the ACH550 Drive and the E Clipse Bypass Should the E Clipse Keypad continue to display a Drive
69. eely then change individual contactor M2 or the complete assembly RCSA 0x 3003 DRV CNTACT M1 contactor indicates Defective Contactor Disconnect incoming STUCK it is not prepared to Defective RBCU power from unit move on a power up Check if contactor check of the contactor armature moves freely or after contact is If armature moves commanded to open freely then change the RBCU If armature does not move freely then change individual contactor M1 or the complete assembly RCSA 0x ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 67 Fault Fault Name In F Code Panel Fault Possible Cause Corrective Action 3004 BYPASS COIL M2 contactor will not Loose J8 connector on Verify that J8 connector OPEN close when RBCU is firmly seated commanded to doso Loose wires on With incoming power contactor terminals A1 disconnected check for and or A2 tightness of A1 and A2 Bad Output on RBCU terminals Bad Contactor Swap RBCU Change Contactor Assembly 3005 DRIVE COIL OPEN M1 contactor will not Loose J8 connector on Verify that J8 connector close when RBCU is firmly seated commanded to do so Loose wires on With incoming power contactor terminals A1 disconnected check for and or A2 tightness of A1 and A2 Bad Output on RBCU terminals Bad Contactor Swap RBCU Change Contactor Assembly 3006 UNDERVOLTAGE Message only occurs if Loose
70. ent acceleration time parameters 2202 ACCELER TIME 1 and 2205 ACCELER TIME 2 e Faulty motor motor cables or connections e Output disconnect device not interlocked e Interaction with external input filter DC OVERVOLT Intermediate circuit DC voltage is excessive Check for and correct e Static or transient overvoltages in the input power supply e Insufficient deceleration time parameters 2203 DECELER TIME 1 and 2206 DECELER TIME 2 e Verify that overvoltage controller is ON using parameter 2005 e Interaction with external input filter DEV OVERTEMP Drive heatsink is overheated Temperature is at or above limit R1 R4 amp R7 R8 115 C 239 F R5 R6 125 C 257 F Check for and correct Fan failure e Obstructions in the air flow Dirt or dust coating on the heat sink Excessive ambient temperature Excessive motor load SHORT CIRC RESERVED Fault current Check for and correct e A short circuit in the motor cable s or motor e Supply disturbances Not used DC UNDERVOLT Intermediate circuit DC voltage is not sufficient Check for and correct e Missing phase in the input power supply e Blown fuse e Undervoltage on mains All LOSS Analog input 1 loss Analog input value is less than AI1FLT LIMIT 3021 Check for and correct e Source and connection for analog input e Parameter settings for AI1FLT LIMIT 3021 and 3001 AI lt MIN FUNCTION Al2
71. f of the cover Loosen the captive screws around the edge of the cover Remove the cover R8 Cabinet Door To open the cabinet door loosen the quarter turn screws that hold the cabinet door closed 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 R7 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 2 AI Note Lift the ACH550 by its metal chassis oS w IP2002 Non English speaking locations Add a warning sticker in the appropriate language over the existing warning on the top of the module ACH550 UH ACH550 Installation Operation and Maintenance Manual 7 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 As required for access remove the rubber plugs 2 Push plugs out from the back of the drive R5 amp R6 Align the sheet metal hood not shown in front of the drive s top mounting holes Attach w as part of next step 1 3 Position the ACH550 onto the mounting screws or bolts and securely tighten in all four corners Tov Note Lift the ACH550 by its metal chassis frame size R6 by
72. f units are kW or Py 746 9909 MOTOR NOM POWER if units are HP e g in US 1006 EXT ROMISSING Parameter values are inconsistent Check for the following e Extension relay module not connected and e 1410 1412 RELAY OUTPUTS 4 6 have non zero values 1007 PAR Parameter values are inconsistent Check for and correct FBUSMISSING A parameter is set for fieldbus control e g 1001 EXT1 COMMANDS 10 COMM but 9802 COMM PROT SEL 0 1008 PAR Parameter values are inconsistent 9904 MOTOR CTRL MODE must be 3 PFAWOSCALAR SCALAR SPEED when 8123 PFA ENABLE is activated 1009 PARPCU1 Parameter values for power control are inconsistent Improper motor nominal frequency or speed Check for both of the following e 1 lt 60 9907 MOTOR NOM FREQ 9908 MOTOR NOM SPEED lt 16 e 0 8 lt 9908 MOTOR NOM SPEED 120 9907 MOTOR NOM FREQ Motor Poles lt 0 992 1010 PAR PFA Both the override mode and PFA are activated at the same time These OVERRIDE modes are mutually incompatible because PFA interlocks cannot be observed in the override mode 1011 PAR OVERRIDE Overeride is enabled but parameters are incompatible Verify that 1701 is PARS not zero and depending on 9904 value 1702 or 1703 is not zero 1012 PAR PFA IO 1 IO configuration is not complete not enough relays are parameterized to PFA Or a conflict exists between Group 14 parameter 8117 NR OF AUX MOT and parameter 8118 AUTOCHNG INTERV 1013 PAR P
73. factory or your local ABB representative Safety ACH550 Installation Operation and Maintenance Manual 3 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 2 gt Q T a S Serial number label attached on upper part of the chokeplate between the mounting holes 21307001 UU TAU AA S N 203 Type code label attached on the heat sink on 1 the side of the enclosure 3 PH 48 63 Hz 1 PH 4 63 Hz 200 240 Vac 200 240 Vac 59 4 A 59 4A kAIC 3 PH 0 500 Hz 0 U1 Vac ABB Inc Made in USA of foreign parts G CE Mfg Date 01 December 2005 Org Firmware V 2 06B SIN 2030700001 Voltage U1 Current lin Output PH 0 500 Hz Voltage U2 1 Vac Current I2n For gt 10 HP Power Pn amen IAAT ACH550 Construction code 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 proceedi
74. g has Stop drive and let cool 181 degrees failed down and restart ee 83 degrees Ambient conditions too Add additional cooling Pe high Replace RBCU Bad RBCU unit ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 73 Alarm Alarm Name In Code Panel Alarm Possible Cause Corrective Action 4008 DRIVE SETUP Alarm generated when Incorrect parameters Set Parameter 1001 to configuration of drive is settings COMM such that bypass can Set Parameter 1002 to not properly control the COMM drive Specifically drive Set Parameter 1601 to parameters COMM 1001 1002 1601 1608 Set Parameter 1608 to COMM 4009 BYPASS RUN Alarm is generated NA NA DELAY when a bypass start command is issued and there is non zero time value in bypass parameter 1614 4010 MTR OVERLOAD Bypass warning if Drive Mode Drive Mode mony aera Bad Motor Refer to 550 manual conditions exist as for proper defined in the drive Bad Ct s rouble shoshi Bad RBCU techniques Bypass mode Bypass Mode Bad motor Check that J2 Bad CT s connector is firmly Bad RBCU seated in RBCU Either mode Check input voltage low input voltage Does overload condition exist 4011 MTR UNDERLOAD Alarm comes at half the NA Parameter 3002 is the time of a mtr underload time fault See fault 3017 for Parameter 3003 is the further text level 4012 BYPASS Alarm will be generated NA NA DISABLE
75. he bypass has lost its communications link with the drive or when the motor or drive protection functions have shut down the drive The specific nature of the fault is indicated on the drive control panel display Refer to the Diagnostics section on page 66 of the ACH550 UH User s Manual for more details Automatic Transfer The Automatic Transfer indication is provided on the bypass control panel The bypass control display will continuously flash an alarm to indicate the system has automatically transferred to Bypass after a Drive fault The Bypass Selected LED flashes green when the system has automatically transferred to bypass operation The bypass event log will also record this event Auto Indication The Auto Indication is provided on the bypass control panel default display when the bypass control panel Auto key is pressed Normally this indicates that the Auto Start contact or serial communications has been selected as the means for starting and stopping the motor in the bypass mode Off Indication The Off Indication is provided on the bypass control panel default display when bypass control panel Off key is pressed Hand Indication The Hand Indication is provided on the bypass control panel default display when the motor has been started manually in the bypass mode Drive Select Key The Drive Select Key selects the drive as the power source for the motor ACH550 E Clipse Bypass 64 ACH550 Installation Operation a
76. he drive 5 Disconnect the fan cable 6 Install the fan in reverse order noting that e The fan air flow is up refer to arrow on fan e The fan wire harness is toward the front The notched housing barb is located in the right rear corner The fan cable connects just forward of the fan at the top of the drive Frame Sizes R5 and R6 To replace the internal enclosure fan in frame sizes R5 or R6 Remove power from drive e Remove the front cover Lift the fan out and disconnect the cable e Install the fan in reverse order e Restore power Frame Sizes R7 R8 UL type 12 enclosures The enclosure fan is located in the exhaust box on top of the UL type 12 enclosure 1 Remove the left and right filter frames of the exhaust fan box by lifting them upwards MINN zl UONI 2 Disconnect the fan s electrical connector from the cabinet roof top right inside the cabinet ACH550 UH ACH550 Installation Operation and Maintenance Manual 35 3 4 Disconnect the fan wiring and capacitor from the fan Install the new fan and capacitor Undo the four fastening screws at the corners of the fan frame The screws are through bolts with nuts on the inside of the cabinet Do not drop the hardware into the drive PC00014 Remove the fan and fan frame as one unit frame Then remove the four screws attaching the fan to the fan frame Remo
77. ies Unsymmetrically grounded networks WARNING Do not attempt to install or remove EM1 or EM3 screws while power is applied to the drive s input terminals Unsymmetrically grounded networks are defined in the following table In such networks the internal connection provided by the EM3 screw on frame sizes R1 R4 only must be disconnected by removing EM3 If the grounding configuration of the network is unknown remove EM3 Note ACH550 UH drives are shipped with the screw removed but included in the conduit box Unsymmetrically Grounded Networks EM3 Must Be Out Grounded at the L1 Grounded at the L1 corner of the mid point of a delta delta leg Le Y L2 L3 L3 Single phase L1 Three phase L1 grounded at an Variac without L1 end point solidly grounded neutral L2 N L3 ACH550 UH 12 ACH550 Installation Operation and Maintenance Manual EM3 an M4x16 screw makes an internal ground connection m Li that reduces electro magnetic emission Where EMC electro magnetic compatibility is a concern and the network is symmetrically grounded EM3 may be installed For reference the diagram at right illustrates a symmetrically a grounded network L2 L3 Floating networks WARNING Do not attempt to install or remove EM1 EM3 F1 or F2 screws while power is applied to the drive s input terminals For floating networks also known as IT u
78. in lbs 7 in lbs 7 in lbs 35 in lbs 35 in lbs 15 ACH550 PxR 046A 2 R3 3 3 4 4 3 3 20 ACH550 PxR 059A 2 R3 50 in lbs 50 in lbs 18 in lbs 18 in lbs pads 50 in lbs 50 in lbs 1 1 1 1 power 25 ACH550 PxR 075A 2 R4 50 in tbs 50in bs 55 in lbs 56 in lbs SOnmection 2 2 1 0 1 0 30 ACH550 PxR 088A 2 R4 Sane SSN 50 in lbs_ 50 in lbs 40 ACH550 PxR 114A 2 R4 360 Mem 300 MCM 50 ACH550 PxR 143A 2 R6 274in lbs 200in lbs 399 MCM 300 MCM 275 in lbs 200 in Ibs 2 0 60 ACH550 PxR 178A 2 R6 3x43 0 2 5 inlbs 250 in lbs 75 FACHO50 FXR 221A 2 R6 on AXO 2x500 MCM 2x500 MCM 350 MCM 100 ACH550 PxR 248A 2 R6 274 in lbs 274 in lbs 274 in lbs 274 in lbs 100 in lbs 1 PxR represents both PCR and PDR 2 Torque values shown relate to current production Check component labels on previously installed units for required tightening torque ACH550 PCR PDR 84 ACH550 Installation Operation and Maintenance Manual 480 Volt Power Wiring Data Base Circuit Circuit Disconnect Disconnect Ground Ground ahaa Breaker Breaker Switch Switch Motor Lugs Lugs HP Type Code UL Type UL Type UL Type UL Type terminals UL Type UL Type Size NEMA NEMA NEMA NEMA NEMA NEMA 1 amp 12 3R 1 amp 12 3R 1 amp 12 3R 1 1 5 ACH550 PxR 03A3 4 R1 2 ACH550 PxR 04A1 4
79. inal block location and terminal data are defined in the ACH550 UH User s Manual e X2 terminal block location is illustrated in the figures starting with Connection diagrams Vertical E Clipse Bypass on page 40 e X2 terminal data are provided in Basic control connections for E Clipse HVAC Default on page 53 e Basic connections are described in the following paragraphs Alternate configurations using the E Clipse Bypass macro are described in the ACH550 User s Manual e On Terminal Block X1 inside the ACH550 analog inputs and outputs and additional digital input and relay output connections Al1 Al2 AO1 AO2 DI1 DI6 and RO1 RO6 are available for use Note The E Clipse Bypass control circuitry uses serial communications connections X1 28 X1 32 inside the ACH550 These connections are not available for any other purpose and must not be reconfigured ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 47 Basic connections The figure on page 53 shows the basic ih control connections for use with the E Clipse Bypass HVAC Default macro N FD fm These connections are described in the following paragraphs In typical installations only analog input wires connect to the ACH550 terminal block with other control connections
80. ion is lost and either e Drive is in local control mode the control panel displays HAND or OFF or e Drive is in remote control mode AUTO and is parameterized to accept start stop direction or reference from the control panel To correct check e Communication lines and connections e Parameter 3002 PANEL LOSS e Parameters in Groups 10 START STOP DIR and 11 REFERENCE SELECT if drive operation is AUTO 2009 DEVICE Drive heatsink is hot This alarm warns that a DEVICE OVERTEMP fault OVERTEMP may be near R1 R4 amp R7 R8 100 C 212 F R5 R6 110 C 230 F Check for and correct Fan failure Obstructions in the air flow Dirt or dust coating on the heat sink Excessive ambient temperature Excessive motor load 2010 MOT OVERTEMP Motor is hot based on either the drive s estimate or on temperature feedback This alarm warns that a Motor Underload fault trip may be near Check e Check for overloaded motor e Adjust the parameters used for the estimate 3005 3009 e Check the temperature sensors and Group 35 parameters 2011 UNDERLOAD Motor load is lower than expected This alarm warns that a Motor Underload fault trip may be near Check e Motor and drive ratings match motor is NOT undersized for the drive e Settings Group 37 USER LOAD CURVE 2012 MOTOR STALL Motor is operating in the stall region This alarm warns that a Motor Stall fault trip may be near 2013 AUTORESET This alarm war
81. n wall conduit clamps not supplied Open the appropriate knockouts in the conduit box See Conduit kit on page 7 3 Install conduit box 4 Connect conduit runs for input power motor 6 Strip wires 7 Connect power motor and ground wires to 10 12 13 14 Connect the ground screen pig tail for digital and control cables to the box Route input power and motor wiring through separate conduits the drive terminals IP2004 Note For R5 frame size the minimum power cable size is 25 mm 4 AWG For R6 frame size refer to Power terminal considerations R6 Frame size on page 16 Route the control cables through the conduit a tenes not the same conduit as either input power or motor wiring Use available secure points and tie strap landings to permanently secure control wiring at a minimum distance of 6 mm 1 4 from power wiring Strip the control cable sheathing and twist the copper screen into a pig tail and analog I O cables at X1 1 Ground only at drive end Connect the ground screen pig tail for RS485 cables at X1 28 or X1 32 Ground only at drive end Strip and connect the individual control wires to the drive terminals IP2005 Install the conduit box cover 1 screw ACH550 UH 14 ACH550 Installation Operation and Maintenance Manual R7 R6 wiring UL type 12 enclosure 1 3 Route the power wiring through conduit Step depends
82. nd Maintenance Manual Bypass Select Key The Bypass Select Key selects the bypass as the power source for the motor Oft Reset Key The Off Reset Key may be used to manually stop the motor if the motor has been running on bypass power The Off Reset key also resets most bypass faults It may take several minutes before the bypass can be reset after an overload trip If a bypass fault condition is present the second press of this key places the bypass in the OFF mode Auto Key The Auto Key selects the Auto Start contact or serial communications as the means for starting and stopping the motor in the bypass mode Hand Key The Hand Key can be used to manually start the motor when the bypass has been selected as the power source for the motor Bypass control panel modes The HVAC Bypass Control Panel has several different modes for configuring operating and diagnosing the bypass Select MENU and use the UP DOWN buttons to select modes The modes are Default Display mode Provides HAND OFF AUTO indication of the bypass operating control mode Bypass Status mode Provides status indications of the current system operating conditions Start Up Parameter Mode Provides a list of parameters or operating conditions that may be configured or viewed during startup Parameter List mode Used to edit parameter values individually Changed Parameter mode Displays changed parameters Bypass Fault Display mode If ther
83. nd OINT boards Contact your local ABB sales representative 20 OPEX PWR Internal fault Low voltage condition detected on OINT power supply Contact your local ABB sales representative 21 CURR MEAS Internal fault Current measurement is out of range Contact your local ABB sales representative ACH550 UH 26 ACH550 Installation Operation and Maintenance Manual Fault Code Fault Name In Panel Description and Recommended Corrective Action 22 SUPPLY PHASE Ripple voltage in the DC link is too high Check for and correct e Missing mains phase e Blown fuse e Interaction with external input filter Set parameter 2619 to ON 23 ENCODER ERR Not used Available only with encoder and parameter Group 50 23 ENCODER ERR The drive is not detecting a valid encoder signal Check for and correct e Encoder presence and proper connection reverse wired loose connection or short circuit e Voltage logic levels are outside of the specified range e A working and properly connected Pulse Encoder Interface Module OTAC 01 e Wrong value entered in parameter 5001 PULSE NR A wrong value will only be detected if the error is such that the calculated slip is greater than 4 times the rated slip of the motor e Encoder is not being used but parameter 5002 ENCODER ENABLE 1 ENABLED 24 OVERSPEED Motor speed is greater than 120 of the larger in magni
84. nformation that proceeded fault Cycle Power Replace RBCU 3205 UNKNOWN CB Bypass control board type is unknown Firmware is not compatible with control board in RBCU Firmware 93F and greater compatible with all RCBU hardware Firmware 93D and earlier can only be loaded in RBCU Rev D and earlier 3206 UNKNOWN DRIVE Drive reports rating not found in bypass software Drive does not match drives configured in bypass RBCU Replace RBCU or reload with most current firmware 3207 UNKNOWN BYPASS NA NA Replace RBCU or load most current firmware Contact ABB at 1 800 HELP 365 option 4 Replace RBCU or load most current firmware Fault History See page 28 ACH550 E Clipse Bypass 72 Alarm listing ACH550 Installation Operation and Maintenance Manual The following table lists the alarms by code number and describes each pak a eg n Alarm Possible Cause Corrective Action 4001 INP PHASE A Alarm will occur in drive Loose J8 connector Check J8 connector LOSS mode In bypass Loose wiring on Check yellow wire on alarm will occur if Contactor assembly input block bypass contactor has BI f Check j i not closed Unit will trip own upstream use i reat on Fault 3010 if the ve ue phase to bypass contactor is groun closed 4002 INP PHASE B Alarm will occur in drive Loose J8 connector Check J8 connector LOSS mode In bypass L
85. ng Failure to observe the warnings and instructions may cause a malfunction or personal hazard A 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 ACH550 UH ACH550 Installation Operation and Maintenance Manual 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 Use a pallet truck to move the transport package enclosure to the installation site 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 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 Use a hoist to lift the drive Do not place drive in final position until mounting site is prepared Unpack the drive 1 2 Unpack the drive Check for any damage and notify the shipper immediately if damaged components are found Check the contents against the order and the shipping label to verify that all parts have been received Tools required
86. ngrounded or impedance resistance grounded networks e Disconnect the ground connection to the internal RFI filters Frame sizes R1 R4 Remove the EM1 screw unit is shipped with EM3 removed see Connection diagrams on page 8 Frame sizes R5 R6 Remove both the F1 and F2 screws see page 9 e Where EMC requirements exist check for excessive emission propagated to neighboring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt use a supply transformer with static screening between the primary and secondary windings e Do NOT install an external RFI EMC filter Using an RFI filter grounds the input power through the filter capacitors which could be dangerous and could damage the unit Checking motor and motor cable insulation A 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 Complete motor cable connections to the motor but NOT to the drive output terminals U2 V2 W2 At the drive end of the motor cable measure the insulation resistance between each motor cable phase and Protective Cu Earth PE Apply a voltage of 1 kV DC and verify that ohm resistance is greater than 1 Mohm ae ACH550 UH ACH550 Installation Operation and Maintenance Manual 13 R1 R6 wiring UL type 1 enclosure 1 Install thi
87. ns that the drive is about to perform an automatic fault note 1 reset which may start the motor e To control automatic reset use parameter Group 31 AUTOMATIC RESET 2014 AUTOCHANGE This alarm warns that the PFA autochange function is active note 1 To control PFA use parameter Group 81 PFA CONTROL 2015 PFA INTERLOCK This alarm warns that the PFA interlocks are active which means that the drive cannot start the following e Any motor when Autochange is used e The speed regulated motor when Autochange is not used 2016 Reserved 2017 OFF BUTTON Note 1 2018 PID SLEEP This alarm warns that the PID sleep function is active which means note 1 that the motor could accelerate when the PID sleep function ends e To control PID sleep use parameters 4022 4026 or 4122 4126 ACH550 UH ACH550 Installation Operation and Maintenance Manual 31 Alarm Code Display Description 2019 ID RUN Performing ID run 2020 OVERRIDE This alarm warns that the Override function is active which may start the motor 2021 START ENABLE 1 MISSING This alarm warns that the Start Enable 1 signal is missing To control Start Enable 1 function use parameter 1608 To correct check e Digital input configuration e Communication settings 2022 START ENABLE 2 MISSING This alarm warns that the Start Enable 2 signal is missing To control Start Enable 2 function use parame
88. of three input wires to the that bypass operation wiring bypass unit will result in motor rotation opposite of drive forward operation 3021 PH A CURR FBK Fault is generated Loose CT connection Check J2 connector for when current in Phase Bad RBCU proper seating A is detected and the Bad CT Check connector on bypass contactor is Current Assembly opan Replace RBCU Replace RCSA unit 3022 PH C CURR FBK Fault is generated Loose CT connection Check J2 connector for when current in Phase Bad RBCU proper seating C is detected and the Bad CT Check connector on bypass contactor is Current Assembly PRAN Replace RBCU Replace RCSA unit 3023 BYP COIL Coil characteristics are Shorted contactor coil Replace RBCU SHORTED checked only on power Shorted damaged Replace RCSA unit up and coil current is cable greater than allowable values Bad RBCU 3024 DRV COIL Coil characteristics are Shorted contactor coil Replace RBCU SHORTED checked only on power Shorted damaged Replace RCSA unit up and coil current is cable greater than allowable val es Bad RBCU 3027 INVALID SUB ASM Contactor assembly as RBCU unit from a Contact ABB at recorded in the RBCU different size bypass 1 800 HELP 365 unit does not match used to replace a Option 4 drive information defective RBCU communicated via 485 Parameters not link matched after Firmware change ACH550 E Clipse Bypass 70 ACH550 Installation Operation and Maintenance Manual
89. om the enclosure Back of Enclosure Mounting sd Screw Filter Bracket Enclosure ACH550 PCR PDR 90 ACH550 Installation Operation and Maintenance Manual 3 Lift the filter out of the filter bracket and replace as appropriate 4 With the filter in the filter bracket align the hooks on the bracket with the slots in the enclosure base and press the hooks up into the slots 5 Slide the filter bracket back making sure that the hooks catch on the enclosure 6 Replace the mounting screw Tighten until the gasket on the bracket is about 50 compressed Enclosure air filter replacement UL Type NEMA 12 floor mount enclosures Filter material Enclosure Type Inlet door Outlet roof JUL Type 7 NEMA 12 3AUA0000006723 qty 1 3AUA0000006722 qty 2 Note When installing the filter media the white side must face the outside of the cabinet and the colored side must face the inside of the cabinet Refer to page 34 Diagnostics Refer to the Diagnostics instructions on page 24 ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 91 Complete ACH550 Drive Parameter List GROUP 01 GROUP 11 1706 OVERRIDE DIR 3004 EXTERNAL FAULT 2 3605 STOP DAY 1 OPERATING DATA REFERENCE SELECT 1707 OVERRIDE REF 3005 MOT THERM PROT 3606 START TIME 2 101 SPEED amp DIR 1101 KEYPAD REF SEL GROUP 20 3006 MOT THERM TIME 3607 STOP TIME 2 102 SPE
90. on 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 Symmetrically IT systems ungrounded piety Screw grounded TN systems gl Arle or high resistance TN S systems y grounded gt 30 ohm EM1 x x e R1 R3 EM3 x e EM1 x xX R4 EM3 x F1 x x R5 R6 F2 x x x Install the screw EMC filter will be connected e Replace the screw with the provided polyamide screw EMC filter will be disconnected Remove the screw EMC filter will be disconnected EM1 and EMS screws are M4 x 12 F1 and F2 screws are M4 x 16 ACH550 UH ACH550 Installation Operation and Maintenance Manual 11 Ground connections For personnel safety proper operation and to reduce electromagnetic emission pick up the drive and the motor must be grounded at the installation site e Conductors must be adequately sized as required by safety regulations e Power cable shields must be connected to the drive PE terminal in order to meet safety regulations e Power cable shields are suitable for use as equipment grounding conductors only when the shield conductors are adequately sized as required by safety regulations In multiple drive installations do not connect drive terminals in ser
91. onnections when the ACH550 with E Clipse Bypass 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 1 Install wiring bypass WARNING Do not connect or disconnect input or output power wiring or control wires when power is applied e Never connect line voltage to drive output Terminals T1 T2 and T3 Do not make any voltage tolerance tests Hi Pot or Megger on any part of the unit Disconnect motor wires before taking any measurements in the motor or motor wires e Make sure that power factor correction capacitors are not connected between the drive and the motor Enclosure Horsepower Range by Voltage Rating Designation 208 240V 480V 600V V1 V2 1 to 7 5 HP 1 to 15 HP 2 to 15 HP V3 V4 10 to 25 HP 20 to 60 HP 20 to 60 HP B1 1 to 7 5 HP 1 to 15 HP 2 to 15 HP B2 10 to 25 HP 20 to 60 HP 20 to 60 HP B3 30 to 100 HP 75 to 200 HP 75 to 150 HP B4 N A 250 to 550 HP N A ACH550 E Clipse Bypass 40 ACH550 Installation Operation and Maintenance Manual Connection diagrams Vertical E Clipse Bypass ACH550 Vertical E Clipse Bypass units are configured for wiring access from the bottom only The following figure shows the Vertical E Clipse Bypass wiring connection points ACH550 E Clipse Bypass Control Board Terminals X2
92. ons 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 floating networks R1 R6 The internal RFI filter is disconnected screws EM1 amp EM3 or F1 amp F2 The drive is properly grounded The input power connections at U1 V1 and W1 are connected and tightened as specified The input power voltage matches the drive nominal input voltage range The input power branch circuit protection is installed The input power motor and control wiring are routed through separate conduit runs The motor connections at U2 V2 and W2 are connected and tightened as specified NO power factor compensation capacitors are in the motor cable NO tools or foreign objects such as drill shavings are inside the drive The control connections are connected and tightened as specified voltage is applied to the output of the drive NO alternate power source for the motor such as a bypass connection is connected no 7 Re install cover ACH550 UH ACH550 Installation Operation and Maintenance Manual 19 8 Apply power Always re install the covers before turning power on WARNING The ACH550 will start up automatically at power up if the external run command is on Apply input power When power is applied to the ACH550 the green LED comes on Note Before increa
93. oose wiring on Check black wire on alarm will occur if Contactor assembly input block bypass contactor has BI t f Check i not closed Unit will trip OWN UPSeaAN TUSE ae reason on Fault 3011 if the vo oe phase to bypass contactor is groun closed 4003 INP PHASE C Alarm will occur in drive Loose J8 connector Check J8 connector LOSS mode In bypass Loose wiring on Check red wire on input alarm will occur if Contactor assembly block bypass contactor has BI t f Check i not closed Unit will trip own Upstream iss ee hacen on Fault 3012 if the vo ae phase to bypass contactor is groun closed 4004 AUTO TRANSFER Message is displayed Drive fault Check drive when the drive faults and the bypass switches to bypass mode as configured in Parameter 1608 4005 EXT COMM ERR Time between fieldbus Incorrect Check Group 518 53 messages has Communication Tighten Connections exceeded timeout settings in Group 51 amp Check C icati interval set with 53 C se G enna en parameter 3005 Poor Connections Seg Noise on Communication Line 4006 Selected by PAR Alarm will occur when Run Enable conditionis Check 24 Volts on 1620 start order is given and not satisfied RBCU unit RUN ENABLE the Lend Enable isnot Bad 24v supply Check for 24 volts on DAMPER END pen Bad digital input respective DI when SWITCH condition is satisfied VALVE OPENING Check Parameter 01 03 PRE LUBE CYCLE for status of digital input 4007 PCB TEMP RBCU unit reached Cabinet coolin
94. out power to the drive and wait five minutes Swap any two motor output wires T1 T2 and T3 Incorrect motor rotation direction may cause equipment damage 6 Increase the speed to 60 Hz or the highest safe operating speed 7 Press the OFF key on the drive control panel The motor should stop If the drive does not operate according to these steps refer to the ACH550 UH User s Manual If the drive operates according to these steps your ACH550 with E Clipse Bypass is ready to use with preset or modified macro settings Note The settings for ALL external serial communication between the ACH550 with E Clipse Bypass and any Building Automation System are configured using the E Clipse Bypass operator panel DO NOT attempt to configure the external serial communication connection using the ACH550 operator panel The settings for internal communication between the ACH550 and the E Clipse Bypass are configured at the factory and require no adjustment ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 57 Note Both the ACH550 Drive and the E Clipse Bypass include preset application macros The only ACH550 Drive macro that provides the proper configuration settings by default is the E Clipse HVAC Default macro 9902 15 If any other ACH550 drive macro or any modified setting of the E Clipse HVAC Default macro is used the following ACH550 Drive parameter values must be set and power cycled or the
95. own arrows and press ENTER VA ENTER 5 Select the appropriate Parameter in a group with the Up Down arrows and press ENTER VA ENTER 6 Press the Up Down arrows to change the Parameter Value VA 7 Press ENTER to store the modified value or press ESC to leave the ENTER or ESC Parameter Edit mode 8 Press ESC to return to the listing of Parameter Groups and again to return to the Main Menu ESC ESC ACH550 E Clipse Bypass 66 ACH550 Installation Operation and Maintenance Manual 9 Press ESC to return to the Default Note In the Parameter Edit mode the current parameter value appears below the parameter name Note To view the default parameter value press the Up Down arrows simultaneously Press Enter to restore the default parameter value or press ESC to leave the Parameter Edit mode Diagnostics Fault listing Fault Fault Name In Code Panel Fault Possible Cause Corrective Action 3001 COIL CURR FBK RBCU is sensing Defective component Change RBCU abnormal current on RBCU feedback when neither contactor should be energized 3002 BYP CNTACT M2 contactor indicates Defective Contactor Disconnect incoming STUCK it is not prepared to Defective RBCU power from unit move on a power up Check if contactor check of the contactor armature moves freely or after contact is If armature moves commanded to open freely then change the RBCU If armature does not move fr
96. r e Parameters 3010 3012 14 EXTERNAL FLT 1 Digital input defined to report first external fault is active See parameter 3003 EXTERNAL FAULT 1 15 EXTERNAL FLT 2 Digital input defined to report second external fault is active See parameter 3004 EXTERNAL FAULT 2 16 EARTH FAULT Possible ground fault detected in the motor or motor cables The drive monitors for ground faults while the drive is running and while the drive is not running Detection is more sensitive when the drive is not running and can produce false positives Possible corrections e Check for correct faults in the input wiring e Verify that motor cable does not exceed maximum specified length A delta grounded input power supply and motor cables with high capacitance may result in erroneous error reports during non running tests To disable response to fault monitoring when the drive is not running use parameter 3023 WIRING FAULT To disable response to all ground fault monitoring use parameter 3017 EARTH FAULT 17 UNDERLOAD Motor load is lower than expected Check for and correct e Disconnected load e Group 37 USER LOAD CURVE 18 THERM FAIL Internal fault The thermistor measuring the internal temperature of the drive is open or shorted Contact your local ABB sales representative 19 OPEX LINK Internal fault A communication related problem has been detected on the fiber optic link between the OITF a
97. r assembly input block contactor and the BI t f Check i RBCU does not sense own upstream fuse ee voltage on Phase A voleeexPrese to ground 3011 INP PHASE B Fault will be generated Loose J7 connector Check J7 connector LOSS only when trying to Loose wiring on Check black wire on close the bypass Contactor assembly input block contactor and the BI t f Check i ABCU does not sense own upstream fuse ie ell voltage on Phase B Vonage preset ground 3012 INP PHASE C Fault will be generated Loose J7 connector Check J7 connector LOSS only when trying to Loose wiring on Check red on input close the bypass Contactor assembly block contactor and the BI t f Check i ABCU does not senses own upstream fuse eh voltage on Phase C vo tage pnase to ground 3013 DRIVE 1ST START Fault generated if NA Run bypass unit in attempting to close the drive mode before bypass contactor with attempting bypass out running the bypass mode in drive mode first 3014 COIL POW Coil power supply has Internal failure on Cycle power on bypass SUPPLY failed to reach rated RBCU unit unit If contactor coil is voltage Shorted contactor coil Shorted fault 3023 or 3024 will be generated If 3023 or 3024 is generated replace respective contactor If 3023 or 3024 is not generated on power up replace RBCU unit 3016 EARTH FAULT Declared if attempting Earth fault in motor Refer to the fault code to close the bypass 16 on page 25 contactor when the drive has earth
98. ration and Maintenance Manual 23 Start up by changing the parameters individually To change the parameters follow these steps Select MENU to enter the main menu Cc Select the Parameters mode with the UP DOWN buttons and select ENTER to select the Parameters mode 2 Select the appropriate parameter group with the UP DOWN buttons and select 3 SEL Select the appropriate parameter in a group with the UP DOWN buttons Select 4 EDIT to change the parameter value Press the UP DOWN buttons to change the parameter value CP id EP id Dja GF Select SAVE to store the modified value or select CANCEL to leave the set mode 6 Any modifications not saved are cancelled A Select EXIT to return to the listing of parameter groups and again to return to w4 7 the main menu v4 Complete the control connections by manually entering the parameters Note The current parameter value appears below the highlighted parameter To view the default parameter value press the UP DOWN buttons simultaneously To restore the default factory settings select the application macro HVAC Default ACH550 UH 24 Diagnostics Fault listing ACH550 Installation Operation and Maintenance Manual Fault Code Fault Name In Panel Description and Recommended Corrective Action 1 OVERCURRENT Output current is excessive Check for and correct e Excessive motor load e Insuffici
99. rive cover 4 5 6 Remove power from drive To replace the fan For Frame Size e R1 R2 Press together the retaining clips on the fan cover sides and lift R3 R4 Press in on the lever located on the left side of the fan mount and rotate the fan up and out Disconnect the fan cable Install the fan in reverse order Restore power Frame Sizes R5 and R6 2 Remove the screws attaching the fan 4 Disconnect the fan cable 5 Install the fan in reverse order 6 Restore power Frame Sizes R7 and R8 Remove power from drive To replace the fan Remove the fan e R5 Swing the fan out on its hinges Bottom View R6 e R6 Pull the fan out X0022 wrt nn Refer to the installation instructions supplied with the fan kit ACH550 UH 34 ACH550 Installation Operation and Maintenance Manual Enclosure fan replacement UL Type 12 enclosures UL type 12 enclosures include an additional fan or fans to move air through the enclosure Frame Sizes R1 to R4 To replace the internal enclosure fan in frame sizes R1 to R4 1 Remove power from drive 2 Remove the front cover 5 3 The housing that holds the fan in place has barbed retaining clips at each corner Press all four clips toward the center to release the barbs 4 When the clips barbs are free pull the housing up to remove from t
100. rm is generated NA Check Parameter when Smoke Control is 0103 and 0104 for active digital input status 4020 OVERRIDE 2 Alarm is generated NA Check Parameter when Fireman s 0103 and 0104 for Override is active digital input status 4021 Selected by PAR Alarm will occur when Run Enable condition is Check 24 Volts on 1621 start order is given and not satisfied RBCU unit Check for 24 volts on respective DI when condition is satisfied Check Parameter 0103 For status of digital input 4022 Selected by PAR 1622 START ENABLE 2 VIBRATION SWITCH LOW SUCTION PRES Alarm will occur when start order is given and the RUN Enable is not present Run Enable condition is not satisfied Bad 24v supply Bad digital input 24 V common is not tied to Digital input common on bypass when using external 24 v supply Check 24 Volts on RBCU unit Check for 24 volts on respective DI when condition is satisfied Check Parameter 0103 For status of digital input 4023 Selected by PAR 1623 START ENABLE 3 VIBRATION SWITCH LOW SUCTION PRES Alarm will occur when start order is given and the RUN Enable is not present Run Enable condition is not satisfied Bad 24v supply Bad digital input 24 V common is not tied to Digital input common on bypass when using external 24 v supply Check 24 Volts on RBCU unit Check for 24 volts on respective DI when condition is satisfied Che
101. se ring lugs Drive s control connection terminals The following table provides specifications for the drive s control terminals Control Frame Size Maximum Wire Size Torque mm AWG Nm lb ft All 1 5 16 0 4 0 3 Control terminal descriptions The following full page diagram provides a general description of the control terminals on the drive Note Terminals 3 6 and 9 are at the same potential Note For safety reasons the fault relay signals a fault when the ACH550 is powered down ACH550 UH ACH550 Installation Operation and Maintenance Manual 17 X1 Drive Control Terminal Description 1 SCR Terminal for signal cable screen Connected internally to chassis ground 2 Alt Analog input channel 1 programmable Default external reference Resolution 0 1 accuracy 1 J1 Al1 OFF 0 2 10 V Rj 312 kQ 2 p gt oy or for OFF H for ON J1 Al1 ON 0 4 20 mA R 100 Q o gt ree AGND Analog input circuit common connected internally to chassis gnd through 1 MQ 10V_ Potentiometer reference source 10 V 2 max 10 mA 1kQ lt R lt 10kQ Q Al2 Analog input channel 2 programmable Default PID feedba
102. sing motor speed check that the motor is running in the desired direction To change rotation direction switch motor leads as shown below Drive Qu Ov O W1 GND U2 V2 W2 OO ae To change rotation direction switch motor leads Drive QUI Ov1 Owl QGND QU2OV2 Owe SZ L1 Input L2 L3 GND 9 Before Start up The ACH550 has default parameter settings that are sufficient for many situations However review the following situations Perform the associated procedures as appropriate Spin motor When first installed and started the control panel displays a welcome screen with the following options e Press Exit to commission the drive as described in section Start up by changing the parameters individually on page 23 Press Enter to move to the following options Select Commission Drive to commission the drive as described in section Start Up by Start up by using the Start Up Assistant on page 23 Select Spin Motor to operate the motor prior to commissioning This option ACH550 UH 20 ACH550 Installation Operation and Maintenance Manual operates the motor without any commissioning except entry of the motor data as described below Spin Motor is useful for example to operate ventilation fans prior to commissioning Note When using Spin Motor the motor speed is limited to the range 1 3 2 3 of maximum speed Also no interlocks are activated Fin
103. sures on enclosures page 89 Check replace floor Floor mount UL Check every 3 See Maintenance on page 34 and mount enclosure inlet Type NEMA 12 months Replace Enclosure air filter replacement air filter enclosures as needed UL Type NEMA 12 hinged door wall mount enclosures on page 89 Check replace NEMA UL Type NEMA Check every 3 See PX3R dimensional 3R enclosure air filters 3R enclosures months Replace information PX3R 5 and as needed higher Check replace floor Floor mount UL Check every 6 See Maintenance on page 35 and mount enclosure Type NEMA 12 months Replace Enclosure air filter replacement exhaust air filter enclosures as needed UL Type NEMA 12 hinged door wall mount enclosures on page 89 Enclosure air filter replacement UL Type NEMA 12 hinged door wall mount enclosures Filter material Material Filter Type American Air Filter 358 35 06A 12A Polykleon White 12 7 mm x 152 4 mm x 304 6 mm stk This procedure applies to drive with input disconnect configurations in UL Type NEMA 12 hinged door wall mount enclosures This filter is located at the bottom of the enclosure Use the following procedure to check and replace filters On the enclosure remove the screw holding the filter bracket in place Slide the filter bracket forward until the hooks on the bracket clear the slots on the enclosure base This step allows the filter and bracket to drop free fr
104. t to have a default value Should not be possible when changing parameters from control panel 10 CAN T EDIT Parameter system is busy e g application macro change is in process at the TRY AGAIN same time when someone is trying to save a value for a parameter Should not be possible when changing parameters from control panel Maintenance See Maintenance for the ACH550 UH on page 37 ACH550 E Clipse Bypass 77 78 ACH550 Installation Operation and Maintenance Manual ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 79 ACH550 PCR PDR Installation A A This information is unique to ACH550 input disconnect configurations PCR or PDR The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive packaged with an input disconnect switch or circuit breaker Refer to the Installation instructions on page 3 for all other information Failure to observe the warnings and instructions may cause a malfunction or personal hazard WARNING Before you begin read Safety on page 2 WARNING When the ACH550 with Input Disconnect 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 ACH550 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 1 Install wiring WA
105. ter 1609 To correct check e Digital input configuration Communication settings 2023 EMERGENCY STOP Emergency stop activated 2024 ENCODER ERROR The drive is not detecting a valid encoder signal Check for and correct Encoder presence and proper connection reverse wired loose connection or short circuit Voltage logic levels are outside of the specified range A working and properly connected Pulse Encoder Interface Module OTAC 01 Wrong value entered in parameter 5001 PULSE NR A wrong value will only be detected if the error is such that the calculated slip is greater than 4 times the rated slip of the motor Encoder is not being used but parameter 5002 ENCODER ENABLE 1 ENABLED 2025 2026 FIRST START RESERVED Signals that a the drive is performing a First Start evaluation of motor characteristics This is normal the first time the motor is run after motor parameters are entered or changed See parameter 9910 MOTOR ID RUN for a description of motor models Not used 2027 USER LOAD CURVE This alarm warns that the condition defined by parameter 3701 USER LOAD C MODE has been valid longer that half of the time difined by 3703 USER LOAD C TIME 2028 START DELAY Shown during the Start delay See parameter 2113 START DELAY Note 1 Even when the relay output is configured to indicate alarm conditions e g parameter 1401 RELAY OUTPUT
106. the lifting holes on both sides at the top Y BAN M 4 Re install the rubber plugs 5 Non English speaking locations Add a warning sticker in the appropriate language R7 Use a hoist to move the cabinet into position over the existing warning on the top of the module R8 Note If the cabinet location does not provide access to the cabinet sides be sure to re mount side panels before positioning cabinet 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 e conduit box screws cover The kit is included with UL type 1 Enclosures ACH550 UH 8 ACH550 Installation Operation and Maintenance Manual Connection diagrams The following diagrams show e 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 e The R5 R6 power and ground terminals e The terminal layout for R7 R8 R1 R4 Diagram shows the R3 frame J1 DIP Switches for Analog Inputs The switch is one of two types o gt Alt in Voltage Position Q P Al2 in Current Position
107. to Vector Speed if very specific application requirements make it necessary to use this type of motor control Operation using the Vector Speed setting is unnecessary for control of almost all fan and pump applications Refer to the ACH550 UH User s Manual for details on setting parameters Press the Drive Select key on the E Clipse Bypass control panel The Drive Select LED should be illuminated Check to see that pressing the e Auto key on the bypass control panel causes the E Clipse Bypass display to indicate Bypass in Auto Hand key on the bypass control panel causes no change to the E Clipse Bypass display e OFF key on the bypass control panel causes the E Clipse Bypass display to indicate Bypass in Off Press the HAND key on the drive control panel Note that the top line of the control panel display indicates HAND and run as a clockwise rotating arrow The Drive Run LED on the E Clipse Bypass control panel should be illuminated Press the UP arrow on the drive control panel Note that the speed reference indication in the top line of the drive control panel display increases from 0 0 SP In the middle line of the drive control panel display the output current indication should indicate 0 0 A Press the DOWN arrow on the drive control panel until the speed and frequency indications return to 0 0 Press the OFF key on the drive control panel Note that the bottom line of the
108. tor Terminals an Input Power Terminals Disconnect Switch or Circuit Breaker Dashed line is ground run Note The terminals on disconnect switches for the following rated ACH550 PDR products is 7 in lbs Do not use a power driver or over tighten to prevent breaking screw heads or stripping the terminal 230 VAC 460 VAC 600 VAC 04A6 2 03A3 4 02A7 6 06A6 2 04A1 4 03A9 6 07A5 2 06A9 4 06A1 6 012A 2 08A8 4 09A0 6 017A 2 012A 4 011A 6 024A 2 015A 4 017A 6 031A 2 023A 4 ACH550 PCR PDR ACH550 Installation Operation and Maintenance Manual 83 Power connection terminals The following tables show maximum wire size and required tightening torque for incoming power grounding and motor terminals 208 240 Volt Power Wiring Data Base Circuit Circuit Disconnect Disconnect Ground Ground aed Breaker Breaker Switch Switch Hii Lugs Lugs HP Type Code UL Type ULType UL Type ULType terminals UL Type UL Type Size NEMA NEMA NEMA NEMA NEMA NEMA 1 amp 12 3R 1812 3R 1812 3R 1 ACH550 PxR 04A6 2 R1 1 5 ACH550 PxR 06A6 2 R1 10 10 10 10 10 10 2 ACH550 PxR 07A5 2 R1 35in lbs 35inlbs 7 bs 7 in Ibs 35in lbs_ 35 in lbs 3 ACH550 PxR 012A 2 Ri 5 ACH550 PxR 017A 2 Ri 7 5 ACH550 PxR 024A 2 R2 6 6 8 8 6 6 10 ACH550 PxR 031A 2 R2 45 in lbs 45
109. tude of 2001 MINIMUM SPEED or 2002 MAXIMUM SPEED Check for and correct Parameter settings for 2001 and 2002 e Adequacy of motor braking torque e Applicability of torque control Brake chopper and resistor 25 RESERVED Not used as of the publication of this manual 26 DRIVE ID Internal fault Configuration Block Drive ID is not valid Contact your local ABB sales representative 27 COMFIG FILE Internal configuration file has an error Contact your local ABB sales representative 28 29 SERIAL 1 ERR EFB CONFIG FILE Fieldbus communication has timed out Check for and correct e Fault setup 3018 COMM FAULT FUNC and 3019 COMM FAULT TIME Communication settings Group 51 or 53 as appropriate e Poor connections and or noise on line Error in reading the configuration file for the embedded fieldbus 30 FORCE TRIP Fault trip forced by the fieldbus See the fieldbus User s Manual 31 EFB 1 32 EFB 2 33 EFB 3 Fault code reserved for the embedded fieldbus EFB protocol application These codes are not used as of the publication of this manual 34 MOTOR PHASE Fault in the motor circuit One of the motor phases is lost Check for and correct e Motor fault Motor cable fault e Thermal relay fault if used Internal fault ACH550 UH ACH550 Installation Operation and Maintenance Manual 27
110. ug near the motor cable terminal block connection point Power connections Standard E Clipse Bypass configurations wall mounted Line input connections Connect input power to the terminals of the disconnect switch or circuit breaker Connect the equipment grounding conductor to the ground lug at the top of the enclosure The figure below shows the connection points for Standard E Clipse Bypass configurations Also see Connection diagrams Standard E Clipse Bypass wall mounted on page 41 and Connection diagrams Standard E Clipse Bypass R8 floor mounted on page 43 Motor connections Connect the motor cables to the output terminal block as shown in the figure below Also see Connection diagrams Standard E Clipse Bypass wall mounted on page 41 and Connection diagrams Standard E Clipse Bypass R8 floor mounted on page 43 The motor grounding conductor can be connected to the ground lug near the terminal block Note Route cables through the cable guides on the left side of the enclosure Use separate conduits for input power and motor cables Follow the guides to separate the cables from each other ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual 45 I User Power l All
111. us 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 e 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 EMS F1 or F2 screws while power is applied to the drive s input terminals General warning warns about AN conditions other than those caused by electricity which can result in physical injury and or damage to the equipment e 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 e WARNING Never attempt to repair a malfunctioning ACH550 contact the factory or your local Authorized Service Center for repair or replacement e WARNING The ACH550 will start up automatically after an input voltage interruption if the external run command is on e WARNING The heat sink may reach a high temperature Note For more technical information contact the
112. ve the old fan _ Pco0020 with the replacement part for ABB Capacitor in the reverse order of the above Ensure the fan is centered on the Velocity velocity stack and rotates freely Stack PC00014 Enclosure air filter replacement UL Type 12 enclosures Frame Sizes R7 R8 UL type 12 enclosure inlet air filter The inlet air filter for the R7 R8 UL type 12 enclosure is located in the enclosure front door While holding the top of the filter frame pull up on the bottom of the frame The filter frame will slide up approximately 3 4 inch and can then safely removed by tilting away from the cabinet and lifting up ACH550 UH 36 2 Lay the filter frame on a flat work Reinstall the 3 filter restraining ACH550 Installation Operation and Maintenance Manual surface Remove the 3 retaining brackets by squeezing the tabbed corners in towards the middle of each bracket until the bracket clears the filter frame Save these brackets for replacement Remove and inspect the filter PC00007 Install the replacement filter Be g sure to tuck the filter into the grove around the entire filter frame This is very important for proper installation PC00013 brackets These will prevent the filter from being pulled out of the filter frame e Install the center bracket first e Install the 2nd bracket overlapping the center bracket by 1 2 to the left BENNE ES a PC00007 e Install the
113. ypass Status 16 Characters Condition Description DRIVE BYPASS DRIVE SELECTED Displays which one is selected drive or BYPASS SELECTED bypass SAFETIES OPEN Displays if safeties START ENABLE 1 and CLOSED or START ENABLE 2 have been applied or if they are missing RUN PERMISSIVES OPEN Displays if RUN ENABLE is present or not CLOSED START REQUEST NOT PRESENT Displays if start request has been applied to PRESENT the system AUTO TRANSFER NOT TRANSFERRED Displays if the system is in Auto Transfer TRANSFERRED state or not Does not reflect to PAR 16 08 AUTO XFER value itself BYP OVERRIDE 1 NOT ACTIVATED Status of Override 1 ACTIVATED BYP OVERRIDE 2 NOT ACTIVATED Status of Override 2 ACTIVATED DRIVE FAULTED NO Displays if drive is faulted or not YES BYPASS FAULTED NO Displays if bypass is faulted or not YES SYSTEM STARTED NO Displays if system is started or not YES SYSTEM RUNNING NO Displays if system is running or not YES BYPASS ALARMS NO ALARMS Displays if there is an active alarm s in ALARM ACTIVE bypass or not HAND OFF AUTO OFF MODE Displays operating mode of the bypass HAND MODE OFF HAND or AUTO AUTO MODE ACH550 E Clipse Bypass ACH550 Installation Operation and Maintenance Manual Error messages Error Message Description 1 CAN T EDIT Try to save value press the ENTER key in Parameter Edit State of a read PAR IS
114. ypass to Drive mode and the drive to OFF ACH550 E Clipse Bypass 56 ACH550 Installation Operation and Maintenance Manual 3 Apply power to the E Clipse Bypass unit The ACH550 Control Panel display should be illuminated On the bypass control panel both the display and Enabled LED should be illuminated If the Enabled LED is not illuminated solid green check to see that closed contacts or jumpers connect terminal X2 3 to X2 4 and X2 2 to X2 7 on the bypass control board 4 The Drive Selected LED should be illuminated If not press the Drive Select key to switch to Drive mode Leave the system in the Drive mode when proceeding to the next step 5 Press the Hand key on the ACH550 Control Panel Press and hold the UP key until the motor just starts rotating Note If the ACH550 Control Panel displays an OVERCURRENT or EARTH FAULT disconnect and lock out power to the E Clipse Bypass unit Wait at least 5 minutes Disconnect the motor leads from the E Clipse Bypass unit and Megger each motor lead to ground to determine if the motor is good Check the power leads from the Drive Bypass to the motor for damaged or improper wiring If the ACH550 Control Panel displays any other drive faults correct the fault condition before proceeding to the next step CAUTION Check motor rotation direction as soon as the motor begins to move If AN motor does not rotate in the correct direction shut down the drive disconnect and lock

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