ABB ACH550-PCR User manual

User’s Manual
ACH550-PCR/PDR Packaged Drive with Disconnect
Supplement to ACH550-UH HVAC User’s Manual

ii ACH550-PCR/PDR Packaged Drive with Disconnect
ACH550 Drive Manuals
GENERAL MANUALS
ACH550-UH HVAC User's Manual (1…550 HP)
• Safety
•Installation
• Start-Up
• Embedded Fieldbus
• Fieldbus Adapter
• Diagnostics
• Maintenance
• Technical Data
ACH550-PCR/PDR Packaged Drive with Disconnect
Supplement for ACH550-UH HVAC User’s Manual
• Safety
•Installation
• Start-Up
• Maintenance
• Technical Data
E-Clipse Bypass Configurations (BCR, BDR, VCR or
VDR) for ACH550 Drives (1…400 HP)
• Safety
•Installation
• Start-Up
• Technical Data
ACH550-CC/CD Packaged Drive with Classic Bypass
Supplement for ACH550-UH HVAC User’s Manual
• Safety
•Installation
• Start-Up
• Technical Data
© 2005 ABB Inc. All Rights Reserved.

ACH550-PCR/PDR Packaged Drive with Disconnect 1
Safety
Safety
WARNING! The ACH550 adjustable speed AC drive with Input Disconnect
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 the input terminals of the
ACH550, there may be dangerous voltage (from external sources) on the
terminals of the relay outputs.
WARNING! When the control terminals of two or more 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 will start up automatically after an input voltage
interruption if the external run command is on.
WARNING! When the ACH550 with Input Disconnect is connected to the line
power, the Motor Terminals T1, T2, and T3 are live even if the motor is not
running. Do not make any connections when the ACH550 with Input
Disconnect is connected to the line. Disconnect and lock out power to the
drive before servicing the drive. Failure to disconnect power may cause
serious injury or death.
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:
• Notes draw attention to a particular condition or fact, or give information on a
subject.
• Warnings caution you about conditions which can result in serious injury or death
and/or damage to the equipment. They also tell you how to avoid the danger. The
warning symbols are used as follows:
Dangerous voltage warning warns of high voltage which can cause physical
injury and/or damage to the equipment.

2 ACH550-PCR/PDR Packaged Drive with Disconnect
Safety
General warning warns about conditions, other than those caused by
electricity, which can result in physical injury and/or damage to the
equipment.

Table of Contents
Safety
Use of Warnings and Notes............................................................................................. 1
Installation
Application ....................................................................................................................... 4
Input Disconnect Features and Functions ....................................................................... 4
Installation Flow Chart ..................................................................................................... 6
Preparing for Installation (Supplement to ACH550-UH User’s Manual) .......................... 7
Installing the Wiring (Supplement to ACH550-UH User’s Manual).................................. 8
Maintenance
Maintenance Intervals.................................................................................................... 13
Enclosure Air Filter Replacement – UL Type 12/NEMA 12 Enclosures......................... 14
Technical Data
Input Power Connections (Supplement to ACH550-UH User’s Manual)....................... 15
Dimensions and Weights (Supplement to ACH550-UH User’s Manual)........................ 25
Degrees of Protection.................................................................................................... 28
Applicable Standards..................................................................................................... 29
Index

4 ACH550-PCR/PDR Packaged Drive with Disconnect
Installation
Installation
Study these installation instructions carefully before proceeding. Failure to observe
the warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read "Safety" on page 1.
WARNING! When the ACH550 with Input Disconnect is connected to the line
power, the Motor Terminals T1, T2, and T3 are live even if the motor is not
running. Do not make any connections when the ACH550 with Input
Disconnect is connected to the line. Disconnect and lock out power to the
drive before servicing the drive. Failure to disconnect power may cause
serious injury or death.
Application
This manual contains supplemental information that is unique to ACH550 input
disconnect configurations (PCR or PDR). Refer to the base manual, ACH550-UH
HVAC User’s Manual (1…550 HP), for all other information.
Input Disconnect Features and Functions
The ACH550 with Input Disconnect is an ACH550 AC adjustable frequency drive
packaged with an input disconnect switch or circuit breaker, and with a door
mounted, external operating handle. The operating handle can be padlocked in the
OFF position (padlock not supplied). Enclosure options are UL Type 1, UL Type 12,
and UL Type 3R (NEMA 1, NEMA 12, and NEMA 3R).
The following is a typical power diagram.
ACH550
Drive with Input Disconnect
Motor
3 Phase Drive 3
3
Disconnect Switch
or Circuit Breaker
Input Power

ACH550-PCR/PDR Packaged Drive with Disconnect 5
Installation
The following shows the front view of the ACH550 Drive with Input Disconnect
standard configurations, and identifies the major components.
Operating Handle
ACH550 Drive
for Disconnect Switch
or Circuit Breaker
UL Type/NEMA 1 & 12 UL Type/NEMA 1 & 12 UL Type/NEMA 1 & 12
Floor Mount
UL Type 3R/NEMA 3R
Enclosures
Control Panel
Vertical Construction
Enclosures Hinged Door Wall Mount Enclosures Enclosures

6 ACH550-PCR/PDR Packaged Drive with Disconnect
Installation
Installation Flow Chart
The installation of Input Disconnect configurations for ACH550 drives follows the
outline below. The steps must be carried out in the order shown. At the right of each
step are references to the detailed information needed for the correct installation of
the unit.
Note! References in the middle column below are to the ACH550-UH User’s
Manual. References in the third column below are to this manual.
Task Refer to the ACH550-UH User’s Manual
“Installation” section
Additional Reference in this
Manual
PREPARE for
installation “Preparing for Installation” • “Drive Identification” on page 7.
• “Note! Some instructions in this
document vary, depending on
the drive’s frame size. To read
the Ratings table, you need the
“Output current rating” entry from
the type code (see
above).Suitable Mounting
Location” on page 8.
PREPARE the Mounting
Location “Prepare the Mounting Location” --
REMOVE the front cover “Remove Front Cover” --
MOUNT the drive “Mount the Drive” --
INSTALL wiring “Wiring Overview” and
“Install the Wiring” “Installing the Wiring (Supplement to ACH550-UH User’s Manual)” on
page 8.
CHECK installation “Check Installation” --
RE-INSTALL the cover “Re-install Cover” --
APPLY power “Apply Power” --
START-UP “Start-Up” --

ACH550-PCR/PDR Packaged Drive with Disconnect 7
Installation
Preparing for Installation (Supplement to ACH550-UH User’s Manual)
Drive Identification
Drive Label
To identify the type of device you are installing, refer to the type code number on the device
identification label.
• Wall mounting base drives – label attached on the side surface of the heat sink.
• Packaged drive with screw cover – label attached to outside surface on the left side of enclosure.
• Enclosure with hinged cover/door – label on inside surface of the cover/door.
Type Code
Use the following to interpret the type code found on the identification label.
ACH550-UH-015A-4 +…+…
AC, HVAC Drive = 550 Product Series
Construction
UH = Base Drive
BCR = E-Clipse Bypass with circuit breaker
BDR = E-Clipse Bypass with disconnect switch
CC = Classic Bypass with circuit breaker
CD = Classic Bypass with disconnect switch
PCR = Drive with circuit breaker
PDR = Drive with disconnect switch
VCR = Vertical bypass with circuit breaker
VDR = Vertical bypass with disconnect switch
Output current rating (See ratings chart for details)
Voltage rating
2 = 208…240 VAC
4 = 380…480 VAC
6 = 500…600 VAC
Enclosure protection class
No specification = UL Type 1/NEMA 1
+B055 = UL Type 12/NEMA 12
+B058 = UL Type 3R/NEMA 3R
Power options
+E213 = Line reactor
+F267 = Service switch
Input/Output option modules
+L511 = Relay output extension
+L512 = 115/230 V digital input interface
Fieldbus adaptors
+K451 – DeviceNet Adapter
+K452 = LonWorks Adapter
+K454 = Profibus Adapter
+K462 = ControlNet Adapter
+K466 = Ethernet Adapter

8 ACH550-PCR/PDR Packaged Drive with Disconnect
Installation
Ratings and Frame Size
The charts in the "Ratings" sections of the ACH550-UH User’s Manual and this
manual list technical specifications, and identify the drive’s frame size.
Note! Some instructions in this document vary, depending on the drive’s frame size.
To read the Ratings table, you need the “Output current rating” entry from the type
code (see above).Suitable Mounting Location
Suitable Mounting Location
For selecting a suitable mounting location for PCR/PDR configurations, refer to:
• The ACH550-UH User’s Manual, and
• The Technical Data in this manual for the appropriate information on dimensions
and weights
Installing the Wiring (Supplement to ACH550-UH User’s Manual)
WARNING!
• Metal shavings or debris in the enclosure can damage electrical equipment
and create a hazardous condition. Where parts, such as conduit plates
require cutting or drilling, first remove the part. If that is not practical, cover
nearby electrical components to protect them from all shavings or debris.
• 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.
Wiring Requirements
Refer to the “Wiring Requirements” Section in the ACH550-UH User’s Manual. The
requirements apply to all ACH550 drives. In particular:
• Use separate, metal conduit runs for the following different classes of wiring:
– Input power wiring.
– Motor wiring.
– Control/communications wiring.
• Properly and individually ground the drive, the motor and cable shields.