EN / ACS550-01/U1 User`s Manual Rev G - Hydro-Temp
Contents
1. m m m M Rm TR mM a a RA ao m er sz ssi sai sas ais res ass 775 905 so osa 00467918 xls C 1 ACS550 01 290A 4 1119 mm 44 1 in 2 UL type 12 not available for ACS550 01 290A 4 Weight The following table lists typical maximum weights for each frame size Variations within each frame size due to components associated with voltage current ratings and options are minor waiwwei Jos aloo roe e as m ea or m Jos fis Psa ruk ype 12 80 178 110 243 170 ars 260 573 426 330 000 r007 00467918 xls C 1 ACS550 x1 246A 4 IP21 UL type 1 70 kg 154 Ib ACS550 01 290A 4 IP21 UL type 1 80 kg 176 Ib 2 ACS550 x1 246A 4 IP54 UL type 12 80 kg 176 Ib ACS550 01 290A 4 IP54 90 kg 198 Ib UL type 12 not available Technical data 300 ACS550 01 U1 User s Manual Degrees of protection Available enclosures P21 UL type 1 enclosure The site must be free of airborne dust corrosive gases or liquids and conductive contaminants such as condensation carbon dust and metallic particles e P54 UL type 12 enclosure This enclosure provides protection from airborne dust and light sprays or splashing water from all directions Note UL type 12 enclosure is not available for tyoe ACS2. Check that the operating time of the fuse is below 0 5 seconds The operating time depends on the fuse type the supply network impedance as well as the cross sectional area material and length of the supply cable In case the 0 5 seconds operating time is exceeded with the gG or T fuses ultra rapid aR fuses will in most cases reduce the operating time to an acceptable level Fuses 208 240 V drives ACS550 x1 Input Caen Input power mains fuses see below IEC 60269 gG A UL Class T A Bussmann type 06A6 2 Es Hes e E E E pre im mo fas fuso an E 00467918 xls C Fuses 380 480 V drives ACS550 x1 Input unen Input power mains fuses see below IEC 60269 gG A UL Class T A Bussmann type 08A8 4 8 8 012A 4 11 9 Ws h Hmki m 15 p00 Ha p p wee rosea e t0 oC osa 8 8 uso m e e MEE 072A 4 90 JJS 90 Technical data ACS550 01 U1 User s Manual 211 ACS550 x1 Input current Input power mains fuses see below A IEC 60269 gG A UL Class T A Bussmann type 087A 4 125 125 JJS 125 z 8 a z BEEN 00467918 xls C Fuses 500 600 V drives ACS550 U1 Input current Input power mains fuses see below IEC 60269 gG A UL Class T A Bussmann type mE pee ae Dus CO Wexs ise 9 8 1458 Wem 8 a uid corms peo rons OR CO E 00467918 xls C Emergency stop devices The overall design of the installation must inclu
3. Faulty motor motor cables or connections 2002 OVERVOLTAGE Overvoltage controller is active Check for and correct Static or transient overvoltages in the input power supply e Insufficient deceleration time parameters 2203 DECELER TIME 1 and 2206 DECELER TIME 2 2003 UNDERVOLTAGE o controller is active Check for and correct Undervoltage on mains 2004 DIR LOCK The change in direction being attempted is not allowed Either Do not attempt to change the direction of motor rotation or Change parameter 1003 DIRECTION to allow direction change if reverse operation is safe 2005 IO COMM Fieldbus communication has timed out Check for and correct Fault setup 3018 COMM FAULT FUNC and 3019 COMM FAULT TIME Communication settings Group 51 EXT COMM MODULE or Group 53 EFB PROTOCOL as appropriate Poor connections and or noise on line 2006 Al1 LOSS Analog input 1 is lost or value is less than the minimum setting Check Input source and connections Parameter that sets the minimum 3021 Parameter that sets the alarm fault operation 3001 2007 AIZ LOSS Analog input 2 is lost or value is less than the minimum setting Check Input source and connections Parameter that sets the minimum 3022 Parameter that sets the alarm fault operation 3001 2008 PANEL LOSS Panel communication is lost and either Drive is in local control mode the control panel displays LOC or Drive is in remote control mode
4. Thermal relay fault if used nternal fault 35 OUTP WIRING Possible power wiring error detected When the drive is not running it monitors for an improper connection between the drive input power and the drive output Check for and correct Proper input wiring line voltage is NOT connected to drive output The fault can be erroneously declared if the input power is a delta grounded system and motor cable capacitance is large This fault can be disabled using parameter 3023 WIRING FAULT Diagnostics 256 ACS550 01 U1 User s Manual Fault name in fs panel Description and recommended corrective action INCOMPATIBLE The drive cannot use the software SW Internal fault The loaded software is not compatible with the drive Call support representative 37 CB OVERTEMP Drive control board is overheated The fault trip limit is 88 C Check for and correct Excessive ambient temperature e Fan failure Obstructions in the air flow Not for drives with an OMIO control board 38 USER LOAD Condition defined by parameter 3701 USER LOAD C MODE has been valid CURVE longer than the time defined by 3703 USER LOAD C TIME 101 SYSTEM ERROR Error internal to the drive Contact your local ABB representative and report 199 the error number 201 SYSTEM ERROR Error in the system Contact your local ABB representative and report the 299 error number UNKNOWN Wrong type of panel i e panel that support
5. 5 Attach the ring lugs to the drive Crimping tool YAV6C L2 MY 29 3 CCL 6 38 ILC 10 Bundy YA4C L4BOX MY29 3 disco o CCL 4 38 MT 25 Bun vacio wes 2 Bumdy YA1C L4BOX MY29 3 2 i CCL 1 0 38 MT 25 Technical data 262 ACS550 01 U1 User s Manual Wire size mem kcmil dus j AWG Thomas Betts Screw on terminal lugs Use the following procedure to attach cables if screw on terminal lugs are supplied and the cable size is 95 mm 3 0 AWG or larger X60003 1 Attach the supplied screw on lugs to the drive end of the cables 2 Attach screw on lugs to the drive Technical data ACS550 01 U1 User s Manual 283 Motor connections WARNING Never connect line power to the drive output terminals U2 V2 or W2 Line voltage applied to the output can result in permanent damage to the drive If frequent bypassing is required use mechanically interlocked switches or contactors WARNING Do not connect any motor with a nominal voltage less than one half of the drive s nominal input voltage WARNING Disconnect the drive before conducting any voltage tolerance Hi Pot test or insulation resistance Megger test on the motor or motor cables Do not conduct these tests on the drive Motor connection specifications Selectable See the availability in the table below Do 4 2 4and 8 kHz 208 240 V All types Frame sizes R1 R4 in scalar control mode Switching frequency 380 48
6. Analog cables Recommendations for analog signal runs Use double shielded twisted pair cable e Use one individually shielded pair for each signal e Do not use a common return for different analog signals Digital cables Recommendation for digital signal runs A double shielded cable is the best alternative but single shielded twisted multi pair cable is also usable Control panel cable If the control panel is connected to the drive with a cable use only Category 5 Patch ethernet cable The maximum length that is tested to meet EMC specifications is 3 m 9 8 ft Longer cables are susceptible to electromagnetic noise and must be user tested to verify that EMC requirements are met Where long runs are required especially for runs longer than about 12 m 40 ft use a RS232 RS485 converter at each end and run RS485 cable Drive s control connection terminals The following table provides specifications for the drive s control terminals mw AWG Nm bt mo pe m M ua 1 Values given for solid wires For stranded wires the maximum size is 1 mm Efficiency Approximately 9896 at nominal power level Technical data ACS550 01 U1 User s Manual 295 Cooling Cooling specifications Internal fan flow direction from bottom to top Free space above and below the ACS550 drive 200 mm 8 in Requirement Free space is not required on the drive s sides ACS550 drives can be mounted side by side Air flo
7. Assistant Control Panels that have the clock function available and enabled The battery keeps the clock operating in memory during power interruptions The expected life for the battery is greater than ten years To remove the battery use a coin to rotate the battery holder on the back of the control panel Replace the battery with type CR2032 Note The battery is NOT required for any control panel or drive function except the clock Maintenance ACS550 01 U1 User s Manual 211 Technical data Ratings By type designation the table below provides ratings for the ACS550 adjustable speed AC drive including e EC ratings e NEMA ratings shaded columns e frame size Ratings 208 240 V drives Abbreviated column headers are described in section Symbols on page 273 Type X Nomalue Heavydutyuse eras i mie see below Lue pe pe poo pe pe E ana CE 1s ps or n n oms ps fps e e i m R oma pe p B 5 5 po Ro om fer p p que po p Rmo 5 m oa a2 8 5 or i E z x HW SOAR ama pe e o po ro o mne ma p m m e w w om fole s s n 00467918 xls C Technical data 274 ACS550 01 U1 User s Manual Derating The load capacity current and power decreases for certain situations as defined below In such situations where full motor power is required oversize the drive so that the derated value provides sufficient capacity For example if your application requires 15 4 A
8. REM and is parameterized to accept start stop direction or reference from the control panel To correct check Communication lines and connections Parameter 3002 PANEL COMM ERR Parameters in Group 10 START STOP DIR and Group 11 REFERENCE SELECT if drive operation is REM Diagnostics 262 ACS550 01 U1 User s Manual Alarm i 2009 DEVICE OVERTEMP Drive heatsink is hot This alarm warns that a DEVICE OVERTEMP fault may be near R1 R4 100 C 212 F R5 R6 110 C 230 F Check for and correct Fan failure Obstructions in the air flow Dirt or dust coating on the heat sink Excessive ambient temperature Excessive motor load 2010 MOTOR TEMP Motor is hot based on either the drive s estimate or on temperature feedback This alarm warns that a MOT OVERTEMP fault trip may be near Check e Check for overloaded motor Adjust the parameters used for the estimate 3005 3009 Check the temperature sensors and Group 35 MOTOR TEMP MEAS 2001 PRESERVED Not used 000000 used z icc ANE STALL Loo a is operating in the stall region This alarm warns that a MOTOR STALL fault trip may be near 2013 AUTORESET This alarm warns that the drive is about to perform an automatic fault Note 1 reset which may start the motor To control automatic reset use Group 31 AUTOMATIC RESET 2014 AUTOCHANGE This alarm warns that the PFC autochange function is active Note 1 Tocontrol PFC u
9. conduit run to the drive enclosure Use a separate conduit run for motor cables also separate input power and control cables Use a separate conduit run for each drive Armored cable When using armored cable Use six conductor 3 phases and 3 grounds type MC continuous corrugated aluminium armor cable with symmetrical grounds Armored motor cable can share a cable tray with input power cables but not with control cables e Shielded cable For shielded cable details see section Motor cable requirements for CE amp C Tick compliance on page 287 Grounding oee section Ground connections on page 279 For CE compliant installations and installations where EMC emissions must be minimized see section Effective motor cable shields on page 288 Drive s motor connection terminals The drive s motor and input power terminals have the same specifications See section Drive s power connection terminals on page 280 Technical data ACS550 01 U1 User s Manual 287 Motor cable requirements for CE amp C Tick compliance The requirements in this section apply for CE or C Tick compliance Minimum requirement CE amp C Tick The motor cable must be a symmetrical three conductor cable with a concentric PE conductor or a four conductor cable with a concentric shield however a symmetrical constructed PE conductor is always recommended The following figure shows the minimum requirement for the motor cable shield
10. corner of the mid point of a delta delta leg Single phase Three phase grounded at an Variac without end point solidly grounded neutral The EMC filter capacitors make an internal ground connection that reduces electro magnetic emission Where EMC electro magnetic compatibility is a concern and the system is symmetrically grounded the EMC filter may be connected For reference the diagram on the right illustrates a symmetrically grounded TN system TN S system Technical data 280 ACS550 01 U1 User s Manual IT systems WARNING Do not attempt to install or remove the EMC filter screws EM1 EM3 F1 or F2 while power is applied to the drive s input terminals For IT systems an ungrounded power system or a high resistance grounded over 30 ohm power system e Disconnect the ground connection to the internal EMC filter see section Disconnecting the internal EMC filter on page 23 e Where EMC requirements exist check for excessive emission propagated to neighboring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt use a supply transformer with static screening between the primary and secondary windings Do NOT install an external RFI EMC filter Using an EMC filter grounds the input power through the filter capacitors which could be dangerous and could damage the drive Drive s power connection terminals Technical data The following
11. fio Ws 2o io wm o ju us ms ws oro qme perma e ju mo soo Jo 099 Ji 00 ao ss so No Mas 530 1 Resistor time constant specification must be 85 seconds ACS550 01 U1 User s Manual 291 380 480 V drives Resistance Resistor minimum continuous power rating a a Deceleration to zero rating P rcont Type AM Continuous ON 01 U1 see below Three phase supply voltage 380 480 V ama 470 wo eo io me feo iso Fea ms eo mana us feo 1 Resistor time constant specification must be gt 85 seconds 500 600 V drives Prcont P Continuous ON A o r60 un 60 s ON gt 60s ON see below Three phase supply voltage 500 600 V oro we eo je us pe p 4 nues ss 60 ur ps sr fea ma oeme zu 60 zs vs fe wwe Nm Hos we 60 wa ws oas fiso 59s 467 8 onas wo 6 far wr vs mor xe orae 5 6 ess i2 wee aus r8 1 Resistor time constant specification must be 85 seconds WARNING Never use a brake resistor with a resistance below the minimum value specified for the particular drive The drive and the internal chopper are not able to handle the overcurrent caused by the low resistance Symbols Ryin Minimum allowed resistance of the braking resistor Rmax Maximum resistance allowed if maximum braking torque is necessary Technical data 292 ACS550 01 U1 User s Manual Px Duty cycle based resistor power rating in decelera
12. for example MCMK Draka NK Cables Insulation jacket Copper wire shield Inner insulation Cable core LE Recommendation for conductor layout The following figure compares conductor layout features in motor cables Recommended CE amp C Tick Allowed CE amp C Tick Symmetrical shielded cable three phase A separate PE conductor is required if the conductors and a concentric or otherwise conductivity of the cable shield is 5096 of the symmetrically constructed PE conductor and a conductivity of the phase conductor shield Shield PE Shield conductor and shield a5 e PE Shield Not allowed for motor cables CE amp C Tick A four conductor system three phase conductors and a protective conductor without a shield Allowed for motor cables with phase P conductor cross section up to 10 mm BNO Technical data 288 ACS550 01 U1 User s Manual Effective motor cable shields The general rule for cable shield effectiveness is the better and tighter the cable s shield the lower the radiated emission level The following figure shows an example of an effective construction for example Olflex Servo FD 780 CP Lappkabel or MCCMK NK Cables Insulation jacket Inner insulator L2 Braided metallic shield L3 EN 61800 3 compliant motor cables The most efficient EMC filtering can be achieved by following these rules Motor cables must have an effective shield as described in section Effect
13. kVA or motor nominal power Check for the following e 1 1 lt 9906 MOTOR NOM CURR 9905 MOTOR NOM VOLT 1 73 Py lt 3 0 where Py 1000 9909 MOTOR NOM POWER if units are kW or Py 746 9909 MOTOR NOM POWER if units are hp e g in US 1006 PAR EXT RO Parameter values are inconsistent Check for the following Extension relay module not connected and 1410 1412 RELAY OUTPUTS 4 6 have non zero values 1007 PAR FIELDBUS Parameter values are inconsistent Check for and correct MISSING A parameter is set for fieldbus control e g 1001 EXT1 COMMANDS 10 COMM but 9802 COMM PROT SEL 0 1008 PAR PFC MODE Parameter values are inconsistent 9904 MOTOR CTRL MODE must be 3 SCALAR FREQ when 8123 PFC ENABLE is activated 1009 PAR PCU 1 Parameter values for power control are inconsistent Improper motor nominal frequency or speed Check for both of the following e 1 lt 60 9907 MOTOR NOM FREQ 9908 MOTOR NOM SPEED lt 16 e 0 8 lt 9908 MOTOR NOM SPEED 120 9907 MOTOR NOM FREQ Motor Poles lt 0 992 1010 RESERVED Not used 1011 1012 PAR PFC IO 1 IO configuration is not complete not enough relays are parameterized to PFC Or a conflict exists between Group 14 RELAY OUTPUTS parameter 8117 NR OF AUX MOT and parameter 8118 AUTOCHNG INTERV 1013 PAR PFC IO 2 IO configuration is not complete the actual number of PFC motors parameter 8127 MOTORS does not match the PFC
14. particles Class 1S2 levels Cooling air must be clean free from T tati IEC 721 3 3 corrosive materials and free from bos E electrically conductive dust Noconductive dust allowed Chemical gases Class 3C2 Chemical gases Class 2C2 Solid particles Class 3S2 Solid particles Class 252 The following table lists the standard stress testing that the ACS550 passes Dog Without shipping package Inside shipping package Mechanical conditions In accordance In accordance with ISTA 1A and 1B Sinusoidal with IEC 60721 3 3 Class 3M4 specifications vibration e 2 9 Hz 3 0 mm a 12 in 9 200 Hz 10 m s 33 ft s Not allowed In accordance with IEC 68 2 29 max 100 m s 330 ft s 11ms Not allowed 76 cm 30 in frame size R1 61cm 24 in frame size R2 Free fall 46 cm 18 in frame size R3 31 cm 12 in frame size R4 25 cm 10 in frame size R5 15 cm 6 in frame size R6 Material specifications PC ABS 2 5 mm color NCS 1502 Y or NCS 7000 N Hot dip zinc coated steel sheet 1 5 2 mm thickness of coating 20 micrometers If the surface is painted the total thickness of the coating zinc and paint is 80 100 micrometers Cast aluminium AlSi Extruded aluminium AlSi Drive enclosure Corrugated board expanded polystyrene plywood raw wood heat dried Package Package wrap consists of one or more of the following PE LD plastic wrap PP or steel bands Technical data 302 Technical data ACS5
15. result in erroneous error reports during non running tests To disable response to fault monitoring when the drive is not running use parameter 3023 WIRING FAULT To disable response to all ground fault monitoring use parameter 3017 EARTH FAULT Note Disabling earth fault ground fault may void the warranty 18 THERM FAIL Internal fault The thermistor measuring the internal temperature of the drive is open or shorted Contact your local ABB representative 19 OPEX LINK Internal fault A communication related problem has been detected on the fiber optic link between the control and OINT boards Contact your local ABB representative 20 OPEX PWR Internal fault Exceptionally low voltage detected on the OINT power supply Contact your local ABB representative 21 CURR MEAS Internal fault Current measurement is out of range Contact your local ABB representative 22 SUPPLY PHASE Ripple voltage in the DC link is too high Check for and correct Missing mains phase Blown fuse ACS550 01 U1 User s Manual 257 Fault Fault name in Description and recommended corrective action code panel 23 ENCODER ERR The drive is not detecting a valid encoder signal Check for and correct Encoder presence and proper connection reverse wired channel A connected to terminal of channel B or vice versa loose connection or short circuit Voltage logic levels are outside of the specified range A working and properly conn
16. 0 V All types Frame sizes R1 R4 except ACS550 01 097A 4 in scalar control mode 500 600 V All types Frame sizes R2 R4 in scalar control mode Cable temperature rating 90 C 194 F rating minimum Maximum motor cable See section Motor cable lengths on page 283 length Motor cable lengths Maximum motor cable lengths for 400 V and 600 V drives are given in the sections below In multimotor systems the calculated sum of all motor cable lengths must not exceed the maximum motor cable length given in the appropriate table below Technical data 284 ACS550 01 U1 User s Manual Motor cable length for 400 V drives Technical data The table below shows the maximum motor cable lengths for 400 V drives with different switching frequencies Examples for using the table are also given Maximum cable length for 400 V drives EMC limits Operational limits Second environment First environment category C3 category C2 mith u 1 4 kHz 8 12 kHz filters Frame 1 4 kHz 8 12 kHz o El El E E o E o R 800 oo 300 so 300 980 300 S80 300 80 300 so 00 330 00 330 50 460 Ls sm Gm oo jo o so 700 a Bm o an zs rn EXC Ci L3 Ed Ed kd Ej Ed o SHO ow wo oO a GO rn er nr oa e ser es o meee gt vo sn woo ov on ses sro See the new terms in section IEC EN 61800 3 2004 Definitions on page 305 2 12 kHz switching frequency is not available Nottested Sine filters further exte
17. 50 01 U1 User s Manual Material specifications The drive contains raw materials that should be recycled to preserve energy and natural resources The package materials are environmentally compatible and recyclable All metal parts can be recycled The plastic parts can either be recycled or burned under controlled circumstances according to local regulations Most recyclable parts are marked with recycling marks Disposal If recycling is not feasible all parts excluding electrolytic capacitors and printed circuit boards can be landfilled The DC capacitors contain electrolyte and if the drive is not provided with the ROHS marking the printed circuit boards contain lead both of which are classified as hazardous waste within the EU They must be removed and handled according to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local ABB distributor ACS550 01 U1 User s Manual 303 Applicable standards Drive compliance with the following standards is identified by the standard marks on the type designation label Mark Applicable standards EN 50178 1997 Electronic equipment for use in power installations IEC EN 60204 1 2005 Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing an emergency stop device a
18. 550 01 290A 4 Compared to the IP21 UL type 1 enclosure the IP54 UL type 12 enclosure has e the same internal plastic shell as the IP21 enclosure a different outer plastic cover e an additional internal fan to improve cooling larger dimensions the same rating does not require a derating Ambient conditions Technical data The following table lists the ACS550 environmental requirements Ambient environment requirements Installation site Storage and transportation in the protective package 0 1000 m 0 3 300 ft Altitude 1000 2000 m 3 300 6 600 ft if Py and y derated 1 every 100 m above 1000 m 300 ft above 3 300 ft Min 15 C 5 F no frost allowed 40 70 C 40 158 F Max fsw 1 or 4 40 C 104 F 50 C 122 F if Py and ly derated to 90 Ambient Max fsw 8 40 C 104 F if Py and ly derated to 80 Max fsw 12 30 C 86 F if Py and Ix derated to 65 to 50 for 600 V R4 frame sizes that is for ACS550 U1 032A 6 ACS550 U1 062A 6 Relative 5 95 no condensation allowed humidity temperature ACS550 01 U1 User s Manual 301 Materials Ambient environment requirements Installation site Storage and transportation in the protective package No conductive dust allowed Storage The ACS550 should be installed in No conductive dust allowed clean air according to enclosure Chemical gases Class 1C2 Contamination eeseiqcen em Solid
19. ACS550 User s Manual ACS550 01 Drives 0 75 160 kW ACS550 U1 Drives 1 200 hp ACS550 01 U1 User s Manual 253 Diagnostics WARNING Do not attempt any measurement parts replacement or other service procedure not described in this manual Such action will void the warranty may endanger correct operation and increase downtime and expense WARNING All electrical installation and maintenance work described in this chapter should only be undertaken by qualified service personnel The safety instructions in chapter Safety on page 5 must be followed Diagnostic displays The drive detects error situations and reports them using the green and red LED on the body of the drive e the status LED on the control panel if an Assistant Control Panel is attached to the drive e the control panel display if a control panel is attached to the drive e the Fault Word and Alarm Word parameter bits parameters 0305 to 0309 See Group 03 FB ACTUAL SIGNALS on page 106 for the bit definitions The form of the display depends on the severity of the error You can specify the severity for many errors by directing the drive to ignore the error situation report the situation as an alarm report the situation as a fault Red Faults The drive signals that it has detected a severe error or fault by enabling the red LED on the drive LED is either steady on or blinking Showing the steady red status LED on the control pan
20. TAC 01 Wrong value entered in parameter 5001 PULSE NR A wrong value will only be detected if the error is such that the calculated slip is greater than 4 times the rated slip of the motor Encoder is not being used but parameter 5002 ENCODER ENABLE 1 ENABLE 2025 FIRST START Signals that a the drive is performing a First Start evaluation of motor characteristics This is normal the first time the motor is run after motor parameters are entered or changed See parameter 9910 ID RUN for a description of motor models USER LOAD This alarm warns that the condition defined by parameter 3701 USER CURVE LOAD C MODE has been valid longer than half of the time defined by 3703 USER LOAD C TIME 2028 Shown during the Start delay See parameter 2113 START DELAY Note 1 Even when the relay output is configured to indicate alarm conditions e g parameter 1401 RELAY OUTPUT 1 5 ALARM or 16 FLT ALARM this alarm is not indicated by a relay output Alarm codes Basic Control Panel The Basic Control Panel indicates control panel alarms with a code A5xxx The following table lists the alarm codes and descriptions Code Description 5001 Drive is not responding 5002 The communication profile is incompatible with the drive 5010 The panel s parameter backup file is corrupted Diagnostics 264 ACS550 01 U1 User s Manual 5041 Parameter backup doesn t fit into memory 5084 Operation is not allowed because drive is busy try ag
21. above limit R1 R4 115 C 239 F R5 R6 125 C 257 F Check for and correct Fan failure Obstructions in the air flow Dirt or dust coating on the heat sink Excessive ambient temperature Excessive motor load 4 SHORT CIRC Fault current Check for and correct e A short circuit in the motor cable s or motor Supply disturbances DC UNDERVOLT Intermediate circuit DC voltage is not sufficient Check for and correct Missing phase in the input power supply Blown fuse Undervoltage on mains T Al1 LOSS Analog input 1 loss Analog input value is less than Alf FAULT LIMIT 3021 Check for and correct Source and connection for analog input e Parameter settings for Al1 FAULT LIMIT 3021 and 3001 AI lt MIN FUNCTION Al2 LOSS Analog input 2 loss Analog input value is less than Al2 FAULT LIMIT 3022 Check for and correct Source and connection for analog input Parameter settings for Al2 FAULT LIMIT 3022 and 3001 AI lt MIN FUNCTION MOT OVERTEMP Motor is too hot based on either the drive s estimate or on temperature feedback Check for overloaded motor Adjust the parameters used for the estimate 3005 3009 Check the temperature sensors and Group 35 MOTOR TEMP MEAS parameters 10 PANEL LOSS Panel communication is lost and either Drive is in local control mode the control panel displays LOC or Drive is in remote control mode REM and is parameterized to accept start stop directio
22. ain 5085 Download is not allowed because drive types are incompatible 5088 Operation failed because a drive memory error was detected 5089 Download failed because a CRC error was detected 5090 Download failed because a data processing error was detected 5091 Operation failed because a parameter error was detected 5092 Download failed because parameter sets do not match 5083 Operation is not allowed because parameter lock is not open 5086 Download is not allowed because drive models are incompatible 5087 Download is not allowed because parameter sets do not match Diagnostics ACS550 01 U1 User s Manual 265 Maintenance WARNING Read chapter Safety on page 5 before performing any maintenance on the equipment Ignoring the safety instructions can cause injury or death Maintenance intervals Heatsink If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB Heatsink temperature check Depends on the dustiness of the See Heatsink on page 265 and cleaning environment every 6 12 months Main cooling fan replacement Every six years See Main fan replacement on page 266 Internal enclosure cooling fan Every three years See nternal enclosure fan replacement replacement on 268 IP54 UL type 12 drives Capacitor reforming Every year when stored See Reforming on page 269 Capacitor replacement Every nin
23. be switched off when overload is detected The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary Depending on a drive parameter value see parameter 3501 SENSOR TYPE the function either monitors a calculated temperature value based on a motor thermal model see parameters 3005 MOT THERM PROT 3009 BREAK POINT FREQ or an actual temperature indication given by motor temperature sensors see Group 35 MOTOR TEMP MEAS The user can tune the thermal model further by feeding in additional motor and load data Technical data 266 ACS550 01 U1 User s Manual The most common temperature sensors are motor sizes IEC180 225 thermal switch e g Klixon motor sizes IEC200 250 and larger PTC or PT100 Ground fault protection ACS550 internal fault logic detects ground faults in the drive motor or motor cable This fault logic is NOT a personal safety or fire protection feature e can be disabled using parameter 3017 EARTH FAULT Note Disabling earth fault ground fault may void the warranty could be tripped by leakage currents input power to ground associated with long high capacitance motor cables Grounding and routing Motor cable shielding Motor cables require shielding using conduit armored cable or shielded cable e Conduit When using conduit Bridge joints with a ground conductor bonded to the conduit on each side of the joint Bond
24. ce with IEC EN 61800 3 2004 See page 305 C Tick marking The drive carries C Tick marking Technical data 304 ACS550 01 U1 User s Manual C Tick marking is required in Australia and New Zealand A C Tick mark is attached to the drive to verify compliance with the relevant standard IEC 61800 3 2004 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods mandated by the Trans Tasman Electromagnetic Compatibility Scheme The Trans Tasman Electromagnetic Compatibility Scheme EMCS was introduced by the Australian Communication Authority ACA and the Radio Spectrum Management Group RSM of the New Zealand Ministry of Economic Development NZMED in November 2001 The aim of the scheme is to protect the radio frequency spectrum by introducing technical limits for emission from electrical electronic products Compliance with IEC EN 61800 3 2004 See page 305 UL CSA markings e U us LISTED g Technical data An UL mark is attached to ACS550 drives to verify that the drive follows the provisions of UL 508C A CSA mark is attached to ACS550 U1 type drives to verify that the drive follows the provisions of C22 2 NO 14 The ACS550 is suitable for use in a circuit capable of delivering not more than 100 kA RMS symmetrical amperes 600 V maximum The ampere rating is based on tests done according to UL 508 Branch circuit protection must be provided i
25. ct it 4 Take off the casing and replace the fan onto the casing s pins Reinstall the casing in reverse order Restore power Maintenance 268 ACS550 01 U1 User s Manual Internal enclosure fan replacement Maintenance Frame sizes R1 R4 3 The housing that holds the fan in place has barbed When the clips barbs are free pull the housing up to IP54 UL type 12 enclosures have an additional internal fan to circulate air inside the enclosure To replace the internal enclosure fan in frame sizes R1 to R3 located at the top of the drive and R4 located in front of the drive Remove power from the drive Remove the front cover retaining clips at each corner Press all four clips toward the center to release the barbs remove from the drive Disconnect the fan cable Install the fan in reverse order noting that e The fan air flow is up refer to the arrow on fan e The fan wire harness is toward the front The notched housing barb is located in the right rear comer The fan cable connecis just forward of the fan at the top of the drive 3AUA000000404 Frame sizes R5 and R6 OU dx SOUS De s To replace the internal enclosure fan in frame sizes R5 or R6 Remove power from the drive Remove the front cover Lift the fan out and disconnect the cable Install the fan in rev
26. de emergency stop devices and any other safety equipment that may be needed Pressing STOP on the drive s control panel does NOT generate an emergency stop of the motor separate the drive from dangerous potential Technical data 2 8 ACS550 01 U1 User s Manual Input power cables wiring Input wiring can be any of e a four conductor cable three phases and ground protective earth Shielding is not required four insulated conductors routed through conduit Size wiring according to local safety regulations appropriate input voltage and the drive s load current In any case the conductor must be less than the maximum limit defined by the terminal size see section Drive s power connection terminals on page 280 The table below lists copper and aluminium cable types for different load currents These recommendations apply only for the conditions listed at the top of the table Based on Based on EN 60204 1 and IEC 60364 5 2 2001 NEC Table 310 16 for copper wires PVC insulation 90 C 194 F wire insulation 30 C 86 F ambient temperature 40 C 104 F ambient temperature 70 C 158 F surface temperature not more than three current carrying cables with concentric copper shield conductors in raceway or cable or earth not more than nine cables laid on cable ladder ilc punen side by side copper cables with concentric copper shield Max load Cu cable Max load Al cable Max load Cu wire size curren
27. ding drive s overload currents to 80 When using the 12 kHz switching frequency parameter 2606 derate all rated currents and powers including drive s overload currents to 6596 to 50 for 600 V R4 frame sizes that is for ACS550 U1 032A 6 ACS550 U1 062A 6 derate ambient temperature maximum to 30 C 86 F e Note The continuous maximum current is limited to opg Note Setting parameter 2607 SWITCH FREQ CTRL 1 ON allows the drive to reduce the switching frequency if when the drive s internal temperature exceeds 80 C with 12 kHz switching frequency or 90 C with 8 KHz switching frequency See the parameter description for 2607 for details ACS550 01 U1 User s Manual 2 5 Input power connections WARNING Do not operate the drive outside the nominal input line voltage range Overvoltage can result in permanent damage to the drive Input power specifications Input power mains connection specifications 208 220 230 240 V AC 3 phase or 1 phase 15 10 for ACS550 x1 xxxx 2 Voltage U 380 400 415 440 460 480 V AC 3 phase 15 10 for ACS550 x1 XXXX 4 500 525 575 600 V AC 3 phase 15 10 for ACS550 U1 xxxx 6 Prospective short Maximum allowed prospective short circuit current in the supply is 100 kA circuit current providing that the input power cable of the drive is protected with IEC 629 appropriate fuses US 100 000 AIC Max 3 of nominal phase to phase input voltage Fu
28. e provisions described below First environment drives of category C2 1 The internal EMC filter is connected 2 The motor and control cables are selected as specified in this manual 3 4 The motor cable length does not exceed the allowed maximum length specified in The drive is installed according to the instructions given in this manual section Motor cable length for 400 V drives on page 284 for the frame size and switching frequency in use WARNING In a domestic environment this product may cause radio inference in which case supplementary mitigation measures may be required Second environment drives of category C3 1 2 The internal EMC filter is connected The motor and control cables are selected as specified in this manual 3 The drive is installed according to the instructions given in this manual Technical data 306 ACS550 01 U1 User s Manual 4 The motor cable length does not exceed the allowed maximum length specified in section Motor cable length for 400 V drives on page 284 for the frame size and switching frequency in use WARNING A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network Note It is not allowed to install a drive with the internal EMC filter connected on IT ungrounded systems The supply network becomes connected to ground potent
29. e type in the following tables Never use resistance below this value Resistance must be low enough to be able to produce the desired braking torque To achieve the maximum braking torque the larger of 150 of heavy duty or 110 of nominal duty the resistance must not exceed Rmax If maximum braking torque is not necessary resistor values can exceed Rmax The resistor power rating must be high enough to dissipate the braking power This requirement involves many factors the maximum continuous power rating for the resistor s the rate at which the resistor changes temperature resistor thermal time constant maximum braking time ON If the regeneration braking power is larger than the resistor rated power there is a limit to the ON time or the resistor overheats before the OFF period begins minimum braking time OFF If the regeneration braking power is larger than the resistor rated power the OFF time must be large enough for the resistor to cool between ON periods Braking ON Time Braking OFF ON time OFF time x ON time Cycle time Duty cycle Cycle time the peak braking power requirement type of braking deceleration to zero vs overhauling load During deceleration to zero the generated power steadily decreases averaging half of the peak power For an overhauling load the braking is countering an external force gravity for example and the braking p
30. e years See Replacement on page 269 frame sizes R5 and R6 Replace battery in the Assistant Every ten years See Battery on page 269 Control Panel Consult your local ABB Service representative for more details on the maintenance On the Internet go to www abb com drive and select Drive Services Maintenance and Field Services The heatsink fins accumulate dust from the cooling air Since a dusty heatsink is less efficient at cooling the drive overtemperature faults become more likely In a normal environment not dusty not clean check the heatsink annually in a dusty environment check more often Clean the heatsink as follows when necessary Remove power from the drive Remove the cooling fan see section Main fan replacement on page 266 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room Maintenance 266 ACS550 01 U1 User s Manual 4 Reinstall the cooling fan 5 Restore power Main fan replacement Maintenance The drive s main cooling fan has a life span of about 60 000 operating hours at maximum rated operating temperature and drive load The expected life span doubles for each 10 C 18 F drop in the fan temperature fan temperature is a function of ambient temperatures and drive loads Fan failure ca
31. ected Pulse Encoder Interface Module OTAC 01 Wrong value entered in parameter 5001 PULSE NR A wrong value will only be detected if the error is such that the calculated slip is greater than 4 times the rated slip of the motor Encoder is not being used but parameter 5002 ENCODER ENABLE 1 ENABLE 24 OVERSPEED Motor speed is greater than 120 of the larger in magnitude of 2001 MINIMUM SPEED or 2002 MAXIMUM SPEED Check for and correct Parameter settings for 2001 and 2002 Adequacy of motor braking torque Applicability of torque control Brake chopper and resistor 26 DRIVE ID Internal fault Configuration Block Drive ID is not valid Contact your local ABB representative 2f CONFIG FILE Internal configuration file has an error Contact your local ABB representative 28 SERIAL 1 ERR Fieldbus communication has timed out Check for and correct Fault setup 3018 COMM FAULT FUNC and 3019 COMM FAULT TIME Communication settings Group 51 EXT COMM MODULE or Group 53 EFB PROTOCOL as appropriate Poor connections and or noise on line Error in reading the configuration file for the embedded fieldbus Fault trip forced by the fieldbus See the fieldbus User s Manual Fault code reserved for the embedded fieldbus EFB protocol application The meaning is protocol dependent 34 MOTOR PHASE Fault in the motor circuit One of the motor phases is lost Check for and correct Motor fault Motor cable fault
32. el if attached to the drive setting an appropriate bit in a Fault Word parameter 0305 to 0307 overriding the control panel display with the display LOC TU FAULT of a fault code in the Fault mode figures on the right FAULT AIl LOSS 00 00 The fault code on the control panel display is i LOC temporary Pressing any of the following keys removes O 0 the fault message MENU ENTER UP or DOWN key EWD e stopping the motor if it was on Diagnostics 254 ACS550 01 U1 User s Manual The message reappears after a few seconds if the control panel is not touched and the fault is still active Flashing green Alarms For less severe errors called alarms the diagnostic display is advisory For these situations the drive is simply reporting that it had detected something unusual In these situations the drive flashes the green LED on the drive does not apply to alarms that arise from control panel operation errors e flashes the green LED on the control panel if attached to the drive sets an appropriate bit in an Alarm Word parameter 0308 or 0309 See Group 03 FB ACTUAL SIGNALS on page 106 for the bit definitions overrides the control panel display with the display LOC U ALARM of an alarm code and or name in the Fault mode figures on the right ALARM 2008 PANEL LOSS 00 00 periodically as long as the alarm condition exists LOC A 0 8 FWD Correcting faults Alar
33. erse order Restore power ACS550 01 U1 User s Manual 269 Capacitors Reforming The drive DC link capacitors need to be reformed re aged if the drive has been non operational for more than one year Without reforming capacitors may be damaged when the drive starts to operate It is therefore recommended to reform the capacitors once a year See section Serial number on page 13 for how to check the date of manufacture from the serial number shown on the drive labels For information on reforming the capacitors refer to Guide for Capacitor Reforming in ACS50 ACS55 ACS150 ACS310 ACS320 ACS350 ACS550 and ACH550 3AFE68735190 English available on the Internet go to www abb com and enter the code in the Search field Replacement The drive intermediate circuit employs several electrolytic capacitors Their life span is from 35 000 90 000 hours depending on drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict a capacitor failure Capacitor failure is usually followed by a input power fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements for frame size R5 and R6 are available from ABB Do not use other than ABB specified spare parts Control panel Cleaning Use a soft damp cloth to clean the control panel Avoid harsh cleaners which could scratch the display window Battery A battery is only used in
34. ial through the EMC filter capacitors which may cause danger or damage the drive Note It is not allowed to install a drive with the internal EMC filter connected to a corner grounded TN system as this would damage the drive Product protection in the USA Technical data This product is protected by one or more of the following US patents 4 920 306 9 301 085 0 463 302 9 921 483 9 032 568 5 589 754 9 612 604 9 654 624 5 799 805 5 940 286 5 942 874 5 952 613 6 094 364 6 147 887 6 175 256 6 184 740 6 195 274 6 229 356 6 252 436 6 265 724 6 305 464 6 313 599 6 316 896 6 335 607 6 370 049 6 396 236 6 448 735 6 498 452 6 552 510 6 597 148 6 600 290 6 741 059 6 774 158 6 844 794 6 856 502 6 859 374 6 922 883 6 940 253 6 934 169 6 956 352 6 958 923 6 967 453 6 972 976 6 977 449 6 984 958 6 985 371 6 992 908 6 999 329 7 023 160 7 034 510 7 036 223 7 045 987 7 057 908 7 059 390 7 067 997 7 082 374 7 084 604 7 098 623 7 102 325 7 109 780 7 164 562 7 176 779 7 190 599 7 215 099 7 221 152 7 227 325 7 245 197 7 250 739 71 262 571 7 271 505 7 274 573 7 279 802 7 280 938 7 330 095 7 349 814 7 352 220 7 365 622 7 372 696 7 388 765 D503 931 D510 319 D510 320 D511 137 D511 150 D512 026 D512 696 D521 466 D541 743S D541 744S D541 745S D548 182S D548 183S Other patents pending
35. imensions and mass for the ACS550 depend on the frame size and enclosure type If unsure of the frame size first find the Type designation on the drive labels see sections Type designation on page 13 and Drive labels on page 12 Then look up that type designation in the rating tables see chapter Technical data page 271 to determine the frame size Mounting dimensions See detail A See detail B Detail A Detail B X0032 IP21 UL type 1 and IP54 UL type 12 Dimensions for each frame size mm om im mm mm im m jm mo wir wo ss oeo ss wo es Jim fes ze os s ma o E E 62 ss uzs es 625 65 ozs oo 0357 e ss oa ss o2 so os se os ss os ss os a ss oa ss o2 es oas ss ozs es oas so o 1 Center to center dimension Technical data 298 ACS550 01 U1 User s Manual Outside dimensions Drives with IP21 UL type 1 enclosures Technical data Types ACS550 x1 246A 4 and ACS550 01 290A 4 frame size R6 H3 X0031 IP21 UL type 1 dimensions for each frame size Wm Im lm ELA LEE oo O E w us as ws is us 50 203 50 2s oa ooo ms fe f s ws rea s zs e02 27 700 2767 00467918 xls C 1 ACS550 x1 246A 4 and ACS550 01 290A 4 979 mm 38 5 in ACS550 01 U1 User s Manual 299 Drives with IP54 UL type 12 enclosures Type ACS550 01 290A 4 IP54 UL type 12 not available frame size R6
36. ive motor cable shields on page 288 Motor cable shield wires must be twisted together into a bundle pig tail the bundle length must be less than five times its width and connected to the terminal marked at the bottom right hand corner of the drive At the motor end the motor cable shield must be earthed 360 degrees with an EMC cable gland or the shield wires must be twisted together into a bundle pig tail not longer than five times its width and connected to the PE terminal of the motor See section Motor cable length for 400 V drives columns EMC limits on page 284 to check the maximum motor cable lengths and the need for filters for 400 V drives for IEC EN 61800 3 compliance AN WARNING Do not use RFI EMC filters on IT systems Technical data ACS550 01 U1 User s Manual 289 Brake components Availability Braking availability for ACS550 drives by frame size is R1 and R2 a built in brake chopper is standard equipment Add appropriate resistor as determined using the following section Resistors are available from ABB R3 R6 does not include an internal brake chopper Connect a chopper and a resistor or a brake unit to the DC link terminals on the drive Contact your ABB representative for appropriate parts Selecting the braking resistors frame sizes R1 and R2 Braking resistor must meet three requirements Resistance must be always higher than the minimum value Rmn defined for the driv
37. m messages disappear from the control panel display after a few seconds The message returns The recommended corrective action for faults is Use the table in section Fault listing below to find and address the root cause of the problem e Reset the drive See section Fault resetting on page 259 Fault listing The following table lists the faults by code number and describes each The fault name is the long form shown in the Fault mode of the Assistant Control Panel when the fault occurs The fault names shown for Assistant Control Panel only in the Fault Logger mode see page 57 and the fault names for parameter 0401 LAST FAULT may be shorter Fault Fault name in ae Description and recommended corrective action code panel 1 OVERCURRENT Output current is excessive Check for and correct Excessive motor load e Insufficient acceleration time parameters 2202 ACCELER TIME 1 and 2205 ACCELER TIME 2 Faulty motor motor cables or connections Diagnostics ACS550 01 U1 User s Manual 255 Fault name in code DC OVERVOLT Intermediate circuit DC voltage is excessive Check for and correct Static or transient overvoltages in the input power supply Insufficient deceleration time parameters 2203 DECELER TIME 1 and 2206 DECELER TIME 2 Undersized brake chopper if present Verify that overvoltage controller is ON using parameter 2005 DEV OVERTEMP Drive heatsink is overheated Temperature is at or
38. motors in Group 14 RELAY OUTPUTS and parameter 8118 AUTOCHNG INTERV 1014 PARPFCIO 3 IO configuration is not complete the drive is unable to allocate a digital input interlock for each PFC motor parameters 8120 INTERLOCKS and 8127 MOTORS 1016 PAR USER LOAD C Parameter values for the user load curve are inconsistent Check that the following conditions are met e 3704 LOAD FREQ 1 lt 3707 LOAD FREQ 2 lt 3710 LOAD FREQ 3 lt 3713 LOAD FREQ 4 lt 3716 LOAD FREQ 5 3705 LOAD TORQ LOW 1 lt 3706 LOAD TORQ HIGH 1 3708 LOAD TORQ LOW 2 lt 3709 LOAD TORQ HIGH 2 3711 LOAD TORQ LOW 3 lt 3712 LOAD TORQ HIGH 3 3714 LOAD TORQ LOW 4 lt 3715 LOAD TORQ HIGH 4 3717 LOAD TORQ LOW 5 lt 3718 LOAD TORQ HIGH 5 Fault resetting The ACS550 can be configured to automatically reset certain faults Refer to parameter Group 31 AUTOMATIC RESET WARNING If an external source for start command is selected and it is active the ACS550 may start immediately after fault reset Diagnostics 260 ACS550 01 U1 User s Manual Flashing red LED To reset the drive for faults indicated by a flashing red LED e Turn the power off for 5 minutes Red LED To reset the drive for faults indicated by a red LED on not flashing correct the problem and do one of the following Press RESET from the control panel e Turn the power off for 5 minutes Depending on the value of 1604 FAULT RESET SEL the following could also be
39. n accordance with local codes The ACS550 has an electronic motor protection feature that complies with the requirements of UL 508C and for ACS550 U1 C22 2 No 14 When this feature is selected and properly adjusted additional overload protection is not required unless more than one motor is connected to the drive or unless additional protection is required by applicable safety regulations See parameters 3005 MOT THERM PROT and 3006 MOT THERM RATE The drives are to be used in a controlled environment See section Ambient conditions on page 300 for specific limits Note For open type enclosures i e drives without the conduit box and or cover for IP21 UL type 1 drives or without the conduit plate and or hood for IP54 UL type 12 drives the drive must be mounted inside an enclosure in accordance with National Electric Code and local electrical codes Brake choppers when applied with appropriately sized brake resistors will allow the drive to dissipate regenerative energy normally associated with quickly decelerating a motor Frame sizes R1 and R2 have a built in brake chopper as standard equipment For frame sizes R3 R6 contact your ABB representative for appropriate parts See section Brake components on page 289 ACS550 01 U1 User s Manual 305 IEC EN 61800 3 2004 Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electr
40. n be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from ABB Do not use other than ABB specified spare parts Frame sizes R1 R4 1 Remove power from the drive 2 Remove drive cover 3 For frame size 4 Disconnect the fan cable To replace the fan R1 R2 Press together the retaining clips on the fan cover sides and lift e R3 R4 Press in on the lever located on the left side of the fan mount and rotate the fan up and out 5 Reinstall the fan in reverse order X0021 6 Restore power Frame size R5 eo dew Mo woe To replace the fan Bottom view m Remove power from drive Remove the screws attaching the fan SUR Remove the fan Swing the fan out on its hinges 4 om J gt Disconnect the fan cable X5023 Reinstall the fan in reverse order Restore power Arrows in the fan show the directions of the rotation and air flow ACS550 01 U1 User s Manual 267 Frame size R6 To replace the fan 1 Remove power from the drive 2 Remove the screw attaching the fan casing and let the casing lean down against the limiters 3 Slide out the cable connector and disconne
41. n or reference from the control panel To correct check Communication lines and connections Parameter 3002 PANEL COMM ERR Parameters in Group 10 START STOP DIR and Group 11 REFERENCE SELECT if drive operation is REM Diagnostics Description and recommended corrective action 256 Diagnostics ACS550 01 U1 User s Manual Fault Fault name in me Description and recommended corrective action code panel 11 ID RUN FAIL The Motor ID Run was not completed successfully Check for and correct Motor connections Motor parameters 9905 9909 12 MOTOR STALL Motor or process stall Motor is operating in the stall region Check for and correct Excessive load e Insufficient motor power e Parameters 3010 3012 14 EXT FAULT 1 Digital input defined to report first external fault is active See parameter 3003 EXTERNAL FAULT 1 15 EXT FAULT 2 Digital input defined to report second external fault is active See parameter 3004 EXTERNAL FAULT 2 16 EARTH FAULT Possible ground fault detected in the motor or motor cables The drive monitors for ground faults while the drive is running and while the drive is not running Detection is more sensitive when the drive is not running and can produce false positives Possible corrections Check for correct faults in the input wiring Verify that motor cable does not exceed maximum specified length A delta grounded input power supply and motor cables with high capacitance may
42. nd the cable lengths Under heading Operational limits the Basic unit columns define the cable lengths with which the basic drive unit works without problems within the drive specification without installing any further options Column With du dt filters defines the cable lengths when an external du dt filter is used The columns under heading EMC limits show the maximum cable lengths with which the units have been tested for EMC emissions The factory guarantees that these cable lengths meet the EMC standard requirements If external sine filters are installed longer cable lengths can be used With sine filters the limiting factors are the voltage drop of the cable which has to be taken into account in engineering as well as the EMC limits where applicable The default switching frequency is 4 kHz WARNING Using a motor cable longer than specified in the table above may cause permanent damage to the drive Examples for using the table Checking and conclusions R1 frame size Check operational limits for R1 and 8 kHz gt for a 150 m 490 ft 8 kHz fsw cable a du dt filter is needed 150 0 do f cable Check EMC limits EMC requirements for Category C2 are met with a 150 m 490 ft cable ACS550 01 U1 User s Manual 285 Checking and conclusions R3 frame size Check operational limits for R3 and 4 kHz gt a 300 m 980 ft cable 4 kHz fsw cannot be used even with a du dt filter A sine filter must be u
43. ndamental power 0 98 at nominal load factor cos phi4 Cable temperature 90 C 194 F rating minimum rating Disconnecting device for isolation Install a hand operated input disconnecting device disconnecting means between the AC power source and the drive The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work Europe To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types a switch disconnector of utilization category AC 23B EN 60947 3 a disconnector having an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector EN 6094 7 3 a circuit breaker suitable for isolation in accordance with EN 60947 2 Other regions The disconnecting device must conform to the applicable safety regulations Fuses Branch circuit protection must be provided by the end user and sized per national and local electric codes The following tables provide fuse recommendations for short circuit protection on the drive s input power The rated fuse currents given in the tables are the maximums for the mentioned fuse types If smaller fuse ratings are used check that the fuse rms current rating is larger than the input current Technical data 2 6 ACS550 01 U1 User s Manual
44. of motor current and a 8 kHz switching frequency calculate the appropriate drive size requirement as follows The minimum size required 15 4 A 0 80 19 25 A Where 0 80 is the derating for 8 kHz switching frequency see section Switching frequency derating on page 274 Referring to y in the ratings tables starting from page 271 the following drives exceed the 5w requirement of 19 25 A ACS550 x1 023A 4 or ACS550 x1 024A 2 Temperature derating In the temperature range 40 C 50 C 104 F 122 F the rated output current is decreased 1 for every 1 C 1 8 F above 40 C 104 F Calculate the output current by multiplying the current given in the rating table by the derating factor Example If the ambient temperature is 50 C 122 F the derating factor is 100 1 C 10 C 90 or 0 90 The output current is then 0 90 oy or 0 90 long Altitude derating In altitudes 1000 4000 m 3300 13 200 ft above sea level the derating is 1 for every 100 m 330 ft If the installation site is higher than 2000 m 6600 ft above sea level please contact your local ABB distributor or office for further information Single phase supply derating For 208 240 V series drives a single phase supply can be used In that case the derating is 50 Switching frequency derating Technical data When using the 8 kHz switching frequency parameter 2606 derate all rated currents and powers inclu
45. omagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not directly supplying domestic premises Drive of category C2 drive of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment Note A professional is a person or organisation having necessary skills in installing and or commissioning power drive systems including their EMC aspects Category C2 has the same EMC emission limits as the earlier class first environment restricted distribution EMC standard IEC EN 61800 3 does not any more restrict the distribution of the drive but the using installation and commissioning are defined Drive of category C3 drive of rated voltage less than 1000 V intended for use in the second environment and not intended for use in the first environment Category C3 has the same EMC emission limits as the earlier class second environment unrestricted distribution Compliance with the IEC EN 61800 3 2004 The immunity performance of the drive complies with the demands of IEC EN 61800 3 category C2 see page 305 for IEC EN 61800 3 definitions The emission limits of IEC EN 61800 3 are complied with th
46. ower is constant The total heat generated from an overhauling load is double the heat generated from deceleration to zero speed for the same peak torque and ON time Technical data 290 Technical data ACS550 01 U1 User s Manual Power Deceleration curve Overhauling load Avg braking power curve overhauling load Avg braking power during deceleration to zero Temperature The many variables in the last requirement above are most easily dealt with using the following tables First determine your maximum braking time ON ONmax minimum braking time OFF OFF yin and load type deceleration or overhauling load Calculate duty cycle ONmax Duty cycle 100 Ue ONmax OF Fin Inthe appropriate table find the column that best matches your data ONyax lt column specification and Duty cycle lt column specification Find the row that matches your drive The minimum power rating for deceleration to zero is the value in the selected row column e For overhauling loads double the rating in the selected row column or use the Continuous ON column 208 240 V drives Resistance Resistor minimum continuous power rating Deceleration to zero rating P Type rcont P Continuous ON ACS550 r60 01 U1 lt 60 s ON gt 60s ON see below Three phase supply voltage 208 240 V Fuse 2 60 t fo pa o po ome 160 eo es
47. s drive X but not the ACS550 DRIVE TYPE has been connected to the ACS550 ACS550 SUPPORTED DRIVES X Faults that indicate conflicts in the parameter settings are listed below Fault Fault name in ee 4 Description and recommended corrective action code panel 1000 PAR HZRPM Parameter values are inconsistent Check for any of the following 2001 MINIMUM SPEED gt 2002 MAXIMUM SPEED 2007 MINIMUM FREQ gt 2008 MAXIMUM FREQ 2001 MINIMUM SPEED 9908 MOTOR NOM SPEED is outside proper range gt 50 2002 MAXIMUM SPEED 9908 MOTOR NOM SPEED is outside proper range gt 50 2007 MINIMUM FREQ 9907 MOTOR NOM FREQ is outside proper range gt 50 2008 MAXIMUM FREQ 9907 MOTOR NOM FREQ is outside proper range gt 50 1001 PAR PFC REF Parameter values are inconsistent Check for the following NEG 2007 MINIMUM FREQ is negative when 8123 PFC ENABLE is active 1003 PAR AI SCALE Parameter values are inconsistent Check for any of the following e 1301 MINIMUM AI1 gt 1302 MAXIMUM AIM e 1304 MINIMUM AI2 gt 1305 MAXIMUM AI2 1004 PARAO SCALE Parameter values are inconsistent Check for any of the following e 1504 MINIMUM AO1 gt 1505 MAXIMUM AO1 e 1510 MINIMUM AC2 gt 1511 MAXIMUM AO2 Diagnostics ACS550 01 U1 User s Manual 259 paul raw halved Description and recommended corrective action code panel 1005 PAR PCU 2 Parameter values for power control are inconsistent Improper motor nominal
48. se Group 81 PFC CONTROL and the PFC macro on page 60 2015 PFC I LOCK This alarm warns that the PFC interlocks are active which means that the drive cannot start the following Any motor when Autochange is used The speed regulated motor when Autochange is not used 2016 RESERVED Not used 2017 2018 PID SLEEP This alarm warns that the PID sleep function is active which means Note 1 that the motor could accelerate when the PID sleep function ends To control PID sleep use parameters 4022 4026 or 4122 4126 20019 ID DRIN Performing ID Run 2021 START ENABLE 1 This alarm warns that the Start Enable 1 signal is missing MISSING To control Start Enable 1 function use parameter 1608 To correct check Digital input configuration Communication settings 2022 START ENABLE 2 This alarm warns that the Start Enable 2 signal is missing MISSING To control Start Enable 2 function use parameter 1609 To correct check Digital input configuration Communication settings Diagnostics ACS550 01 U1 User s Manual 263 Display Description 2023 EMERGENCY Emergency stop activated STOP 2024 ENCODER ERROR The drive is not detecting a valid encoder signal Check for and correct Encoder presence and proper connection reverse wired loose connection or short circuit Voltage logic levels are outside of the specified range A working and properly connected Pulse Encoder Interface Module O
49. sed and Category C3 the voltage drop of the cable must be taken into account in the 300 m 980 ft cable installation Check EMC limits gt EMC requirements for Category C3 are met with a 300 m 980 ft cable R5 frame size Check operational limits for R5 and 8 kHz gt for a 150 m 490 ft 8 kHz fsw cable the basic unit is sufficient 150 0 290 fh cable Check EMC limits gt EMC requirements for Category C3 cannot be met with a 300 m 980 ft cable The installation configuration is not possible An EMC plan is recommended to overcome the situation R6 frame size Check operational limits for R6 and 4 kHz gt for a 150 m 490 ft 4 kHz fsw cable the basic unit is sufficient RA mer EMC limits do not need to be checked as there are no EMC 150 m 490 ft cable requirements Motor cable length for 600 V drives The table below shows the maximum motor cable lengths for 600 V drives with different switching frequencies As the 600 V drives are not CE approved cable lengths for EMC limits are not given Maximum cable length for 600 V drives pe a Re we mm 100 mn mera 20 mm 100 0 Rs ow so so ooh 12 kHz switching frequency is not available WARNING Using a motor cable longer than specified in the table above may cause permanent damage to the drive Motor thermal protection According to regulations the motor must be protected against thermal overload and the current must
50. supply disconnecting device IEC EN 60529 2004 Degrees of protection provided by enclosures IP code IEC 60664 1 2002 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC EN 61800 5 1 2003 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy IEC EN 61800 3 2004 Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods IEC EN 61000 3 12 Electromagnetic compatibility EMC Part 3 12 Limits Limits for harmonic currents produced by equipment connected to public low voltage systems with input current gt 16 A and 75 A per phase IEC EN 61800 3 2004 Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods UL 508C UL Standard for Safety Power Conversion Equipment third edition C22 2 No 14 CSA Standard for Industrial Control Equipment for ACS550 U1 drives only C A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage and EMC Directives CE marking Note The 600 V ACS550 U1 drives are not CE approved Compliance with the EMC Directive The Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard IEC EN 61800 3 2004 covers requirements stated for drives Complian
51. t current current AWG kemil Aluminium cable cannot be used with frame sizes R1 R5 because of its lower Capacity 165 3x120 178 191 3x150 205 257 3x240 264 250 MCM or 2 x 1 274 3x 3x50 300 MCM or 2 x 1 0 285 2x 3x95 350 MCM or 2 x 2 0 Technical data ACS550 01 U1 User s Manual 2 9 Ground connections For personnel safety proper operation and reduction of electromagnetic emission pick up the drive and the motor must be grounded at the installation site e Conductors must be adequately sized as required by safety regulations Power cable shields must be connected to the drive PE terminal in order to meet safety regulations Power cable shields are suitable for use as equipment grounding conductors only when the shield conductors are adequately sized as required by safety regulations In multiple drive installations do not connect drive terminals in series Corner grounded TN systems WARNING Do not attempt to install or remove the EMC filter screws EM1 EM3 F1 or F2 while power is applied to the drive s input terminals Corner grounded TN systems are defined in the following table In such systems disconnect the internal ground connection through the EMC filter capacitors do this also if the grounding configuration of the system is unknown see section Disconnecting the internal EMC filter on page 23 Corner grounded TN systems EMC filter must be disconnected Grounded at the Grounded at the
52. table provides specifications for the drive s power connection terminals U1 V1 W1 U2 V2 W2 Earthing PE terminal BRK UDC terminals Maximum Tightening Maximum Tightening wire size wire size or ss jas ouo am ALES o e C s fe 00467918 xls C Aluminium cable cannot be used with frame sizes R1 R5 because of its lower capacity Aluminium cable cannot be used with type ACS550 01 290A 4 because of the terminal size See section Power terminal considerations R6 frame size on page 261 Note See the recommended cable sizes for different load currents in section nput power cables wiring on page 278 ACS550 01 U1 User s Manual 281 Power terminal considerations R6 frame size WARNING For R6 power terminals if screw on terminal lugs are supplied they can only be used for wire sizes that are 95 mm 3 0 AWG or larger Smaller wires will loosen and may damage the drive They require crimp on ring lugs as described below Crimp on ring lugs On the R6 frame size if screw on terminal lugs are supplied but the cable size used is less than 95 mm 3 0 AWG or if no screw on terminal lugs are supplied at all use crimp on ring lugs according to the following procedure 1 Select appropriate ring lugs from the following table Remove the screw on terminal lugs if supplied 3 Attach the ring lugs to the drive end of the cables Isolate the ends of the ring lugs with insulating tape or shrink tubing
53. tion braking where x is ONwax time Installing and wiring resistors All resistors must be installed outside the drive module in a place where they can dissipate heat WARNING The surface temperature of the resistor is very high and air flowing from the resistor is very hot Materials near the brake resistor must be non flammable Provide protection from accidental contact with the resistor To ensure that the input fuses protect the resistor cable use resistor cables with the same rating as used for the power input to the drive The maximum length of the resistor cable s is 10 m 33 ft See section Power connection diagrams on page 27 for the resistor cable connection points Mandatory circuit protection The following setup is essential for safety it interrupts the main supply in fault situations involving chopper shorts Equip the drive with a main contactor e Wire the contactor so that it opens if the resistor thermal switch opens an overheated resistor opens the contactor Below is a simple wiring diagram example L1 L2 L3 1 Off E Fuses 2 1 3 5 13 3 2 4 6 14 acs550 1 U1 V1 W1 Q Thermal switch standard in ABB resistors ape e m Parameter set up To enable dynamic braking switch off the drive s overvoltage control Set parameter 2005 O DISABLE Technical data 294 ACS550 01 U1 User s Manual Note Never mix 24 V DC and 115 230 V AC signals in the same cable
54. used to reset the drive digital input Serial communication When the fault has been corrected the motor can be started History Po Se D a For reference the last three fault codes are stored into parameters 0401 0412 0413 For the most recent fault identified by parameter 0401 the drive stores additional data in parameters 0402 0411 to aid in troubleshooting a problem For example parameter 0404 stores the motor speed at the time of the fault The Assistant Control Panel provides additional information about the fault history See section Fault Logger mode on page 57 for more information To clear the fault history all of the Group 04 FAULT HISTORY parameters Using the control panel in the Parameters mode select parameter 0401 Press EDIT or ENTER on the Basic Control Panel Press UP and DOWN at the same time Press SAVE Correcting alarms Diagnostics The recommended corrective action for alarms is Determine if the alarm requires any corrective action action is not always required Use the table in section Alarm listing below to find and address the root cause of the problem ACS550 01 U1 User s Manual 261 Alarm listing The following table lists the alarms by code number and describes each Ea OVERCURRENT Current limiting controller is active Check for and correct Excessive motor load e Insufficient acceleration time parameters 2202 ACCELER TIME 1 and 2205 ACCELER TIME 2
55. w 208 240 V drives The following table lists heat loss and air flow data for 208 240 V drives Drive Air flow ACS550 x1 012A 2 R1 118 404 017A 2 024A 2 031A 2 046A 2 059A 2 075A 2 088A 2 114A 2 143A 2 178A 2 221A 2 248A 2 pi A By BY A KR BR BY BY AR NI NI NI NIN O CO O CO NI N O1 0 00467918 xls C Air flow 380 480 V drives The following table lists heat loss and air flow data for 380 480 V drives Drive Air flow ACS550 x1 m h ft min 03A3 4 04A1 4 05A4 4 06A9 4 08A8 4 012A 4 015A 4 023A 4 KR gt KR gt O O O O1 NINI O O MR os a ar pu LEN pe 5 LONE Technical data 296 ACS550 01 U1 User s Manual he Maik Aw Hema m po fast o Ne Pew m fimo om o qme Hswa m oi os a E Hewi Re feos MN E Mora Re foes Oa Hmwa m 9 Gus es Jm 00467918 xls C Air flow 500 600 V drives The following table lists heat loss and air flow data for 500 600 V drives Drive Air flow EN AN Rosso Fames W BN wm usn mes m n je u wes m qw m m e mess m pm mro m m mes m qm m e amp ome m qme ues us dm Hmws m qme a us mb pus m qme qme us m pes Re qme mae ju m 00467918 xls C Technical data ACS550 01 U1 User s Manual 297 Dimensions and weights The d
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