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ACS550-01/U1 Drive User`s Manual

1. 380 480 Volt Drive Input Fuse Ratings Frame HP Identification Size 00 Toe 1 1 5 ACH550 xx 03A3 4 R1 15 KTK R 15 2 ACH550 xx 04A1 4 R1 15 KTK R 15 3 ACH550 xx 06A9 4 R1 15 KTK R 15 5 ACH550 xx 08A8 4 R1 15 KTK R 15 7 5 ACH550 xx 012A 4 R1 15 KTK R 15 10 ACH550 xx 015A 4 R2 30 KTK R 30 15 ACH550 xx 023A 4 R2 30 KTK R 30 20 ACH550 xx 031A 4 R3 40 JJS 40 25 ACH550 xx 038A 4 R3 40 JJS 40 30 ACH550 xx 044A 4 R4 100 JJS 100 40 ACH550 xx 059A 4 R4 100 JJS 100 50 ACH550 xx 072A 4 R4 100 JJS 100 60 ACH550 xx 077A 4 R6 125 JJS 125 75 ACH550 xx 096A 4 R6 125 JJS 125 100 ACH550 xx 124A 4 R6 150 JJS 150 125 ACH550 xx 157A 4 R6 200 JJS 200 150 ACH550 xx 180A 4 R6 225 JJS 225 200 ACH550 xx 245A 4 R7 400 JJS 400 250 ACH550 xx 316A 4 R8 400 JJS 400 300 ACH550 xx 368A 4 R8 400 JJS 400 350 ACH550 xx 414A 4 R8 600 JJS 600 400 ACH550 xx 486A 4 R8 600 JJS 600 Note Fuses listed are similar in function to fuses listed in the ACH550 UH User s Manual physical characteristics may differ Fuses from other manufacturers can be used if they meet the ratings given in the table The fuses recommended in the table are UL recognized Line Reactor The ACH550 E Bypass may contain optional input line reactors to provide an additional input impedance to limit the harmonics back to the power line This impedance is in addition to the approximately 5 input impedance provided by internal reactors that are sta
2. Dimensions R1 R2 R3 R4 R5 R6 Ref mm in mm in mm in mm in mm in mm in Ww 443 17 4 443 17 4 521 20 5 521 20 5 713 28 1 713 28 1 W1 320 12 6 320 12 6 400 15 7 400 15 7 713 28 1 713 28 1 H 862 33 9 862 33 9 995 39 2 995 39 2 1282 50 5 1282 50 5 H1 810 31 9 810 31 9 920 36 2 920 36 2 1175 46 3 1175 46 3 D 319 12 6 319 12 6 365 14 4 365 14 4 485 19 1 485 19 1 kg Ib kg Ib kg Ib kg Ib kg Ib kg Ib Mass 35 4 78 38 1 84 55 8 123 63 9 141 122 9 271 165 6 365 3 8 Input Disconnect and Bypass Configurations for ACH550 Standard E Bypass UL type 1 R7 R8 W Chapter 3 Installation Instructions BP0017 Standard E Bypass UL type 1 R7 R8 Dimensions Ref del de mm in mm in W 806 31 7 806 31 7 H 2065 81 3 2065 81 3 D 659 25 9 659 25 9 kg Ib kg Ib Mass 303 668 454 1000 Input Disconnect and Bypass Configurations for ACH550 3 9 Chapter 3 Installation Instructions Standard E Bypass UL type 12 R7 R8 BP0018 Standard E Bypass UL type 12 R7 R8 Dimensions Ref ii mm in mm in Ww 806 31 7 806 31 7 H 2318 91 3 2318 91 3 D 659 25 9 659 25 9 kg Ib kg Ib Mass 324 713 474 1045 3 10 Input Disconnect and Bypass Configurations for ACH550 Electrical Installation Cable Entries
3. Pre Wired to ACH550 terminal block X1 Do NOT Disturb Internally Supplied 24 VDC Pre Wired to ACH550 terminal block X1 Do NOT Disturb RO1 Bypass Fault N O RO1 tee aso Fault COM ROZ SystemRun NO RO2 SystemRun N O NO RO2 SystemRun COM A Y Run COM RO3 System Staried NO RO3 System Started N O Started NO RO3 System Started COM 3 RO4 Mode Override N C To Damper Actuator RO4 Mode Override N O RO4 Mode Override COM ROS Drive Fat NO Drive Fault NO O Drive Fault COM Ba he ne o Hand Off Auto N C RO6 Hand Off Auto N O RO6 Hand Off Auto COM BP0074 Parameter Number Description Setting 1001 EXTERNAL 1 COMMANDS 1 DI1 1002 EXTERNAL 2 COMMANDS 1 DI1 1601 RUN ENABLE 2 DI2 1401 RELAY OUTPUT 1 7 STARTED 1403 RELAY OUTPUT 3 3 FAULT 1 Figure 2 7 Basic Control Connections for Damper Actuator Control Input Disconnect and Bypass Configurations for ACH550 2 15 Chapter 2 Overview of ACH550 with E Bypass X1 Terminals on the ACH550 Control Board 1 Terminal for Signal Cable Shield 2 Analog Input Channel 1 3 3 Analog Input Common 10 V 10 mA Reference Voltage for Potentiometer 15 Digital Input Bypass Faul DD T8 Digital Input 4 Safeties Closed DD ACH550 Drive 18 Digital Input 6 Bypass M
4. H Y Ie D gt BP0064 Vertical E Bypass UL type 1 Dimensions R1 R2 R3 R4 Ref mm in mm in mm in mm in W 136 5 4 136 5 4 220 8 7 220 8 7 W1 98 3 9 98 3 9 160 6 3 160 6 3 H 1095 43 1 1195 47 1361 53 6 1466 57 7 H1 1078 42 4 1178 46 4 1332 52 4 1437 56 6 D 219 8 6 230 9 269 10 6 269 10 6 kg Ib kg Ib kg Ib kg Ib Mass 18 40 23 50 50 8 112 59 4 131 3 6 Input Disconnect and Bypass Configurations for ACH550 Standard E Bypass UL type 1 R1 R6 Chapter 3 Installation Instructions a o E ta L lh En Al 3 Y W1 gt ta D Ww BP0063 Standard E Bypass UL type 1 R1 R6 Dimensions R1 R2 R3 R4 R5 R6 Ret mm in mm in mm in mm in mm in mm in Ww 443 17 4 443 17 4 521 20 5 521 20 5 713 28 1 713 28 1 W1 320 12 6 320 12 6 400 IS 400 1S7 713 28 1 713 28 1 H 849 33 4 849 33 4 957 S7 957 Sail 1212 47 7 1212 47 7 H1 810 31 9 810 31 9 920 36 2 920 36 2 1175 46 3 1175 46 3 D 319 12 6 319 12 6 365 14 4 365 14 4 485 19 1 485 19 1 kg Ib kg Ib kg Ib kg Ib kg Ib kg Ib Mass 35 4 78 38 1 84 54 4 120 62 6 138 1206 266 163 3 360 Input Disconnect and Bypass Configurations for ACH550 3 7 Chapter 3 Installation Instructions Standard E Bypass UL type 12 R1 R6 O Y BP0062 Standard E Bypass UL type 12 R1 R6
5. 118 Digital Input 6 X2 Terminals on the Electronic Bypass Control Board MSas UU O O So Y Run Enable Safety Interlocks Override 1 Fireman s Override Override 2 Bypass Override 1 O Power Supply Not Used 7 Pre Wired to ACHBED Do NOT Disturb Safety Output 1 Drive RO1 N O Drive RO1 Com 3 Drive RO3 N C 4 Drive RO3 Com Common Used ONLY with Internal 24VDC Supply RO1 Bypass Fault N C 3 rs Pre Wired to ACH550 terminal block X1 Do NOT Disturb 1 RO1 Bypass Fault N O RO1 Bypass Fault COM RO2 System Run N C o RO2 System Run N O RO2 System Run COM RO3 System Started N C RO3 System Started N O RO3 System Started COM RO4 Mode Override N C RO4 Mode Override N O RO4 Mode Override COM 2 3 4 5 6 7 8 9 10 11 12 15 16 18 19 a 22 23 28 29 30 83 ACH550 Drive E Bypass Jumper J3 Internal External 24VDC 110 VAC Powered Powered vo VO E BP0071 Parameter Number Description Setting 1001 EXTERNAL 1 COMMANDS 1 DI1 1002 EXTERNAL 2 COMMANDS 1 DI1 1601 RUN ENABLE 2 DI2 1401 RELAY OUTPUT 1 7 STARTED 1403 RELAY OUTPUT 3 3 FAULT 1 Figure 3 8 Basic Control Connections for E Bypass Macro Input Disconnect and Bypass Configurations for ACH550 3 23 Chapter 3 Installation Inst
6. Terminal Sizes Chapter 3 Installation Instructions ACH550 Vertical E Bypass units are configured for wiring access from the bottom only ACH550 Standard Mount E Bypass units are configured for wiring access from the top At least three separate metallic conduits are required one for input power one for output power to the motor and one for control signals Power and motor cable terminal sizes are shown in the Table 3 3 to Table 3 6 for connections to an input circuit breaker or disconnect switch a motor terminal block and ground lugs The table also lists torque that should be applied when tightening the terminals Table 3 3 208 240 Volt Vertical E Bypass Power Terminal Data 208 240 Volt Eram Maximum Wire Size Capacities of Power Terminals A Circuit Disconnect Motor Terminal Overload Ground me entitication sire Breaker Switch Block Relay Lugs 1 ACH550 Vx 04A6 2 R1 3 8 6 N A 4 44 in Ibs 7 in Ibs 13 in lbs 35 in Ibs 1 5 ACH550 Vx 06A6 2 R1 3 8 6 N A 4 44 in Ibs 7 in Ibs 13 in lbs 35 in Ibs 2 ACH550 Vx 07A5 2 R1 3 8 6 N A 4 44 in Ibs 7 in Ibs 13 in lbs 35 in Ibs 3 ACH550 Vx 012A 2 R1 3 8 6 N A 4 44 in Ibs 7 in Ibs 13 in lbs 35 in Ibs 5 ACH550 Vx 017A 2 R1 3 8 6 N A 4 44 in Ibs 7 in Ibs 13 in lbs 35 in Ibs 7 5 ACH550 Vx 024A 2 R2 3 8 6 N A 4 44 in Ibs 7 in Ibs 13 in lbs 35 in Ibs 10 ACH550 Vx 031A 2 R3 3 4 2 0
7. 1 2 override 1 line reactor 2 4 contact wiring 3 25 location descripta e ra aaah lona 2 8 connectors diagrams 3 15 relay description 2 10 e bypass dip SW ae kaa ti dee eral NA 4 2 override 2 e bypass jumpers 00 4 2 contact wiring o ooooooo 3 25 e bypass PO S non eee eee eee eee 4 2 mode operation a 2 8 MOUNUNG cia ia a NGA 3 4 relay description 2 10 M P macro l parameter parameter settings for non e bypass 4 6 config for non e bypass macro 4 6 manual how to USO o oooooooo 1 1 manuals ds BAWA 0 ii 1 2 Input Disconnect and Bypass Configurations for ACH550 parameters matching drive to motor 4 6 ELLA AA AA 3 1 R ratings relay contacts AA 3 26 ready LED kaa dee wee DA haa 2 6 relay contact drive fault description 2 10 fireman s override description 2 10 input descriptions 2 10 output descriptions 2 10 override 2 description 2 10 PALINGS veneer nian ere weeded ne beeen ae E 3 26 run enable description 2 10 safety interlock description 2 10 start stop description 2 10 relay contacts NI AA AA 3 24 reset key Loco 2 7 rotation check direction 4 8 run enable contact wiring 3 24 run enable r
8. If the relay contacts are used to control inductive loads such as the coils of relays or contactors some form of noise suppression must be provided at the load This is to reduce the electrical noise that could interfere with the electronics in the drive as well as increase the life of the contacts in the relay DC coils should be suppressed with a diode although this is not required because of the small amount of noise generated by these type of circuits If a diode is used it should have a voltage rating greater than or equal to the supply voltage rating Wiring Practices The external control wiring to X1 and X2 must not be run in the same metallic conduit or raceway with any high power wiring The external speed reference signal must be wired using a twisted pair shielded cable The shield connection must be terminated at the ground terminal provided X1 1 The other end of the shield should be cut and taped back at the signal source 3 26 Input Disconnect and Bypass Configurations for ACH550 Chapter 4 Start up Procedure This chapter explains how to inspect the installation and how to start up the ACH550 with E Bypass Safety Precautions Before start up read and follow the precautions listed below e After the supply voltage is disconnected from the input the DC Bus capacitors should discharge to a safe voltage in about five minutes To ensure that the voltage level is safe measure the voltage between the DC Bus term
9. Standard E Bypass configurations Also see Figure 3 3 for R7 or R8 a LL zil Tr PN i rr y I q a g I A pamm 7 y Ti Ea Y USOUSO E o e BP0041 BP0043 Input Power Cable Standard Configuration R5 R6 Standard Configuration R1 R4 Figure 3 5 Input Power Wiring Standard E Bypass Wall Mounted Install the motor wiring away from other wire routes Avoid long parallel runs with other wires A dedicated metallic conduit should be provided from the drive to the motor for the output wiring WARNING Check the motor and motor wiring insulation before connecting the ACH550 to line power Follow the procedure provided below 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 Input Disconnect and Bypass Configurations for ACH550 Chapter 3 Installation Instructions Checking Motor Wiring and Motor Insulation Motor Cable Length Output Connections Vertical E Bypass Configurations 1 Check that the motor wires are disconnected from the E Bypass output on Terminals T1 T2 and T3 2 Check that the motor wires are disconnected from the motor and remove bridging connections at the motor 3 Measure the insulation resistances of the motor The voltage range of the insulation resistance meter must be at le
10. a Start command must be present 2 the Safety Interlock input contact must be closed and 3 there can be no fault present in the system The Start command can come from the bypass control board terminal block the ACH550 keypad the bypass keypad or serial communications depending on the operational mode selected The System Started relay is ideal for use in damper actuator circuits opening the dampers only under those conditions where the system is preparing to run the motor Closing the dampers if the safeties open the system faults or when a Stop command is issued Mode Override The Mode Override relay is a configurable relay The function of the relay is selectable between Mode and Override operation If the Mode Override relay is configured for Mode operation Default the relay is energized when the Bypass mode is selected and de energized when the Drive mode is selected If the Mode Override relay is configured for Override operation the relay is energized when the Override mode is selected and de energized in all other modes See E Bypass Jumper Switch and Pot Settings on page 4 2 Bypass Fault The Bypass Fault relay is energized during normal operation The Bypass Fault relay is de energized when a bypass fault has occurred or when the bypass motor overload underload protection has tripped Hand Off Auto The Hand Off Auto relay is energized when the bypass is in the Auto mode and de energized in the Hand mode and when t
11. input can be connected to an external contact that is closed to select the Bypass Override mode See Bypass Override Mode on page 2 8 for a description of this mode The Drive Fault relay is energized during normal operation The Drive Fault relay is de energized when an ACH550 drive fault has occurred The System Run relay is energized when the E Bypass System is running The System Run relay provides an output when the motor is running whether powered by the ACH550 drive or the bypass Separate Drive Runand Bypass Run contacts can be created by using the common C contact of the System Run relay and connecting the the normally open NO contact of the System Run relay to the common C contact of the Mode Override relay To do this the Mode Override relay must be configured for Mode relay operation See E Bypass Jumper Switch and Pot Settings on page 4 2 The normally closed NC contact of the Mode relay becomes the Drive Run contact and the normally open NO contact of the Mode relay becomes the Bypass Runcontact This configuration provides outputs that are closed when the motor is running See Typical Applications and Configurations at the end of this Chapter 2 10 Input Disconnect and Bypass Configurations for ACH550 Chapter 2 Overview of ACH550 with E Bypass System Started The System Started relay is energized when the E Bypass system is started Three conditions must be met in order for the relay to energize 1
12. 0 390 4 90 10 8 22 5 34 2 67 5 93 6 139 5 270 0 439 2 100 12 0 25 0 38 0 75 0 104 0 155 0 300 0 488 0 Underload Trip The underload protection trip current must be adjusted to a percentage Current Adjustment of the motor nameplate current using the P2 adjustment potentiometer Potentiometer located in the lower right hand area of the bypass control board as shown in Figure 4 1 Potentiometer settings are adjustable from 0 to 100 of the P1 overload trip setting The default setting is 0 which effectively removes the underload protection trip feature from the system Circuit Breaker Settings The circuit breakers on ACH550 E Bypasses with output ratings above 120 amps have adjustable switch settings for instantaneous and overload current protection The factory default settings are practical for most applications Refer to the ABB SACE Instruction Sheet supplied with your equipment for additional information on the adjustment of these settings Input Disconnect and Bypass Configurations for ACH550 4 5 Chapter 4 Start up Procedure Macros and Parameter Settings Keypad Control Tests Motor Disconnected from the ACH550 with E Bypass Apply power to the E Bypass unit The display should show the operating status of the drive If the motor is a standard 208 V 60 Hz motor connected to a 208 V drive or a 480 V 60 Hz motor connected to a 480 V drive the default parameter settings shoul
13. 0 N A 2 120 in lbs 120 in lbs 120 in lbs 50 in Ibs 30 ACH550 Bx 088A 2 R4 300MCM 1 0 250MCM N A 3 x 3 0 275 in lbs 70 in lbs 275 in lbs 250 in lbs 40 ACH550 Bx 114A 2 R4 300MCM 1 0 250MCM N A 3 x 3 0 275 in lbs 70 in lbs 275 in lbs 250 in lbs 50 ACH550 Bx 143A 2 R6 300MCM 350MCM 250MCM N A 3 x 3 0 275 in lbs 200 in lbs 275 in lbs 250 in lbs 60 ACH550 Bx 178A 2 R6 300MCM 350MCM 400MCM N A 3 x 3 0 275 in lbs 200 in lbs 375 in lbs 250 in lbs 75 ACH550 Bx 221A 2 R6 350MCM 350MCM 400MCM N A 3 x 3 0 275 in lbs 200 in lbs 375 in lbs 250 in lbs 100 ACH550 Bx 248A 2 R6 350MCM 350MCM 400MCM N A 3 x 3 0 275 in lbs 200 in lbs 375 in lbs 250 in lbs Input Disconnect and Bypass Configurations for ACH550 3 13 Chapter 3 Installation Instructions Table 3 6 380 480 Volt Standard E Bypass Power Terminal Data 380 480 Volt Fess Maximum Wire Size Capacities of Power Terminals Heer Circuit Disconnect Motor Terminal Overload HP Identification Size Breaker Switch Block Relay Ground Lugs 1 1 5 ACH550 Bx 03A3 4 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in lbs 2 ACH550 Bx 04A1 4 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 3 ACH550 Bx 06A9 4 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 5 ACH550 Bx 08A8 4 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 7 5 ACH550 Bx 012A 4 R1 6 6 6 N
14. A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 10 ACH550 Bx 015A 4 R2 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 15 ACH550 Bx 023A 4 R2 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 20 ACH550 Bx 031A 4 R3 2 0 2 0 2 0 N A 2 120 in lbs 120 in lbs 120 in lbs 50 in lbs 25 ACH550 Bx 038A 4 R3 2 0 2 0 2 0 N A 2 120 in lbs 120 in lbs 120 in lbs 50 in lbs 30 ACH550 Bx 044A 4 R4 2 0 2 0 2 0 N A 2 120 in lbs 120 in los 120 in lbs 50 in lbs 40 ACH550 Bx 059A 4 R4 2 0 2 0 2 0 N A 2 120 in lbs 120 in Ibs 120 in lbs 50 in lbs 50 ACH550 Bx 072A 4 R4 2 0 2 0 2 0 N A 2 120 in lbs 120 in lbs 120 in lbs 50 in lbs 60 ACH550 Bx 077A 4 R5 300MCM 1 0 2 0 N A 3 x 3 0 275 in lbs 70 in Ibs 53 in lbs 250 in lbs 75 ACH550 Bx 096A 4 R5 300MCM 1 0 2 0 N A 3 x 3 0 275 in lbs 70 in lbs 53 in lbs 250 in lbs 100 ACH550 Bx 124A 4 R6 300MCM 350MCM 250MCM N A 3 x 3 0 275 in lbs 200 in lbs 275 in lbs 250 in lbs 125 ACH550 Bx 157A 4 R6 300MCM 350MCM 250MCM N A 3 x 3 0 275 in lbs 200 in lbs 275 in lbs 250 in lbs 150 ACH550 Bx 180A 4 R6 300MCM 350MCM 250MCM N A 3 x 3 0 275 in lbs 200 in lbs 275 in lbs 250 in lbs 200 ACH550 Bx 245A 4 R7 2x250MCM 2x250MCM 350MCM N A 5 Bus Bar holes 275 in lbs 275 in lbs 350 in lbs 13 32 bolts 250 ACH550 Bx 316A 4 R8 2 x 250MCM 2 x 250MCM 2 x 600MCM N A 5 Bus Bar holes 275 in lbs 275 in lbs 500 in lbs 13 32 bolts 300 ACH550 Bx 368A 4 R8 2x500MCM 2x 500MCM 2 x 600MC
15. Enable LED should be illuminated If the Enable LED is not illuminated check to see that closed contacts or jumpers connect terminal X2 2 and X2 3 on the bypass control board to terminal X2 15 5 Either the Drive Selected or Bypass Selected 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 keypad switches the system between modes Leave the system in the Bypass mode when proceeding to the next step Input Disconnect and Bypass Configurations for ACH550 Chapter 4 Start up Procedure 6 Check to see that pressing the Auto key on the bypass keypad causes the Auto LED to be illuminated pressing the Hand key causes the Hand LED to be illuminated and pressing the OFF key causes either the Hand or Auto LED to go off Leave the Hand and Auto LEDs off when proceeding to the next step 7 For Steps 8 through 13 Parameter 9904 must be set to Scalar Freq After successful completion of Step 12 Parameter 9904 may be set 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 8 Press the Drive Select key on the bypass keyp
16. key The Hand or Auto LED will go out The motor can be restarted by pressing the Hand key or the bypass can be returned to the Auto mode by pressing the Auto key If the system is in the Drive mode pressing the OFF key will take the bypass out of the Auto mode but will not affect motor operation from the drive If the system is switched to the Bypass mode a motor that is running will stop If the ACH550 is in the Auto mode and the motor is running in the Drive mode the motor will transfer to bypass operation and continue running if the system is switched to the Bypass mode and the bypass is in the Auto mode with the Start Stop Input contact closed If the motor is running in the Bypass mode the motor will transfer to drive operation and continue running if the system is switched to the Drive mode and the drive is in the Auto mode with the Start Stop Input contact closed If the Safety Interlock and Run Enable Input contacts are closed and the system is in the Bypass mode and in either the Hand or Auto mode the motor will start across the line as soon as power is applied If the system is in the Drive mode with the drive in the Auto mode the motor will start on the drive as soon as power is applied When the Automatic Transfer option is selected the motor is automatically transferred to line power if the drive trips out ona protective trip If automatic restart has been enabled in the drive the drive will attempt to automatically resta
17. stop commands The user can switch to the Fireman s Override mode by closing the Fireman s Override input contact When the Fireman s Override input contact is closed the system is forced to bypass and runs the motor The Automatic Transfer LED flashes green when the system is in override While in Fireman s Override the system does not respond to any other inputs including overloads faults safeties and enables Fireman s Override is designed for Run to Destruction operation Normally when the Fireman s Override input contact is switched from closed to open the system returns to the operating mode that existed prior to entering Override and can be controlled using the Drive and Bypass keys The exception to this is when the Bypass Override Override 2 input contact is closed in which case the system switches to Bypass Override mode In the Bypass Override Override 2 mode the motor is powered by AC line power through the bypass contactor The source of the start command is internal and unaffected by external stop commands The user can switch to the Bypass Override mode by closing the Bypass Override input contact When the Bypass Override input contact is closed the system is forced to bypass and does not respond to the Drive and Bypass keys The Automatic Transfer LED flashes green when the system is in override While in Bypass Override the system responds to bypass overloads faults safeties and enables Normally when the Bypass Ove
18. the input terminals of the ACH550 there may be dangerous voltage from external sources on the terminals of the relay outputs R01 R03 Warning When the control terminals of two or more drive units 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 units or an external supply Warning The ACH550 is not a field repairable unit Never attempt to repair a malfunctioning unit contact the factory or your local Authorized Service Center for replacement Warning The ACH550 will start up automatically after an input voltage interruption if the external run command is on PP PPP PPE Note For more technical information contact the factory or your local ABB sales representative Use of Warnings and Notes There are two types of safety instructions throughout this manual 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 A Dangerous voltage warning warns of high voltage which can cause physical injury and or damage to the equipment General warning warns about conditions other than those caused by electricity which can result in physical injury and or damage to the equipment Input Disconnect
19. 0 165 60 ACH550ACH550 xx 077A 4 1295 4420 99 75 ACH550ACH550 xx 096A 4 1440 4915 99 100 ACH550ACH550 xx 124A 4 1940 6621 238 125 ACH550ACH550 xx 157A 4 2310 7884 238 150 ACH550ACH550 xx 180A 4 2810 9590 238 200 ACH550ACH550 xx 245A 4 3850 13000 300 250 ACH550ACH550 xx 316A 4 5300 18000 700 300 ACH550ACH550 xx 368A 4 6850 23000 700 350 ACH550ACH550 xx 414A 4 7000 24000 700 400 ACH550ACH550 xx 486A 4 7600 26000 700 If the cooling air contains dust clean the cooling surfaces of the unit regularly using compressed air and a brush If the ACH550 is in a UL type 1 enclosure cover the vents during cleaning to prevent the dust from entering the unit If the heatsink is not cleaned and is not able to dissipate the expended heat the ACH550 s thermal protection will activate causing a fault indication which stops the drive The ACH550 can be started again when the temperature of the heatsink has fallen below the trip level Input Disconnect and Bypass Configurations for ACH550 3 3 Chapter 3 Installation Instructions Mounting Location Wiring Requirements Initial Inspection Procedure When mounting the unit take the following precautions e DO NOT mount in direct sunlight DO NOT mount on surfaces with temperatures above 104 F 40 C DO NOT allow the ambient temperature around the ACH550 to exceed the ambient temperature as stated in Environment above e Mount the E Bypass enclosure vertically with the ACH550 con
20. 0 xx 248A 2 R6 O O O O m N O UO ol olw w S SIS Input Disconnect and Bypass Configurations for ACH550 4 3 Chapter 4 Start up Procedure Table 4 2 208 240 Volt Codes for Overload Trip Current DIP Switch 208 240 Volt HP identification PAG lee 1 ACH550 xx 04A6 2 R1 A 1 5 ACH550 xx 06A6 2 R1 A 2 ACH550 xx 07A5 2 R1 A 3 ACH550 xx 012A 2 R1 A 5 ACH550 xx 017A 2 R1 B 7 5 ACH550 xx 024A 2 R2 B 10 ACH550 xx 031A 2 R3 C 15 ACH550 xx 046A 2 R3 D 20 ACH550 xx 059A 2 R3 D 25 ACH550 xx 075A 2 R4 D 30 ACH550 xx 088A 2 R4 F 40 ACH550 xx 114A 2 R4 F 50 ACH550 xx 143A 2 R6 G 60 ACH550 xx 178A 2 R6 G 75 ACH550 xx 221A 2 R6 G 100 ACH550 xx 248A 2 R6 G Table 4 3 DIP Switch Settings Switch Switch Setting Configurations Position Switch Code A B C D E F G H OFF ON Automatic Transfer Bypass Feature OFF ON OFF ON Mode Override Relay RO4 Mode Override RESERVED OFF OFF ON NEMA Class 30 NEMA Class 20 overload trip curve RESERVED OFF OFF OFF OFF OFF ON ON ON ON OFF OFF ON ON OFF OFF ON ON Nf O oO A j N OFF ON OFF ON OFF ON OFF ON Default settings in parentheses 4 4 Input Disconnect and Bypass Configurations for ACH550 Chapter 4 Start up Proce
21. 2 44 in lbs 18 in lbs 120 in lbs 50 in lbs 40 ACH550 Vx 059A 4 R4 3 4 2 0 N A 2 44 in lbs 18 in lbs 120 in lbs 50 in lbs 50 ACH550 Vx 072A 4 R4 3 1 0 2 0 N A 2 44 in lbs 55 in Ibs 120 in lbs 50 in lbs 3 12 Input Disconnect and Bypass Configurations for ACH550 Table 3 5 208 240 Volt Standard E Bypass Power Terminal Data Chapter 3 Installation Instructions 208 240 Volt Fiame Maximum Wire Size Capacities of Power Terminals ARN Circuit Disconnect Motor Terminal Overload Ground Tap genitieation oe Breaker Switch Block Relay Lugs 1 ACH550 Bx 04A6 2 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 1 5 ACH550 Bx 06A6 2 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 2 ACH550 Bx 07A5 2 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 3 ACH550 Bx 012A 2 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 5 ACH550 Bx 017A 2 R1 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 7 5 ACH550 Bx 024A 2 R2 6 6 6 N A 4 13 in lbs 13 in lbs 13 in lbs 35 in Ibs 10 ACH550 Bx 031A 2 R3 2 0 2 0 2 0 N A 2 120 in lbs 120 in lbs 120 in lbs 50 in Ibs 15 ACH550 Bx 046A 2 R3 2 0 2 0 2 0 N A 2 120 in lbs 120 in lbs 120 in lbs 50 in Ibs 20 ACH550 Bx 059A 2 R3 2 0 2 0 2 0 N A 2 120 in lbs 120 in lbs 120 in lbs 50 in Ibs 25 ACH550 Bx 075A 2 R4 2 0 2 0 2
22. 8 240 Volt Heat a HP Identification Watts BTU Hr CFM 1 ACH550ACH550 xx 04A6 2 55 189 26 1 5 ACH550ACH550 xx 06A6 2 73 249 26 2 ACH550ACH550 xx 07A5 2 81 176 26 3 ACH550ACH550 xx 012A 2 116 404 26 5 ACH550ACH550 xx 017A 2 161 551 26 7 5 ACH550ACH550 xx 024A 2 227 776 52 10 ACH550ACH550 xx 031A 2 285 373 52 15 ACH550ACH550 xx 046A 2 420 1434 79 20 ACH550ACH550 xx 059A 2 536 1829 79 25 ACH550ACH550 xx 075A 2 671 2290 165 30 ACH550ACH550 xx 088A 2 786 2685 165 40 ACH550ACH550 xx 114A 2 1014 3463 165 50 ACH550ACH550 xx 143A 2 1268 4431 238 60 ACH550ACH550 xx 178A 2 1575 5379 238 75 ACH550ACH550 xx 221A 2 1952 6666 238 100 ACH550ACH550 xx 248A 2 2189 7474 238 3 2 Input Disconnect and Bypass Configurations for ACH550 Chapter 3 Installation Instructions Table 3 2 380 480 Volt Heat Dissipation for ACH550 E Bypass Units 380 480 Volt Heat PRO miya Airflow HP Identification Watts BTU Hr CFM 1 1 5 ACH550ACH550 xx 03A3 4 40 137 26 2 ACH550ACH550 xx 04A1 4 52 177 26 3 ACH550ACH550 xx 06A9 4 97 331 26 5 ACH550ACH550 xx 08A8 4 127 433 26 7 5 ACH550ACH550 xx 012A 4 172 587 26 10 ACH550ACH550 xx 015A 4 232 792 52 15 ACH550ACH550 xx 023A 4 337 1150 52 20 ACH550ACH550 xx 031A 4 457 1560 79 25 ACH550ACH550 xx 038A 4 562 1918 79 30 ACH550ACH550 xx 044A 4 667 2276 165 40 ACH550ACH550 xx 059A 4 907 3096 165 50 ACH550ACH550 xx 072A 4 1120 382
23. Disconnect Switch or Circuit Breaker Ground Lug s E Bypass Control Board Terminals X2 Disconnect Switch or Circuit Breaker R5 R6 BP0051 Figure 3 2 Wiring Connection Points Standard E Bypass Wall Mount 3 16 Input Disconnect and Bypass Configurations for ACH550 Chapter 3 Installation Instructions Standard E Bypass Figure 3 3 shows the Standard E Bypass floor mounted wiring Floor Mount connection points Refer to the ACH550 UH User s Manual for control connections to the drive Ground Lug ACH550 Bar Gia utpu Terminals Output erie Lug Terminals l i Tonya yaoi q A gt il Input Power Terminals E Bypass Control Board Terminals X2 Service Switch Optional ACH550 FI Control Board Terminals X1 A aa Bi oy RE Eto APA R7 R8 Disconnect Switch BP0053 or Circuit Breaker Figure 3 3 Wiring Connection Points Standard E Bypass Floor Mount Input Disconnect and Bypass Configurations for ACH550 3 17 Chapter 3 Installation Instructions Input Wiring Input Connections Vertical E Bypass Configurations Power wiring must conform to the requirements defined in Wiring Requirements on page 3 4 When connected to a 480 VAC power source the ACH550 with E Bypass with the circuit breaker option is suitable for use on a circuit capable of delivering not more than 20 000 RMS symmetrical amperes 14 000 RMS symmetrical amp
24. Drive Low Voltage AC Drives User s Manual Input Disconnect and Bypass Configurations for ACH550 Drives 1 550 Hp AA ED ED FADED ACH550 Drive Manuals GENERAL MANUALS ACH550 UH HVAC User s Manual 1 150 HP Safety Installation Start Up e Diagnostics e Maintenance Technical Data ACH550 U2 Installation Supplement 200 550 HP Safety Installation e Maintenance Technical Data ACH550 Input Disconnect and Bypass Supplement 1 550 HP Safety Installation Start Up e Maintenance Technical Data OPTION MANUALS Fieldbus Adapters I O Extension Modules etc manuals delivered with optional equipment Relay Output Extension Module typical title Installation Programming Fault tracing Technical data 2004 ABB Oy All Rights Reserved ii Input Disconnect and Bypass Configurations for ACH550 Safety Warning The ACH550 adjustable speed AC drive with bypass should ONLY be installed by a qualified electrician Warning Even when the motor is stopped dangerous voltage is present at the Power Circuit terminals U1 V1 W1 and U2 V2 W2 and depending on the frame size UDC and UDC or BRK and BRK Warning Dangerous voltage is present when input power is connected After disconnecting the supply wait at least 5 minutes to let the intermediate circuit capacitors discharge before removing the cover Warning Even when power is removed from
25. H550 with E Bypass in this manual If the E Bypass is stored before start up verify that the environmental conditions in the storage room meet the following conditions e Temperature between 40 F and 158 F 40 C and 70 C Relative humidity less than 95 percent No condensation The warranty covers defects in manufacturing The manufacturer carries no responsibility for damage incurred during transport or unpacking If any questions arise concerning the ACH550 with E Bypass please contact your Distributor or local ABB Drives Office Input Disconnect and Bypass Configurations for ACH550 Chapter 3 Installation Instructions Mechanical Installation Securely mount the ACH550 with E Bypass on a wall in a vertical position Use the four mounting notches at the top and bottom of the unit Before mounting the unit verify that the environmental conditions conform to the specifications listed in Pre Installation Planning in this chapter To ensure safe installation check that the surface of the mounting location is flat Attach the E Bypass enclosure at the mounting notches and tighten the bolts Dimensions and The dimensions and weights of the ACH550 E Bypass units are given Weights 7 in the following illustrations Input Disconnect and Bypass Configurations for ACH550 3 5 Chapter 3 Installation Instructions Vertical E Bypass UL type 1 R1 R4
26. M N A 5 Bus Bar holes 275 in lbs 275 in lbs 500 in lbs 13 32 bolts 350 ACH550 Bx 414A 4 R8 2 x 500MCM 2 x 500MCM 2 x 600MCM N A 5 Bus Bar holes 275 in lbs 275 in lbs 500 in lbs 13 32 bolts 400 ACH550 Bx 486A 4 R8 2x 500MCM 2x 500MCM 2 x 600MCM N A 5 Bus Bar holes 275 in lbs 275 in lbs 500 in lbs 13 32 bolts 3 14 Input Disconnect and Bypass Configurations for ACH550 Chapter 3 Installation Instructions Connection Points Vertical E Bypass Figure 3 1 shows the Vertical E Bypass wiring connection points Refer to the ACH550 UH User s Manual for control connections to the drive ACH550 7 T E Service Switch Optional E Bypass Control Board Terminals X2 BOT I Wi Output Terminals Service Switch Optional q AA LARA q Disconnect Switch or Circuit Breaker Input Power Cable Ulollolic Terminals Input L P GA lolo Ground liar Ground Lug s bo n n Output R4 Output Ground Terminals BP0054 Figure 3 1 Wiring Connection Points Vertical E Bypass Input Disconnect and Bypass Configurations for ACH550 3 15 Chapter 3 Installation Instructions Standard E Bypass Wall Mount Figure 3 2 shows the Standard E Bypass wall mounted wiring connection points Refer to the ACH550 UH User s Manual for control connections to the drive ACH550 Ground Lug s Output Terminals Input Power Terminals Output Terminals
27. N A 2 44 in Ibs 18 in lbs 120 in lbs 50 in Ibs 15 ACH550 Vx 046A 2 R3 3 4 2 0 N A 2 44 in Ibs 18 in lbs 120 in lbs 50 in Ibs 20 ACH550 Vx 059A 2 R3 3 4 2 0 N A 2 44 in Ibs 18 in lbs 120 in lbs 50 in Ibs 25 ACH550 Vx 075A 2 R4 3 1 0 2 0 N A 2 44 in lbs 55 in Ibs 120 in Ibs 50 in Ibs Input Disconnect and Bypass Configurations for ACH550 3 11 Chapter 3 Installation Instructions Table 3 4 380 480 Volt Vertical E Bypass Power Terminal Data 380 480 Volt Frame Maximum Wire Size Capacities of Power Terminals PASA i Circuit Disconnect Motor Terminal Overload Ground HE identification Bike Breaker Switch Block Relay Lugs 1 1 5 ACH550 Vx 03A3 4 R1 3 8 6 N A 4 44 in lbs 7 in lbs 13 in lbs 35 in lbs 2 ACH550 Vx 04A1 4 R1 3 8 6 N A 4 44 in lbs 7 in lbs 13 in lbs 35 in lbs 3 ACH550 Vx 06A9 4 R1 3 8 6 N A 4 44 in lbs 7 in lbs 13 in lbs 35 in lbs 5 ACH550 Vx 08A8 4 R1 3 8 6 N A 4 44 in lbs 7 in lbs 13 in lbs 35 in lbs 7 5 ACH550 Vx 012A 4 R1 3 8 6 N A 4 44 in lbs 7 in lbs 13 in lbs 35 in lbs 10 ACH550 Vx 015A 4 R2 3 8 6 N A 4 44 in lbs 7 in lbs 13 in lbs 35 in lbs 15 ACH550 Vx 023A 4 R2 3 8 6 N A 4 44 in lbs 7 in lbs 13 in lbs 35 in lbs 20 ACH550 Vx 031A 4 R3 3 4 2 0 N A 2 44 in lbs 18 in lbs 120 in lbs 50 in lbs 25 ACH550 Vx 038A 4 R3 3 4 2 0 N A 2 44 in lbs 18 in lbs 120 in lbs 50 in lbs 30 ACH550 Vx 044A 4 R4 3 4 2 0 N A
28. O4 Mode Override N C RO4 Mode Override N O RO4 Mode Override COM ROS Drive Fault N C ROS Drive Fault N O ROS Drive Fault COM RO6 Hand Off Auto N C ae RO6 Hand Off Auto N O RO6 Hand Off Auto COM N BILL 2 3 5 6 7 8 9 10 12 14 15 16 18 19 20 22 23 24 26 28 29 Bo B2 B3 Parameter Number Description Setting 1001 EXTERNAL 1 COMMANDS 1 DI1 1002 EXTERNAL 2 COMMANDS 1 DI1 1601 RUN ENABLE 2 DI2 1401 RELAY OUTPUT 1 7 STARTED 1403 RELAY OUTPUT 3 3 FAULT 1 Figure 2 6 Basic Control Connections for Externally Supplied 115 VAC Power 2 14 Input Disconnect and Bypass Configurations for ACH550 Chapter 2 Overview of ACH550 with E Bypass x 1 Terminals on the ACH550 Control Board ogas ACH550 Drive me Digialinpuit6 o o oooi i E 7 lala e w X2 Terminals on the Electronic Bypass Control Board Run Enable Safety Interlocks Override 1 Fireman s Override Override 2 Bypass Override 1 O Power Supply Not Used ACH550 24V Voltage Supply Start Stop 2 Run Enable 2 10 Safety Output 11 Drive RO1 N O 12 Drive RO1 Com 13 DriveRO3 N C 14 Drive ROS Com CIA Used ONLY with Internal 24VDC Supply a RO1 Bypass Fault N C Auto Start Damper End Switch Firestat Freezestat High Static Switch E Bypass
29. WG and X2 accepts one wire per terminal in wire sizes ranging from 26 AWG to 14 AWG Up to three wires per terminal can be connected with a proportional reduction in maximum wire size The control terminals should be tightened to 4 inch pounds of torque Figure 3 8 shows the basic control connections for use with the E Bypass macro These connections are described in the following paragraphs Analog inputs and outputs and additional digital input and relay output connections are available on Terminal Block X1 inside the ACH550 Note that the E Bypass control circuitry uses inputs and outputs DI1 DI2 RO1 and ROS These inputs and outputs are not available for any other purpose and must not be reconfigured Al1 Al2 AO1 AO2 DI3 DI4 DI5 DI6 and RO2 are available for use Refer to the ACH550 UH User s Manual for information about control connections on Terminal Block X1 When making connections to Terminal Block X1 be careful not to disturb the factory installed wiring between ACH550 terminal block X1 and E Bypass control board terminal X2 3 22 Input Disconnect and Bypass Configurations for ACH550 Chapter 3 Installation Instructions X1 Terminals on the ACH550 Control Board Terminal for Signal Cable Shield Analog Input Channel 1 1 2 3 Analog Input Common 4 Internal 24VDC Control 4 10 V 10 mA Reference Voltage for Potentiometer 115 Digital Input 3 116 Digital Input 4 Digital Input 5
30. ad The Drive Select LED should be illuminated 9 Press the HAND key on the ACH550 keypad Note that the bottom line of the display indicates HAND and RUN and a Right Arrow The Drive Run LED on the Bypass keypad should be illuminated 10 Press the UP arrow Note that the reference frequency indication in the top line of the display increases from 0 0 Hz The large actual output frequency indication in the center line of the display should also increase from 0 0 Hz 11 In the top line of the display the output current indication should indicate 0 0 A and the torque indication should indicate 0 12 Press the DOWN arrow until the frequency indications return to 0 0 Hz 13 Press the OFF key Note that the bottom line of the display indicates Off If the ACH550 Drive and E Bypass operate according to these steps disconnect and lock out power to prepare for the next test WARNING Wait at least five minutes after disconnecting power A from the drive before you attempt to service the drive Bus capacitors in the intermediate DC circuit must discharge before servicing the drive Check for zero volts at Terminals UC and UC Meter must be rated for 1000 VDC If the drive does not operate according to these steps refer to the ACH550 UH User s Manual Motor Connected tothe After successfully testing the drive with the motor disconnected E Bypass continue testing the drive as fo
31. and Bypass Configurations for ACH550 iii Safety Input Disconnect and Bypass Configurations for ACH550 Table of Contents Safety Use of Warnings and Notes 000 00 oo iii Table of Contents Chapter 1 Introduction How To Use This Manual 22 a 1 Intended Audience eee eee eee 1 Terminal Block Nomenclature a 1 Warranty and Liability Information 0 s notaria ised eed ed eed ee eae 2 Chapter 2 Overview of ACH550 with E Bypass General Information About the ACH550 0000 e eee eee 1 Detailed Description of Operation 0 a 5 Typical Applications and Configurations cece eee ees 12 Chapter 3 Installation Instructions Pr installation Planning ii nawa vice eae ob eee PRA SS ee Re ee Mae 1 Mechanical Installation 0 0000 eee 5 Electrical Installation 0 0 0 000 eee 11 Bypass Control Board Relay Contact Inputs AA aaa 24 Bypass Control Board Relay Contact Outputs 25 Chapter 4 Start up Procedure Safety PreCaulIONS ss cindy sda A REARS Yee OF BAe kab bla thoes 1 Installation INSPOCUOM lt lt ds ars sie dat pale Sens ise idea Sd NG nG Hees Biers ee 1 E Bypass Jumper Switch and Pot Settings 2 Macros and Parameter Settings ccc eee eee 6 Keypad Control Tests 2 a seat naa Saw Vara Sew Sed waved Ween Hace 6 Index Input Disconnect and Bypass Config
32. are used for setting the PID reference and receiving the transducer feedback actual signal Refer to the ACH550 UH User s Manual for additional information The Output Frequency analog output of the ACH550 provides a 4 to 20 mA signal proportional to the drive output frequency or motor speed Typical Applications The following figures show the connections for several typical and Configurations applications 2 12 Input Disconnect and Bypass Configurations for ACH550 Internally Supplied 24 VDC Drive Run Bypass Run 23 N O NB RO4 Mode Override N C Mag RO4 Mode Override N O Chapter 2 Overview of ACH550 with E Bypass Terminals on the ACH550 Control Board Digital Input 4 Digital Input 5 Digital Input 6 4 Override 1 Fireman s Override gt 5 Override 2 Bypass Override 1 0 Power Supply Not Used ACH550 24V Voltage Supply Start Stop 2 Run Enable 2 Safety Output Pre Wired to ACH550 terminal block X1 Do NOT Disturb Drive RO1 N O Hi to ahead lerminal bloc Drive RO1 Com Do NOT Disturb Common Used ONLY with Internal 24VDC Supply Rot tymsFat no 7 Rosson sean 7 28 j E Rosskerarenrais wo ACH550 Drive E Bypass Jumper J3 Internal External 24VDC 110 VAC Powered Powered vo VO E BP0076 Parameter Number Descriptio
33. ast equal to the line voltage but not exceeding 1000 V The insulation resistance must be greater than 1 MQ 4 Measure the insulation resistance of the motor wiring between the phases and between each phase and ground The insulation resistance must be greater than 1 MQ 5 Perform the Keypad Control Test before connecting the motor Refer to Keypad Control Tests on page 4 6 The rapid rate of voltage changes causes capacitive coupling between motor wiring and the grounded metallic conduit This phenomenon can cause substantially higher measured current than actual motor current which may result in nuisance overcurrent trips or ground faults Table 3 7 lists the maximum motor cable length based on capacitive coupling It may also be necessary to consider motor insulation requirements related to drive output dv dt Table 3 7 Maximum Recommended Motor Wire Lengths Maximum Cable Length Frame Size Feet Meters R1 330 100 R2 R3 R4 660 200 R5 R6 R7 R8 990 300 Connect the motor cables to the terminals at the bottom of the bypass section as shown in Figure 3 6 Also see Figure 3 1 Connect the motor grounding conductor to the ground lug near the motor cable terminal block connection point 5l o 54 Output Power Cables Gnd BP0044 Figure 3 6 Output Power Wiring Vertical E Bypass 3 20 Input Disconnect and Bypass Configurations for ACH550 Chapter 3 Installation Instructions Ou
34. check y AG Ame NN BM Ng tes a AA ar ww 3 20 output contactor setting 4 5 maximum length aaa 3 20 motor parameter K SCUINGS aa mahaL tae ar 4 6 motor protection key overload lays ances Kng Aka AG BE 2 5 AUO a a GANANG a a PANA 2 7 reset Key aa ANA iol aoe 2 7 aypan a E E as A short circuit and ground fault 2 3 o i BG AA AA 3 4 OSa rene na Logan a E Pina A AT 2 7 LEBEL aa AG a ii 2 7 N keypad nomenclature terminal block 1 1 bypass control a 2 6 description of operation 2 6 O keypad control tests 4 6 off key 2 7 operator control overview 2 5 Er AD tei PREP KK GEN 2 9 L operator control detailed description of operation 2 5 LED OVEIVIEW a 2 5 AULO 22 7 Na Ried landed tied wee ve a ed ee 2 7 option automatic transfer 2 7 circuit breaker is a kina etal ites SA 2 3 bypass fault aaa 2 6 fieldbus adapter module 2 5 bypass run BA NPA cues Sapa ah ta 27 outputs bypass selected aaa 2 6 ACH550 AA 2 11 drive Faull makaaasa 2 7 relay GOMACIS 4 5 as ld 2 10 drive rUNNINg PANAPAAN mentees aa 2 6 overload drive selected 0 0 AA 2 6 A Sere keen fab 4 2 Bang an KA Sasa ses ea as AA aka A So relay reset key saa dees et kman ws 2 7 cc J relay motor protection 2 5 ready Pia NGANGA KAKA 26 trip current pot adjustment 4 5 liability information
35. d connect all power motor and control wiring It also explains the initial inspection procedures Pre Installation Before beginning installation review the installation instructions in this Planning chapter and make sure that the installation requirements can be met The following topics should be considered in pre installation planning Environment e Heat Dissipation Requirements Mounting Area e Wiring Requirements Environment The ACH550 with E Bypass must be installed in a heated indoor controlled environment that is relatively free of moisture and conductive contaminants such as condensation carbon dust and the like The maximum ambient temperature allowed is 104 F 40 C for an ACH550 in the E Bypass enclosure The rating is based on a variable torque load with the load current lower than or equal to the continuous maximum load current Input Disconnect and Bypass Configurations for ACH550 3 1 Chapter 3 Installation Instructions Heat Dissipation ACH550 drives are self cooled The cooling air entering the drive must Requirements be clean and free from corrosive materials The tables below give the heat dissipated into the hot air exhausted from the drives If the drives are installed in a confined space the heat must be removed from the area by ventilation or air conditioning equipment Table 3 1 208 240 Volt Heat Dissipation for ACH550 E Bypass Units 20
36. d be suitable for the initial tests described below If the motor s rating is not 208 V or 480 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 The only macro that provides the proper configuration settings by default is the E Bypass macro If any other macro will be used the selected macro can be set after completing the initial tests When using any other macro the following parameter values must be set or portions of the E Bypass will not function properly Parameter 1001 must be set to D11 Parameter 1002 must be set to D11 Parameter 1601 must be set to DI2 e Parameter 1401 RO1 must be set to Started Parameter 1403 RO3 must be set to Fault 1 Refer to the ACH550 UH User s Manual for additional information After setting the Start up Data parameters test and become familiar with the operation of the ACH550 Drive with E Bypass without the motor connected as follows 1 Disconnect and lock out power to the E Bypass unit wait at least five minutes after disconnecting power 2 Disconnect the motor from the E Bypass unit 3 Apply power to the E 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 bypass keypad the Ready LED and
37. dure Output Contactor In the unlikely event of failure in the bypass control electronics the Control user can engage the drive output contactor without the control electronics by moving jumper J2 to the position as shown in Figure 4 1 When the jumper is in the Output Contactor position the Drive contactor is energized and the Bypass contactor is de energized The contactors and therefore the system are not controlled by the bypass electronics when jumper J2 is in the Output Contactor position The system is incapable of Bypass or Override operation in this configuration Overload Trip The overload protection trip current must be adjusted to the motor Current Adjustment nameplate current using the P1 adjustment potentiometer located in Potentiometer the lower right hand area of the bypass control board as shown in Figure 4 1 Table 4 4 shows the trip currents for the various frame sizes for potentiometer settings of 10 to 100 Table 4 4 Overload Trip Current Potentiometer Settings Overload Trip Current Values in Amps Aa Switch Code A B C D E F G H 10 1 2 25 3 8 75 10 4 15 5 30 0 48 8 20 2 4 5 0 7 6 15 0 20 8 31 0 60 0 97 6 30 3 6 7 5 11 4 22 5 31 2 46 5 90 0 146 4 40 4 8 10 0 15 2 30 0 41 6 62 0 120 0 195 2 50 6 0 12 5 19 0 37 5 52 0 77 5 150 0 244 0 60 7 2 15 0 22 8 45 0 62 4 93 0 180 0 292 8 70 8 4 17 5 26 6 52 5 72 8 108 5 210 0 341 6 80 9 6 20 0 30 4 60 0 83 2 124 0 240
38. e BC E Bypass with circuit breakers BD E Bypass with disconnect switches PC Drive with circuit breakers PD Drive with disconnect switches VC Vertical E Bypass with circuit breakers VD Vertical E Bypass with disconnect switches Output current rating See Ratings chart for details Voltage rating 2 208 240 VAC 4 380 480 VAC Enclosure protection class No specification IP 21 UL type 1 B056 IP 54 UL type 12 Line reactor E213 Line Reactor Service Switch F267 Service switch Figure 2 1 Type Code Description for the ACH550 E Bypass Input Disconnect and Bypass Configurations for ACH550 2 1 Chapter 2 Overview of ACH550 with E Bypass E Bypass Features and Functions ACH550 Drive ACH CP B Control Panel Bypass Keypad Giling Handle for Disconnect Switch or Circuit Breaker E Bypass The ACH550 with E Bypass is an ACH550 AC adjustable frequency drive in an integrated UL type 1 or UL type 12 package with a bypass motor starter The ACH550 with E Bypass provides a disconnect switch or circuit breaker with door mounted operator padlockable in the OFF position a bypass starter motor overload protection a local operator keypad with indicating lights and provisions for external control connections An optional drive service switch drive input disconnect may also be provided Figure 2 2 shows the front view of the ACH550 E Bypass configurations and identifies
39. eady LED Drive Bypass Enable LED Selected LEDs Drive Bypass Drive and Bypass Select Keys Running Stopped Faulted LEDs MOTOR TRANS Bypass Fi AUTOMATIC FER Automatic LED Auto LED Bypass Fault LED Hand LED Reset Key ON Hand Key Auto Key OFF Key Figure 2 4 Bypass Control Keypad The Ready LED is illuminated when the disconnect switch or circuit breaker is closed and power is applied to the ACH550 and bypass The Enable LED is illuminated under the following conditions 1 Both the Safety Interlock and Run Enable contacts are closed 2 The Safety Interlock contact is closed with no Start command present The Enable LED flashes if the Run Enable contact is open and when the Safety Interlock contact is closed and a Start command is present The Enable LED is not illuminated when the Safety Interlock contact is open The Drive Run LED is illuminated green when the ACH550 drive is running The Bypass Fault LED indicates the status of the bypass overload underload protection The LED is red when the bypass has tripped on an overload underload or the bypass control board has faulted The Drive Selected LED is illuminated green when the ACH550 drive has been selected as the power source for the motor The Bypass Selected LED is illuminated green when the E Bypass has been selected as the power source for the motor 2 6 Input Disconnect and Bypass Configurations for ACH550 Chapter 2 Overview of ACH550 w
40. edure E Bypass Jumper Figure 4 1 shows the locations of the jumpers DIP switch and Switch and Pot potentiometers on the E Bypass control board The functions and Settings settings of these items are kanaba in the solemn paragraphs Jumper J3 sm lo Ol DIP SWITCH oo gu Mia ON Internal External e BYPASS Mano Ll fd alba ad lb fa 12345678 24VDC 110 VAC Se30 Powered Powered e VO VO Jumper J2 da oo Co op Normal Output Setting Contactor Potentiometers P2 and P1 O P2 Underload Potentiometer P1 Overload Potentiometer BP0091 Figure 4 1 E Bypass Control Board DIP Switch Settings The DIP switch is used to configure the bypass overload protection select the Mode Override relay s function and enable the automatic bypass feature Match the DIP Switch Codes to your drive model using Table 4 1 or Table 4 2 and Table 4 3 4 2 Input Disconnect and Bypass Configurations for ACH550 Chapter 4 Start up Procedure Table 4 1 208 240 Volt Codes for Overload Trip Current DIP Switch 208 240 Volt ENEN Frame Switch HP Identification Size Code 1 ACH550 xx 04A6 2 R1 A 1 5 ACH550 xx 06A6 2 R1 ACH550 xx 07A5 2 R1 ACH550 xx 012A 2 R1 ACH550 xx 017A 2 R1 7 5 ACH550 xx 024A 2 R2 10 ACH550 xx 031A 2 R3 15 ACH550 xx 046A 2 R3 20 ACH550 xx 059A 2 R3 25 ACH550 xx 075A 2 R4 30 ACH550 xx 088A 2 R4 40 ACH550 xx 114A 2 R4 50 ACH550 xx 143A 2 R6 60 ACH550 xx 178A 2 R6 75 ACH550 xx 221A 2 R6 100 ACH55
41. elay description 2 10 S O bee ee R 0 iii start up instructions 4 1 safety interlock contact wiring 3 24 output descripti0N 2 11 safety interlock relay description 2 2 0 0 eee eee 2 10 start start up safety 2 0 05 4 1 start stop contact wiring 3 24 start stop relay description 2 10 starting on application of power 2 9 switch see DIP switch system run contact wiring 3 25 system started contact wiring 3 25 T terminal block nomenclature 1 1 terminals max wire size 0 3 11 TOQUE a a KNANG KA aa eae KGG 3 11 tests keypad control aaa 4 6 motor disconnected 4 6 transfer LED eee eae 2 7 TYPO COG i sont wot alos bees EER ee 2 1 U underload trip current pot adjustment 4 5 underload pot JOC ATOM is 4 ares ata tets a Ba Aaah NG DAN GAAN 4 2 Index W warning automatic start Up Aa 0 iii dangerous voltages 0 iii E Ka PATAKAN KNANG a Se 0 iii not field repairable 0 iii parallel control connections 0 iii qualified installer 0 iii warranty information 000 1 2 weight s tc a e APA 3 5 wiring bypass fault contact 3 26 cable entries 2222055 3 11 connector loca
42. eres for the 3 and 5 Hp models When connected to a 240 VAC power source the ACH550 with E Bypass with the circuit breaker option is suitable for use on a circuit capable of delivering not more than 50 000 RMS symmetrical amperes WARNING 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 Make sure that power factor correction capacitors are not connected between the drive and the motor Connect the input power to the terminals at the bottom of the disconnect switch or circuit breaker as shown in Figure 3 4 Also see Figure 3 1 Connect the equipment grounding conductor to the ground lug near the input power connection point AR pl A A Input Power Cables Ground BP0044 Figure 3 4 Input Power Wiring Vertical E Bypass Input Disconnect and Bypass Configurations for ACH550 Input Connections Standard E Bypass Configurations Output Wiring A Chapter 3 Installation Instructions 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 Figure 3 5 shows the connection points for
43. erlock input is closed Run Enable permissives such as damper end switches are normally closed dry contacts connected in series between bypass terminals X2 2 and X2 15 When any of these contacts opens the motor will stop and the System Run relay will de energize whether in DRIVE or BYPASS Safety Interlocks such as Freeze Fire and Smoke protection are normally closed dry contacts connected in series between bypass terminals X2 3 and X2 15 When any of these contacts opens the motor will stop and the System Started 8 System Run relays will de energize whether in DRIVE or BYPASS 3 24 Input Disconnect and Bypass Configurations for ACH550 Fireman s Override Override 1 Contact Bypass Override Override 2 Contact Bypass Control Board Relay Contact Outputs Drive Fault System Run System Started Chapter 3 Installation Instructions Fireman s Override is designed for Run to Destruction operation See Fireman s Override Mode on page 2 8 for a description of this mode Connect the Fireman s Override contact between bypass terminals X2 4 and X2 15 If the Bypass Override Override 2 input contact is closed the system is forced to the Bypass Override mode See Bypass Override Mode on page 2 8 for a description of this mode Connect the Bypass Override contact between bypass terminals X2 5 and X2 15 Caution There are pre wired connections on bypass terminals X2 7 through X2 9 and X2 11 thro
44. es Drive Mode Under normal conditions the system is in the Drive mode The ACH550 drive provides power to the motor and controls its speed The source of the drive s start stop and speed commands is determined by the Auto or Hand mode selection of the drive s keypad Commands come from the control terminals when the Auto mode has been selected or from the drive keypad when the Hand mode has been selected The user can normally switch to the Drive mode by pressing the Drive key on the bypass keypad Bypass Mode In the Bypass mode the motor is powered by AC line power through the bypass contactor The source of the bypass start stop commands is determined by the Auto or Hand mode selection of the bypass keypad Commands come from the control terminals when the Auto mode has been selected or from the bypass keypad when the Hand mode has been selected The user can normally switch to the Bypass mode by Input Disconnect and Bypass Configurations for ACH550 2 7 Chapter 2 Overview of ACH550 with E Bypass Fireman s Override Mode Bypass Override Mode Hand Mode Auto Mode pressing the Bypass key on the bypass keypad Alternative methods of bypass control called Overrides are also available Refer to the following descriptions of the Override modes In the Fireman s Override Override 1 mode the motor is powered by AC line power through the bypass contactor The source of the start command is internal and unaffected by external
45. he bypass is Off In the Auto mode the bypass start stop command comes from the Start Stop input terminal on the bypass control board Digital Output Safety Interlock The Safety Interlock output is active when the Safety Interlock Input contact is closed The Safety Interlock output is available for customer connection and routing through the ACH550 drive User s can select from a variety of optional communication protocols to monitor the Safety Interlock status through the ACH550 digital inputs Refer to the ACH550 UH User s Manual and the appropriate communications manual for additional information about monitoring ACH550 digital inputs ACH550 Drive Some of the ACH550 inputs and outputs are pre wired to the bypass Inputs and Outputs control board and not available for external use The inputs and outputs that are not pre wired are available for external use by connecting directly to the terminals in the ACH550 The pre wired and available inputs and outputs are described below Refer to the ACH550 UH User s Manual for additional information about the inputs and outputs See also Chapter 3 Installation Instructions for additional information and connection instructions Input Disconnect and Bypass Configurations for ACH550 2 11 Chapter 2 Overview of ACH550 with E Bypass The ACH550 has two relay outputs that are pre wired to the bypass control board These two relay outputs are used to provide the System Drive Started and Dr
46. iew of ACH550 with E Bypass Terminals on the ACH550 Control Board 4 10 10 mA Reference Voltage for Potentiometer Digital Input 3 16 Digital Input 4 Digital Input 5 Digital Input 6 X2 Terminals on the Electronic Bypass Control Board Start Stop Run Enable Safety Interlocks Override 1 Fireman s Override Override 2 Bypass Override I O Power Supply Not Used ACH550 24V Voltage Supply Start Stop 2 9A Salety Output Drive RO1 N O Drive RO1 Com Pre Wired to ACH550 terminal block X1 Do NOT Disturb Pre Wired to ACH550 terminal block X1 Do NOT Disturb RO1 Bypass Fault N C RO1 Bypass Fault N O RO1 Bypass Fault COM Bn Fault COM ROG Hand Off Auto N O 7 Hand Off Auto NO IO Hand Off Auto COM ACH550 Drive E Bypass Jumper J3 Internal External 24VDC 110 VAC Powered Powered vo VO OU BP0072 Parameter Number Description Setting 1001 EXTERNAL 1 COMMANDS 1 DI1 1002 EXTERNAL 2 COMMANDS 1 DI1 1601 RUN ENABLE 2 DI2 1401 RELAY OUTPUT 1 7 STARTED 1403 RELAY OUTPUT 3 3 FAULT 1 Figure 2 9 Customer Control Connection Worksheet Input Disconnect and Bypass Configurations for ACH550 2 17 Chapter 2 Overview of ACH550 with E Bypass 2 18 Input Disconnect and Bypass Configurations for ACH550 Chapter 3 Installation Instructions This chapter explains how to install the ACH550 with E Bypass an
47. inals UC and UC inside the ACH550 drive unit The testing meter must be rated for 1000 VDC WARNING When the ACH550 with E Bypass is connected to the A 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 E Bypass is connected to the line Disconnect and lock out power to the drive before servicing the drive Failure to disconnect power may cause death or serious injury Installation Inspection Inspect the mechanical and electrical installation of the ACH550 with E Bypass for compliance with your local electrical installation regulations and codes Note Do not connect the motor wires before proceeding with the Keypad Control Test with Motor Disconnected Refer to Keypad Control Tests in this chapter After installation inspect the following e ACH550 with E Bypass and motor grounding Supply and motor wire size and connections e Control cable connections wire shield grounding and control cable location away from the power wires Quantity and quality of cooling air for the ACH550 with E Bypass Connect the ACH550 with E Bypass to supply voltage Check that the voltage between L L L L and L L is Vy 10 Refer to Chapter 3 Installation Instructions in this manual for detailed installation instructions and requirements Input Disconnect and Bypass Configurations for ACH550 4 1 Chapter 4 Start up Proc
48. ings Refer to the ACH550 UH User s Manual for programming instructions Input Disconnect and Bypass Configurations for ACH550 4 9 Chapter 4 Start up Procedure 4 10 Input Disconnect and Bypass Configurations for ACH550 A ATON cis 3 2 analog inputs J1 setting 3 24 applications blank form 2 17 damper actuator control 2 15 external 115 VAC 0 200 2 14 HVAC hand auto 000 0 3 23 outputs routed through drive 2 16 separate drive amp bypass run commands 2 13 typical diagrams 2 2 12 audience intended 1 1 auto key 2 7 auto ED tx naani ad PLA NGA 2 7 auto mode ooo 2 8 automatic bypass aa 2 9 automatic transfer LED 2 7 B bypass automatic bypass 2 9 contactors description 2 5 control board description 2 9 drive bypass mode transfers 2 9 fault contact wiring 3 26 faut EED coca KAKAIN ade 2 6 jumpering over e bypass description 2 9 MODE i cata haan e es wand ale adie 2 7 PUNE ED Ha E eee pe 2 7 selectkey 2 0 cee ee 2 7 selected LED 2 4 2 6 C circuit breaker door interlocked oooo oo 2 3 SOMOS cua as 4 5 configurations typical diagraMS oo ooooooo oo 2 12 contactor bypass descripti0N oo ooo o 2 5 jumper descripti
49. ith E Bypass Drive FaultLED The Drive Fault LED is illuminated red when the motor or drive protection functions have shut down the ACH550 Bypass Run LED The Bypass Run LED is illuminated green when the motor is running in bypass Automatic Transfer LED The Automatic Transfer LED is illuminated green to indicate the system has automatically transferred to Bypass after a Drive fault The Automatic Transfer LED flashes green to indicate the system has been placed in an Override condition Auto LED The Auto LED is illuminated green when the Auto Start contact has been selected as the means for starting and stopping the motor in the bypass mode Hand LED The Hand LED is illuminated green when the motor has been started manually in the bypass mode Drive Select Key The Drive Select key selects the ACH550 drive as the power source for the motor Bypass Select Key The Bypass Select key selects the bypass as the power source for the motor Reset Key The Reset key resets the bypass fault It may take several minutes before the bypass can be reset after an overload trip Auto Key The Auto key selects the Auto Start contact 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 OFF Key The OFF key can be used to manually stop the motor if the motor has been running on bypass power Operating Mod
50. ive Fault outputs that are described above Two of the ACH550 s digital inputs the Auto Mode Start Stop input and the Run Enable input are also pre wired to the bypass control board These two digital inputs are coordinated with the Start Stop and Run Enable inputs that control the motor in both the Drive and Bypass modes of operation A Caution The E Bypass will not work properly if the Drive relay outputs RO1 and RO3 or the Drive digital inputs DI1 and DI2 are reassigned by changing ACH550 configuration settings The only macro that by default provides the proper configuration settings is the E Bypass macro If any other macro will be used see Macros and Parameter Settings on page 4 6 Four of the digital inputs of the ACH550 are available for routing E Bypass outputs digital and relay through the ACH550 drive Users can select from a variety of communication protocols to monitor the E Bypass status through the ACH550 digital inputs The digital inputs of the ACH550 are also available for selecting constant speeds or providing Speed Increase and Speed Decrease inputs The functions of these inputs is determined by the ACH550 macro selection Refer to the ACH550 UH User s Manual for additional information The ACH550 Auto Mode External Reference input is an analog input that sets the operating speed when the ACH550 HVAC macro is selected and the drive is in the Auto mode When the HVAC PID Control macro is selected analog inputs
51. llows 1 Disconnect and lock out power to the E Bypass unit 2 Connect the motor to the output terminals Input Disconnect and Bypass Configurations for ACH550 4 7 Chapter 4 Start up Procedure A CAUTION If the Fireman s Override Override 1 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 Bypass Override Override 2 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 tests with the motor disconnected 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 bypass to Drive mode and the drive to OFF 3 Apply powe
52. n Setting 1001 EXTERNAL 1 COMMANDS 1 DI1 1002 EXTERNAL 2 COMMANDS 1 DI1 1601 RUN ENABLE 2 DI2 1401 RELAY OUTPUT 1 7 STARTED 1403 RELAY OUTPUT 3 3 FAULT 1 Figure 2 5 Basic Control Connections for Separate Drive Run 4 Bypass Run Commands Input Disconnect and Bypass Configurations for ACH550 2 13 Chapter 2 Overview of ACH550 with E Bypass X1 Terminals on the ACH550 Control Board 1 Terminal for Signal Cable Shield 2 Analog Input Channel 1 3 3 Analog Input Common 10V 10 mA Reference Voltage for Potentiometer 15 Digital Input3 16 Digital Inputs ACH550 Drive 118 Digital Input 6 X2 Terminals on the Electronic Bypass Control Board Msas J E Bypass 2 Run Enable Safety Interlocks Override 1 Fireman s Override Override 2 Bypass Override 1 O Power Supply Not Used ACH550 24V Voltage Supply Pre Wired to ACH550 terminal block X1 Jumper J3 Start Stop 2 Do NOT Disturb Run Enable 2 aa lo ol Safety Output O o un 1 Drive RO1 N O Mat iar chat wr 590 Internal External Drive RO1 Com Do NOT Disturb 24VDC 110 VAC 3 Drive RO3 N C Powered Powered Drive RO3 Com vo vo Common Used ONLY with Internal 24VDC Supply E o RO1 Bypass Fault N C RO1 Bypass Fault N O RO1 Bypass Fault COM RO2 System Run N C RO2 System Run N O RO2 System Run COM RO3 System Started N C RO3 System Started N O RO3 System Started COM R
53. ndard in the drive 2 4 Input Disconnect and Bypass Configurations for ACH550 Bypass Contactors Motor Overload Protection A Operator Control E Bypass Options Detailed Description of Operation Chapter 2 Overview of ACH550 with E Bypass The bypass circuit available with the ACH550 E Bypass includes two contactors One contactor is the bypass contactor 2M that can be used to manually connect the motor directly to the incoming power line in the event that the ACH550 is out of service The other contactor is the ACH550 output contactor 1M for R1 through R4 and 3M for R5 through R8 that disconnects the ACH550 from the motor when the motor is operating in the Bypass mode The drive output contactor and the bypass contactor are interlocked to prevent back feeding applying line voltage to the ACH550 output terminals In the Drive mode motor overload protection is provided by the ACH550 In the Bypass mode motor overload protection is provided by the bypass control board WARNING If power is applied and the switches and contacts in the control circuit are commanding the motor to run the motor will start as soon as the overload protection is reset Use caution when resetting the overload protection to make sure it is safe to start the motor The ACH CP B Control Panel is a keypad with an LCD unit that provides status indication and operator control for the ACH550 drive In normal operation with the E B
54. nt that a component fails in the drive s power circuitry Since fast acting fuses are provided the branch circuit protection will not clear when the drive input fuses blow If the drive input fuses blow the motor can be switched to Bypass without replacing fuses or resetting a circuit breaker The drive s electronic protection circuitry is designed to clear drive output short circuits and ground faults without blowing the drive input fuses Drive input fuse specifications are listed in Table 2 1 and Table 2 2 Table 2 1 208 240 Volt Drive Input Fuse Rating 208 240 Volt Drive Input Fuse Ratings Frame HP Identification Size EAN e ei 1 ACH550 xx 04A6 2 R1 15 KTK R 15 1 5 ACH550 xx 06A6 2 R1 15 KTK R 15 ACH550 xx 07A5 2 R1 15 KTK R 15 ACH550 xx 012A 2 R1 15 KTK R 15 ACH550 xx 017A 2 R1 30 KTK R 30 7 5 ACH550 xx 024A 2 R2 30 KTK R 30 10 ACH550 xx 031A 2 R3 40 JJS 40 15 ACH550 xx 046A 2 R3 80 JJS 80 20 ACH550 xx 059A 2 R3 80 JJS 80 25 ACH550 xx 075A 2 R4 100 JJS 100 30 ACH550 xx 088A 2 R4 125 JJS 125 40 ACH550 xx 114A 2 R4 150 JJS 150 50 ACH550 xx 143A 2 R6 200 JJS 200 60 ACH550 xx 178A 2 R6 225 JJS 225 75 ACH550 xx 221A 2 R6 350 JJS 350 100 ACH550 xx 248A 2 R6 350 JJS 350 Input Disconnect and Bypass Configurations for ACH550 2 3 Chapter 2 Overview of ACH550 with E Bypass Table 2 2 380 480 Volt Drive Input Fuse Rating
55. od of manufacturer s warranty is 12 months after installation and not more than 18 months from the date of delivery Extended warranty may be available with certified start up Contact your local distributor for details Your local ABB Drives company or distributor may have a different warranty period which is specified in their sales terms conditions and warranty terms If you have any questions concerning your ACH550 with E Bypass contact your local distributor or ABB Drives office The technical data and specifications are valid at the time of printing ABB reserves the right to subsequent alterations without notice Input Disconnect and Bypass Configurations for ACH550 Chapter 2 Overview of ACH550 with E Bypass This chapter explains the numbers and letters on the control nameplate describes the E Bypass features and provides a detailed description of operation It also describes the E Bypass hardware components and input output connections General Information About the ACH550 Control Identification The ACH550 with E Bypass is a packaging arrangement that provides space for mounting factory installed options as designated by the type code characters following a plus sign after the ACH550 base unit type code Locate the Control Nameplate on the E Bypass and use Figure 2 1 to verify the model number ACH550 BC 08A8 4 AC HVAC Drive 550 product series Construction region specific UH Base driv
56. ode X2 Terminals on the Electronic Bypass Control Board SariSiop 2 Run Enable Safety Interlocks Override 1 Fireman s Override Override 2 Bypass Override I O Power Supply Not Used ACH550 24V Voltage Supply Pre Wired to ACH550 terminal block X1 8 Start Stop 2 Do NOT Disturb 9 Run Enable 2 110 Safety Output Drive RO1 N O Pre Wired to ACH550 terminal block X1 12 Drive RO1 Com Do NOT Disturb Drive RO3 N C Drive RO3 Com 14 15 Common Used ONLY with Internal 24VDC Supply 16 E Bypass N 4 Jumper J3 Internal External 24VDC 110 VAC Powered Powered vo VO E Internally Supplied 24 VDC RO1 Bypass Fault N C RO1 Bypass Fault N O RO1 Bypass Fault COM 118 5 19 po o N N 23 RO3 System Started N O 24 RO3 System Started COM 25 25 27 28 2 Bo FRes Reraronrai n AJ N N a ND N N 7 BP0073 Parameter Number Description Setting 1001 EXTERNAL 1 COMMANDS 1 DI1 1002 EXTERNAL 2 COMMANDS 1 DI1 1201 CONST SPEED SEL 0 NOT SEL 1601 RUN ENABLE 2 DI2 1401 RELAY OUTPUT 1 7 STARTED 1403 RELAY OUTPUT 3 3 FAULT 1 Figure 2 8 Basic Control Connections for Routing Outputs Through the ACH550 2 16 Input Disconnect and Bypass Configurations for ACH550 Chapter 2 Overv
57. ology e No experience or training in installing operating or servicing the ACH550 with E Bypass Basic knowledge of standard electrical wiring practices electronic components and electrical schematic symbols The audience for this manual will install and start up the ACH550 with E Bypass If you do not possess the skills listed above please refer the installation to a qualified installer Terminal Block This manual expresses specific terminal blocks and connections as a Nomenclature letter a number a colon and another number The letter and number to the left of the colon identify the terminal block for example X1 The number to the right of the colon identifies the terminal number for example 9 In this manual a terminal connection numbered 9 located on a terminal block named X1 is identified as X1 9 Input Disconnect and Bypass Configurations for ACH550 1 1 Chapter 1 Introduction Warranty and Liability Information The warranty for your ABB E Bypass covers manufacturing defects The manufacturer carries no responsibility for damage due to transport or unpacking In no event and under no circumstances shall the manufacturer be liable for damages and failures due to misuse abuse improper installation or abnormal conditions of temperature dust or corrosives or failures due to operation above rated capacities Nor shall the manufacturer ever be liable for consequential and incidental damages The peri
58. on 2 9 contactor jumper setting 4 5 control identificati0N 2 1 control panel ACH550 000 2 5 control wiring 3 21 cooling requirements a 3 2 D description of operati0N o 2 5 digital output safety interlock description 2 11 dimensions eee eee eeee 3 5 Index DIP switch location 4 2 SOUINOS 00000 a dina a Se ma nk 4 2 disconnect switch a 2 3 drive fault contact wiring 3 25 faUt LED Xa a NAAT NAN 2 7 fault relay description 2 10 LED to AA PAASA 2 6 MOE NAA pake Beata NGA UG Ie aed 2 7 selectkey 2 eee ee 2 7 selected LED aa 2 6 E enable LED iis ci maka pan DADAANAN averted 2 6 environment 00 eee eee 3 1 F fireman s override contact wiring 3 25 mode operation 0 2 8 relay description 2 10 fuses drive 240 v input fuse rating table 2 3 drive 480 v input fuse rating table 2 4 drive input fuseS 0004 2 3 H hand keya pananaga kka BREAD NINA NEN aie 2 7 hand LED cess pi BALANG HA ee ead ner DURAN 2 7 hand mode ooo 2 8 hand off auto contact wiring 3 26 heat dissipation 0 0 aa 3 2 heat sink cleaning oooooooooooo 3 3 l identification control type code 2 1 input power circuit b
59. or circuits Input Disconnect and Bypass Configurations for ACH550 3 25 Chapter 3 Installation Instructions Mode Override Form C contacts of a Mode Override relay are provided at bypass terminals X2 25 NC X2 26 NO and X2 27 COM The Mode Override relay is a configurable relay The function of the relay is selectable between Mode and Override operation If the Mode Override relay is configured for Mode operation Default the relay is energized when the Bypass mode is selected and de energized when the Drive mode is selected If the Mode Override relay is configured for Override operation the relay is energized when the Override mode is selected and de energized in all other modes See E Bypass Jumper Switch and Pot Settings on page 4 2 Bypass Fault Form C contacts of a Bypass Fault relay are provided at bypass terminals X2 16 NC X2 17 NO and X2 18 COM The Bypass Fault relay is energized when the bypass is energized and not faulted and the underload overload protection is reset Hand Off Auto Form C contacts of a Hand Off Auto relay are provided at bypass terminals X2 31 NC X2 32 NO and X2 33 COM The Hand Off Auto relay is energized when the bypass is in the Auto mode and de energized in the Hand mode and when the bypass is Off Relay Contact Ratings The relay contact ratings are Maximum Voltage 30 VDC 125 VAC Maximum Switching Current 8 A at 24 VDC 0 4 A at 125 VAC Maximum Continuous Current 2 Arms
60. r to the E Bypass unit 4 Press the Hand key on the ACH550 control panel CAUTION Check motor rotation direction as soon as the motor begins to move If motor does not rotate in the correct direction shut down the drive disconnect and lock 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 5 Slowly increase the output frequency by pressing the UP ARROW key Verify that motor speed varies as frequency varies 6 Increase the speed to 60 Hz or the highest safe operating speed 7 Measure the output current in all three phases The current should be balanced and should not exceed the motor or drive rating 8 Press the OFF key on the ACH550 control panel The motor should stop Input Disconnect and Bypass Configurations for ACH550 Chapter 4 Start up Procedure A CAUTION Check the motor rotation direction in bypass Press the OFF key and then the Bypass Select key on the bypass keypad Press the Hand key and then quickly press the OFF key to bump the motor If the motor turns in the wrong direction swap any two input power leads at the disconnect switch Do not swap the motor leads 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 Bypass is ready to use with preset or modified macro sett
61. reaker 2222005 2 3 description 2 3 disconnect switch 000 2 3 drive input fuses aaa 2 3 inputs ACH550 drive 0a 2 11 relay contacts ce era raati EE DIRETA 2 10 inspection of installation o ooooooo oo 4 1 UNDAGKNO arrera i e E ee eee 3 4 Input Disconnect and Bypass Configurations for ACH550 Index installation mechanical installation 3 5 clearance space requirements 3 4 mode electrical oooooooooooooo 3 11 MO AA AA 2 8 environment occ 3 1 bypass mode 20 0 0 e eee ee aes 2 7 inspectionof 0s 4 1 No NAA eee ee PD ee A 2 7 JOC ATOM AA 3 4 drive bypass mode transfers 2 9 mounting unit 3 5 fireman s override operation 2 8 planning reesi KENA hak eae eked 3 1 handi cnt the a ints AA 2 8 installation planning PIA AA AA 2 9 COOL ici Sees DAG hg 3 1 operating mode descriptions 2 7 environment 0 02 eee eee eee 3 1 override 1 description 2 8 insulation check override 2 description 2 8 motor cable aaan naunau naaa 3 20 override 2 operation 2 8 mode override J contact wiring o o o o ooooo 3 26 motor saan input type 0 cece eee ee 3 24 rotation directi0N 4 8 contactor control description 2 9 motor cable e bypass J2 J3 location ADA PAR 4 2 insulation
62. rride input contact is switched from closed to open the system switches to the Drive mode and can be controlled using the Drive and Bypass keys The exception to this is when the Fireman s Override Override 1 input contact is closed in which case the system remains in Fireman s Override mode When the system is in the Bypass mode the operator can manually start the motor by pressing the Hand key The motor will run and the Hand LED will be illuminated green In order to run the motor the Safety Interlock and Run Enable contacts must be closed green Enable LED and any bypass fault must be reset In the Auto mode the bypass start stop command comes from the Start Stop input terminal on the bypass control board The Auto mode is selected by pressing the Auto key on the bypass keypad The Auto LED is illuminated green when the bypass is in the Auto mode If the system is in the Bypass mode the motor will run across the line if the Auto mode is selected the Start Stop Safety Interlock and Run Enable contacts are closed and any bypass fault is reset Input Disconnect and Bypass Configurations for ACH550 Off Mode Bypass Drive Mode Transfers Starting the Motor on Application of Power Automatic Transfer Option Output Contactor Control Bypass Control Board Inputs and Outputs Chapter 2 Overview of ACH550 with E Bypass If the motor is running in the Bypass mode the operator can manually stop the motor by pressing the OFF
63. rt before the motor is transferred to line power The Automatic Transfer option is selected by setting a configuration switch on the bypass control board See E Bypass Jumper Switch and Pot Settings on page 4 2 The Automatic Transfer LED is illuminated green once the system has automatically transferred to bypass operation In the unlikely event of failure in the bypass control electronics the user can engage the drive output contactor without the control electronics by using a configuration jumper on the bypass control board See Output Contactor Control on page 4 5 The E Bypass control board has five relay contact digital inputs six relay outputs and one digital output that are available for connection to external control circuits The internal 24VDC supply is normally used in conjunction with the relay contact inputs Use of an external 110 VAC power supply requires re configuring Jumper J3 Care should be taken when using external supply voltages so as not to damage the drive and bypass electronics The input and output functions are described below Refer to Chapter 3 Installation Instructions for additional information and connection instructions Input Disconnect and Bypass Configurations for ACH550 2 9 Chapter 2 Overview of ACH550 with E Bypass Relay Contact Inputs Start Stop Run Enable Safety Interlock Fireman s Override Override 1 Bypass Override Override 2 Relay Contact Outputs Drive Faul
64. ructions Analog Input A Bypass Control Board Relay Contact Inputs Start Stop Input Contact Run Enable Input Contacts Safety Interlock Input Contacts One of the available analog inputs is usually used with the E Bypass macro The customer s external Auto Speed Reference is connected to ACH550 terminals X1 2 and X1 3 The analog inputs can accept a voltage signal 0 10 VDC ora current signal 0 20 mA Switch J1 located on the ACH550 control board J1 is used for both Al1 and Al2 determines the signal type Set J1 to either the voltage or current position according to the type of external signal that will be connected Figure 3 9 shows switch positions To locate J1 refer to the ACH550 UH User s Manual or for R7 and R8 refer to Figure 3 3 Q Alt in Voltage Position 2 gt Al2 in Current Position o gt El Mm z Al1 amp Al2 in Voltage Position O gt 2 O O N Al1 8 Al2 in Current Position N Figure 3 9 ACH550 J1 Position Examples Caution There are pre wired connections on bypass terminals X2 7 through X2 9 and X2 11 through X2 14 Do not disturb these connections when adding external wiring connections To start the ACH550 by dry contact maintained connect the contact between bypass terminals X2 1 and X2 15 Closing this contact will start the system when the drive or bypass is in the Auto mode provided the Safety Int
65. t System Run The Start Stop input is connected to a normally open contact that starts and stops the system When the E Bypass is in the Drive mode and the ACH550 is in the Auto mode the Start Stop input contact controls the motor by starting and stopping the ACH550 drive When the E Bypass is in the Bypass mode and the Auto LED is illuminated green the Start Stop input contact controls the motor by controlling the bypass contactor The Run Enable input is connected to the series combination of any external normally closed permissive contacts such as damper end switches that must be closed to allow the motor to run If any of these external contacts are open while a Start command is present the Enable LED will flash and the motor is prevented from running The Safety Interlock input is connected to the series combination of any external normally closed interlock contacts such as Firestat Freezestat and high static pressure switches switches that must be closed to allow the motor to run If any of these external contacts are open the Enable LED is not illuminated the drive output contactor bypass contactor and System Started relay are de energized preventing the motor from running The Fireman s Override Override 1 input can be connected to an external contact that is closed to select the Fireman s Override mode See Fireman s Override Mode on page 2 8 for a description of this mode The Bypass Override Override 2
66. the major components ACH550 Drive ACH CP B Bypass Keypad Operating Handle for Disconnect Switch or Circuit Breaker E Bypass E Bypass BPoogo Figure 2 2 E Bypass Configurations Exterior View The following is a typical power diagram Disconnect Switch Drive with E Bypass or Circuit Breaker Bypass Control ACH550 3 Phase Ba InputPower 3 Drive Service Switch _ ___ gt Bypass Optional SSS SSS SS SS SS a Contacts Figure 2 3 Typical Power Diagram for E Bypass 2 2 Input Disconnect and Bypass Configurations for ACH550 Input Power Door Interlocked Disconnect Switch Door Interlocked Circuit Breaker Drive Input Fuses Chapter 2 Overview of ACH550 with E Bypass Input power is connected to the ACH550 with E Bypass through a door interlocked disconnect switch or circuit breaker The door interlocked disconnect switch is not fused The branch circuit that provides power to the ACH550 with E Bypass must include appropriate motor branch circuit protective devices to provide short circuit and ground fault protection for the motor in the bypass mode The door interlocked circuit breaker is an optional alternative to the door interlocked disconnect switch The circuit breaker provides short circuit and ground fault protection for the motor in the bypass mode Drive input fuses are provided to disconnect the drive from power in the eve
67. tions diagrams 3 15 ee AA 3 21 drive fault contact 3 25 fireman s override contact 3 25 hand off auto contact 3 26 input power 2 0 eee eee 3 18 mode override contact 3 26 MOOK AA AAKALA al Coates 3 19 OQUIPUL 0 000 002 ma Fuma gra a eee a 3 19 override 2 contact 3 25 PIACICES serei at beg Pei bates e 3 26 relay contactS 0000005 3 24 requirements power cable 3 4 run enable contact 3 24 safety interlock contact 3 24 start stop contact 3 24 system run contact 3 25 system started contact 3 25 terminal sizes 22000055 3 11 Input Disconnect and Bypass Configurations for ACH550 1 3 Ab ED ED FADED 3AUA0000006289 REV A EN EFFECTIVE APR 2 2004 SUPERSEDES NONE ABB Oy AC Drives P O Box 184 FIN 00381 HELSINKI FINLAND Telephone 358 10 22 11 Telefax 358 10 22 22681 Internet http www abb com ABB Inc Automation Technologies Drives amp Machines 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 800 HELP 365 Telefax 262 780 5135
68. tput Connections Connect the motor cables to the output terminal block as shown in Standard E Bypass Figure 3 7 Also see Figure 3 3 for R7 or R8 The motor grounding Configurations conductor can be connected to the ground lug near the terminal block Output Power Cable Ja an a O _ A LA USOUSO WVVVVVVYY BP0043 BP0041 Standard Configuration R5 R6 Standard Configuration R1 R4 Figure 3 7 Output Power Wiring Standard E Bypass Wall Mounted Control Wiring The control wiring includes connections to an analog speed command signal and a start stop relay contact for controlling the motor in the AUTO mode There may also be connections to external run enable interlock contacts and a connection from the Motor Run contact to an external status indicating circuit For a detailed description of the control circuit functions refer to the section entitled Detailed Description of Operation on page 2 5 Input Disconnect and Bypass Configurations for ACH550 3 21 Chapter 3 Installation Instructions Connect Control Wires Basic Connections Additional Connections Connect control wiring to terminal block X1 on the ACH550 control board and to terminal block X2 on the E Bypass control board Figure 3 1 Figure 3 2 and Figure 3 3 show the location of X2 for various configurations Refer to the ACH550 UH User s Manual for the location of X1 X1 accepts one wire per terminal in wire sizes ranging from 22 AWG to 16 A
69. trol panel and Bypass control panel visible and the disconnect accessible Enclosure dimension drawings are presented in this chapter For proper cooling each unit must have two inches 50 mm of clear space on each side If units are to be mounted next to each other there must be a total of four inches 100 mm from unit to unit The units cannot be mounted one above the other The ACH550 with E Bypass is designed for use on a three phase system Four wires three phase wires plus a ground wire are required for the input wiring Input and output conductors and branch circuit protection must be sized to local codes All field power wiring shall be copper rated for 60 C if rated for less than 100 amps or 75 C if rated 100 amps or more At least three separate metallic conduits are required one for input power one for output power to the motor and one for control signals The External Speed Reference signal must be wired using a shielded twisted pair cable Refer to Electrical Installation on page 3 11 for detailed wiring information As you unpack the ACH550 with E Bypass check for any signs of damage and verify that the delivery is complete by examining the contents for items such as the user s manual keypad etc In the event of damage please contact the shipping company or the supplier Locate the drive nameplate and confirm that the E Bypass is configured to the order specifications Refer to Chapter 2 Overview of AC
70. ugh X2 14 Do not disturb these connections when adding external wiring connections Form C contacts of a Drive Fault relay are provided at bypass terminals X2 28 NC X2 29 NO and X2 30 COM The drive fault relay is energized when the drive is energized and not faulted Form C contacts of a System Run relay are provided at bypass terminals X2 19 NC X2 20 NO and X2 21 COM The System Run relay is energized when the E Bypass System is running The System Run relay provides an output when the motor is running whether powered by the ACH550 drive or the bypass Separate normally open Drive Run and Bypass Run contacts can be created by using the System Run relay with the Mode Override relay This is done by using X2 21 COM and connecting X2 20 NO to X2 27 COM X2 25 NC becomes the Drive Run contact and X2 26 NO becomes the Bypass Run contact This configuration provides outputs that are closed when the motor is running To do this the Mode Override relay must be configured for Mode relay operation See E Bypass Jumper Switch and Pot Settings on page 4 2 Form C contacts of a System Started relay are provided at bypass terminals X2 22 NC X2 23 NO and X2 24 COM Three conditions must be met in order for the relay to energize 1 a Start command must be present 2 the Safety Interlock input contact must be closed and 3 there can be no fault present in the system The System Started relay is ideal for use in damper actuat
71. urations for ACH550 v Table of Contents Vi Input Disconnect and Bypass Configurations for ACH550 Chapter 1 Introduction This chapter explains the purpose and contents of this manual intended audience and conventions used in this manual How To Use This The purpose of this manual is to provide you with the information Manual necessary to install and start up your ACH550 with E Bypass This manual also explains features and functions of the E Bypass and requirements such as external drive control connections wiring cable sizes and cable routing The ACH550 with E Bypass user documentation also includes the ACH550 UH User s Manual Both the ACH550 UH User s Manual and this E Bypass manual are required to properly install and operate the ACH550 with E Bypass Chapter 1 Introduction the chapter you are reading now introduces you to this User s Manual for the ACH550 with E Bypass Chapter 2 Overview of ACH550 with E Bypass explains drive identification and the available features and functions and provides a detailed description of operation Chapter 3 Installation Instructions covers E Bypass pre installation planning initial inspection mounting and electrical wiring Chapter 4 Start up Procedure includes safety precautions configuration settings installation inspection and initial start up tests Intended Audience The audience for this manual has e Minimal knowledge of ABB product names and termin
72. ypass the ACH550 should be placed in the Auto mode by pressing the Auto key on the ACH CP B Control Panel Refer to the ACH550 UH User s Manual for additional information on the ACH CP B Control Panel and other aspects of ACH550 operation The E Bypass has a separate keypad that is used for selecting the Drive or Bypass mode and for manually starting and stopping the motor in the Bypass mode The bypass keypad has LEDs that indicate the status of both the bypass and the drive The bypass keypad is described in detail in the Detailed Description of Operation In addition to the line reactor and circuit breaker options described above the E Bypass has space for factory installation of a drive service switch drive input disconnect The drive service switch provides a superior implementation and functional equivalent of a three contactor bypass arrangement The following paragraphs provide a detailed description of the various features and functions of the E Bypass Circuit diagrams for this product are shipped with the unit Input Disconnect and Bypass Configurations for ACH550 2 5 Chapter 2 Overview of ACH550 with E Bypass Bypass Control Keypad Ready LED Enable LED Drive Run LED Bypass Fault LED Drive Selected LED Bypass Selected LED Figure 2 4 shows the bypass control keypad and identifies the keys and LED indicating lights The functions of the various keys and LEDs are described in the following paragraphs R

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