ABB ACS550-U2 Owner's manual

DriveIT Low Voltage AC Drives
Installation Supplement
ACS550-U2 Drives (150…550 HP)

2 Installation Supplement for ACS550-U2 Drives
ACS550 Drive Manuals
GENERAL MANUALS
ACS550-01/U1 User's Manual (0.75…90 kW) /
(1…150 HP)
• Safety
• Installation
• Start-Up
• Diagnostics
• Maintenance
• Technical Data
ACS550-02/U2 User's Manual (110…355 kW) /
(150…550 HP)
• Safety
• Installation
• Start-Up
• Diagnostics
• Maintenance
• Technical Data
ACS550 Technical Reference Manual
• Detailed Product Description
– Technical product description including Dimensional
drawings
– Cabinet mounting information including power
losses
– Software and control including complete parameter
descriptions
– User interfaces and control connections
– Complete options descriptions
– Spare parts
–Etc.
• Practical Engineering Guides
– PID & PFC engineering guides
– Dimensioning and sizing guidelines
– Diagnostics and Maintenance information
–Etc.
OPTION MANUALS
(Fieldbus Adapters, I/O Extension Modules etc., manuals
delivered with optional equipment)
Relay Output Extension Module (typical title)
• Installation
• Start-Up
• Diagnostics
• Technical Data

Installation Supplement for ACS550-U2 Drives 3
Safety
Safety
General
In this manual, ACS550 refers, unless otherwise stated, to type ACS550-U2.
Warning! The ACS550 adjustable speed AC drive should ONLY be installed by
a qualified electrician.
Warning! Even when the motor is stopped, dangerous voltage is present at the
Power Circuit terminals U1, V1, W1 and U2, V2, W2 and UDC+, UDC-.
Warning! Even when power is removed from the input terminals of the
ACS550, there may be dangerous voltage (from external sources) on the
terminals of the relay outputs RO1…RO3 or on option modules.
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 any covers.
Warning! The ACS550-U2 is field repairable by qualified personnel only. To
service or repair a malfunctioning unit, contact your local Authorized Service
Center.
Warning! The ACS550 will start up automatically after an input voltage
interruption if the external run command is on.
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
form a single source, which can either be one or the units, or an external
supply.
Warning! The heat sink may reach a high temperature. See Technical Data
chapter in User’s Manual.
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.
General warning warns about conditions, other than those caused by electricity,
which can result in physical injury and/or damage to the equipment.

4 Installation Supplement for ACS550-U2 Drives
Table of Contents
Table of Contents
Safety
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table of Contents
Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Moving the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting Power and Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Separating the Drive and Extension Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Technical Data
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation Supplement for ACS550-U2 Drives 5
Installation
Installation
Introduction
ACS550-U2 drives include an extension
module that is not covered in the
ACS550-02/U2 User’s Manual. The
extension module is attached to the drive
module at the factory.
This supplement provides the additional
extension module information required
for ACS550-U2 drives:
• Additional installation steps and
considerations.
• Steps for separating the drive from the
extension module for drive service
access.
• Dimensions for the extension module.
This supplement requires and routinely refers to the document: ACS550-02/U2
User’s Manual.
WARNING! Only qualified electricians are allowed to carry out the work described in
this chapter. Follow requirements in "Safety" on the first pages of this manual.
Ignoring the safety instructions can cause injury or death.
Planning
When planning for cable/conduit routing, refer to the ACS550-02/U2 User’s Manual,
but note that, for the ACS550-U2, all connections are routed through the top of the
extension module.
Moving the Unit
1. Move the transport package by pallet truck to the installation
site.
2. Unpack the transport package.
3. To position the unit, use a lift, connected as shown.
Drive
Extension
Module Module

6 Installation Supplement for ACS550-U2 Drives
Installation
Mounting
Fastening the Unit
See the "Dimensional Drawings" in the "Technical Data" section of this document for
the exact locations of the mounting points.
1. Use at least four screws – two at the front, two at the back – to attach the unit base
plate to the floor.
2. Use at least two screws to attach the back of the enclosure to a wall.
There are two holes available at the top of each: the extension module and the drive
module.
Connecting Power and Control Cables
Additional considerations that apply with the enclosure extension:
• The power cable connection diagram that applies for the ACS550-U2 is:
• Temporarily remove the upper high voltage shield (clear plastic) to gain access to
the power connections in the extension module.
• To avoid metal shavings inside the cabinet, temporarily remove the gland/conduit
plate at the top of the extension module. Then drill holes and mount conduit or
cable fittings as needed.
Extension Module ACS550-02
Control
Panel
Switch-fuse
Disconnect
3 ~
Motor
Supply
Control
Wiring
Drive Module
V2U2 W2
V1U1 W1
3
3
3
L1 L2 L3 PE U1 V1 W1
PE
PE
OMIO

Installation Supplement for ACS550-U2 Drives 7
Installation
• Route all power and control wiring through the top of the extension module.
• The following diagram shows the power and control connection points in the
enclosure module supplied with the R7 drive module.
PDM-146378-8
Switch Fuse
Input (U1,V1,W1)
Output (U2,V2,W2)
PE Connection
Gland/Conduit Plate
OMIO Board
(Control Wiring Terminals
and Option Module Mounts)
R7 Frame Size (Cable fittings shown
are typical examples
)

8 Installation Supplement for ACS550-U2 Drives
Installation
• The following diagram shows the power and control connection points in the
enclosure module supplied with the R8 drive module.
• Re-mount the high voltage shield.
Warning! Always replace all high voltage shields before applying power.
• See the ACS550-02/U2 User’s Manual for detailed instructions on control
connections, installation check list and drive start-up process.
Switch Fuse
Input (U1,V1,W1)
Output (U2,V2,W2)
PE Connection
OMIO Board
(Control Wiring Terminals
and Option Module Mounts)
R8 Frame Size Gland/Conduit Plate
(Cable fittings show
n
are typical example
s)

Installation Supplement for ACS550-U2 Drives 9
Maintenance
Maintenance
This section describes the procedure for separating the drive and extension
modules, which is required to provide service access to the drive module.
Safety
WARNING! Read "Safety" on the first pages of this manual before performing any
maintenance on the equipment. Ignoring the safety instructions can cause injury or
death. Note: There are parts carrying dangerous voltages near the OMIO board
when the drive is powered.
Separating the Drive and Extension Modules
The drive module is mounted on a trolley that straddles a pedestal. The following
procedure removes mechanical connections so that the drive module and trolley can
roll forward for service access.
1. Disconnect all power sources from the drive/
extension modules and wait at least 5 minutes for
internal capacitors to fully discharge.
2. Remove all front covers from the drive module.
3. Disconnect the control panel cable.
4. Remove the upper side plate from the drive module
if convenient.
5. Remove screws (if any) that fasten the drive module
to the wall.
6. Inside the pedestal, toward the rear are screws that
attach the drive bus bars to the pedestal bus bars.
The connections are staggered for easy access
using a wrench with an extension. Remove these
screws (6).
Torque when re-assembling:
• R7: M8 (5/16 in) screws, 15…22 Nm (11…16 lb
ft)
• R8: M10 (3/8 in) screws, 30…44 Nm (22…32 lb
ft)
Warning! Be careful not to drop screws inside the
pedestal. Loose metal pieces inside the unit may
cause damage.
R7 5
6

10 Installation Supplement for ACS550-U2 Drives
Maintenance
7. The following cables between the drive and the
extension module are split by a connector located
at the front of the drive. Disconnect both cables at
this location.
• The power supply cable to the OMIO board.
• The power supply cable to the extension
module cooling fan.
8. At the OTIF board, disconnect the two fiber optic
cables. Make note of the terminal colors for use
when reconnecting.
9. Carefully remove the cables disconnected in the
above steps: Pull the cables down inside the
pedestal and bundle them so that they will not get
damaged or caught in the trolley when the drive
module is wheeled out.
10. Remove screws fastening the drive module trolley
to the pedestal.
Warning! These screws are an important step
during re-assembly – the screws are required for
grounding the drive.
11. R8: The front of the trolley includes support
braces that fold out. Lift each brace slightly and
fold it out.
12. Remove screws that fasten the drive module to
the extension module.
CAUTION! The drive module is now separated
and could tip over. Use care when moving the
drive module.
13. Pull on the handle to wheel the drive module out.
Drive Maintenance
See the ACS550-02/U2 User’s Manual for drive
maintenance procedures.
Re-Assembly
Re-attach the modules in reverse order to the above.
R7
7
8
9
R7
13
10
10 Pedesta
l
Trolley
12

Installation Supplement for ACS550-U2 Drives 11
Technical Data
Technical Data
Dimensional Drawings
See the ACS550-02/U2 User’s Manual for drive module dimensions.
Extension Module R7
3AFE 64626264 30.04.02
Dimensions are listed in millimeters and [inches]

12 Installation Supplement for ACS550-U2 Drives
Technical Data
Detail
Dimensions are listed in millimeters and [inches]

Installation Supplement for ACS550-U2 Drives 13
Technical Data
Extension Module R8
3AFE 64626388 30.04.02
US gland/conduit
Dimensions are listed in millimeters and [inches]

14 Installation Supplement for ACS550-U2 Drives
Technical Data
Detail
Dimensions are listed in millimeters and [inches]

Installation Supplement for ACS550-U2 Drives 15
Technical Data

ABB Oy
AC Drives
P.O. Box 184
FIN-00381 HELSINKI
FINLAND
Telephone [phone]
Telefax [phone]
Internet http://www.abb.com
ABB Inc.
Automation Technologies
Drives & Machines
16250 West Glendale Drive
New Berlin, WI 53151
USA
Telephone [phone]
800 HELP-365
Telefax 262 780-5135
3AUA0000004067 REV A/ EN EFFECTIVE: Oct. 22, 2003 SUPERSEDES: None