ABB ACH550 series User manual

User’s Manual
E-Bypass Configurations (BC, BD, VC, or VD) for
ACH550 Drives (1…400 HP)

ii E-Bypass Configurations for ACH550 Drives
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
Input Disconnect Configurations (PC or PD) for
ACH550 Drives (1…550 HP)
• Safety
• Installation
• Start-Up
• Technical Data
E-Bypass Configurations (BC, BD, VC or VD) for
ACH550 Drives (1…400 HP)
• Safety
• Installation
• Start-Up
• Technical Data
©
2004, 2005 ABB Inc. All Rights Reserved.

E-Bypass Configurations for ACH550 Drives 1
Safety
Safety
WARNING! The ACH550 adjustable speed AC drive with E-Bypass should
ONLY be installed by a qualified electrician.
WARNING! Even when the motor is stopped, dangerous voltage is present at
the Power Circuit terminals U1, V1, W1 and U2, V2, W2 and, depending on the
frame size, UDC+ and UDC-, or BRK+ and BRK-.
WARNING! Dangerous voltage is present when input power is connected.
After disconnecting the supply, wait at least 5 minutes (to let the intermediate
circuit capacitors discharge) before removing the cover.
WARNING! Even when power is removed from 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 E-Bypass is connected to the line power,
the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do
not make any connections when the ACH550 with E-Bypass is connected to
the line. Disconnect and lock out power to the drive before servicing the drive.
Failure to disconnect power may cause serious injury or death.
Note! For more technical information, contact the factory or your local ABB sales
representative.

2 E-Bypass Configurations for ACH550 Drives
Safety
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.

E-Bypass Configurations for ACH550 Drives 3
Table of Contents
Table of Contents
Safety
Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents
Installation
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E-Bypass 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
Check E-Bypass Jumpers, Switches and Pots . . . . . . . . . . . . . . . . . . . . . . . . 19
Start-up
Bypass Control Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Bypass Control Board Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ACH550 Drive Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
The Bypass Application Macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical Data
Input Power Connections (Supplement to ACH550-UH User’s Manual) . . . . . 37
Motor Connections (Supplement to ACH550-UH User’s Manual) . . . . . . . . . . 44
E- Bypass Control Panel Connections
(Supplement to ACH550-UH User’s Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Dimensions and Weights (Supplement to ACH550-UH User’s Manual) . . . . . 46
Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Index

4 E-Bypass Configurations for ACH550 Drives
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 E-Bypass is connected to the line power,
the Motor Terminals T1, T2, and T3 are live even if the motor is not running. Do
not make any connections when the ACH550 with E-Bypass is connected to
the line. Disconnect and lock out power to the drive before servicing the drive.
Failure to disconnect power may cause serious injury or death.
Application
This manual is a supplement to the ACH550-UH User’s Manual and documents
E-Bypass configurations.
E-Bypass Features and Functions
The ACH550 with E-Bypass is an ACH550 AC adjustable frequency drive in an
integrated UL type 1 or UL type 12 package with a bypass motor starter. The
ACH550 with E-Bypass provides:
• Disconnect switch or circuit breaker with door mounted control lever. The lever
can be padlocked in the OFF position (padlock not supplied).
• Bypass starter.
• Motor overload protection.
• Local operator keypad with indicating lights.
• Provisions for external control connections.
• Optional drive service switch (drive input disconnect), the functional equivalent of
a three-contactor bypass arrangement.

E-Bypass Configurations for ACH550 Drives 5
Installation
The following shows the front view of the ACH550 E-Bypass vertical configuration,
and identifies the major components.
The following shows the front view of the ACH550 E-Bypass standard
configurations, and identifies the major components.
BP0091 E-Bypass
Bypass Keypad
Operating Handle
for Disconnect Switch
or Circuit Breaker
ACH-CP-B
Control Panel
ACH550 Drive
BP0092
ACH-CP-B
Bypass Keypad
Operating Handle
ACH550 Drive
Control Panel
for Disconnect Switch
or Circuit Breaker
E-Bypass
E-Bypass
(R1 … R6)
(R7, R8)

6 E-Bypass Configurations for ACH550 Drives
Installation
The following is a typical power diagram.
Installation Flow Chart
The installation of E-Bypass 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.
Task Reference in ACH550-UH User’s Manual
“Installation” section Reference in this Manual
PREPARE for
installation “Preparing for Installation” "Drive Identification" on page 7.
"Suitable Mounting Location
(Supplement to ACH550-UH User’s
Manual)" 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)"
starting on page 8.
CHECK jumpers,
switches and pots -- "Check E-Bypass Jumpers, Switches and Pots" on page 19.
CHECK installation “Check Installation” "Keypad Control Tests" on page 16.
RE-INSTALL the cover “Re-install Cover” --
APPLY power “Apply Power” --
START-UP “Start-Up” "Start-up" on page 24.
ACH550
Drive with E-Bypass
Motor
3 Phase Drive 3
3
Disconnect Switch
or Circuit Breaker
Service Switch
(Optional)
Input Power
Bypass
Contactor
Bypass
Control Drive Output
Contactor

E-Bypass Configurations for ACH550 Drives 7
Installation
Preparing for Installation (Supplement to ACH550-UH User’s Manual)
Drive Identification
Drive Labels
To determine the type of drive you are installing, refer to either:
• Serial number label attached on
upper part of the chokeplate
between the mounting holes.
• Type code label attached on the
heat sink – on the right side of the
unit cover.
Type Code
Use the following chart to interpret the type code found on either label.
Ser. no.
ACH550-BC-316A-4
*2030700001*
U1
I2N
PN 100 A
400
3~ 200...280 V
2042500001
Input
Voltage (U1)
Current (I1ND)
3 Phase 48…63 Hz
200…240 V
100 A
1 Phase 48…63 Hz
200…240 V
100 A
Output
Voltage (U2)
Current (I2ND)
3 Phase 48…63 Hz
0…Input Voltage (U1)
100 A
1 Phase 48…63 Hz
0…Input Voltage (U1)
100 A
ULType 12 / IP54
ACH550–BC–100A–2+K454+L502+L503+N661+P901
Nominal Motor
Power (PND)
Short Circuit Rating Mfg. Date: June 10, 2004 Org. Firmware: V.2.03B
ABB Inc.
Made in USA with foreign parts
OEM Part Number
15 HP
100 kAIC
400 HP
100 kAIC
ACH550-BC-316A-4+…+…
AC, HVAC Drive – 550 product series
4 = 380…480 VAC
BC = E-Bypass with circuit breaker
2 = 208…240 VAC
Construction
Output current rating (See Ratings chart for details)
Voltage rating
UH = Base drive
Enclosure protection class
No specification = IP 21 / UL type 1
+B055 = IP 54 / UL type 12
BD = E-Bypass with disconnect switch
PC = Drive with circuit breaker
PD = Drive with disconnect switch
VC = Vertical E-Bypass with circuit breaker
VD = Vertical E-Bypass with disconnect switch
Line reactor
+E213 = Line Reactor
Service Switch
+F267 = Service switch
Fieldbus Adapters
+K451 = DeviceNet Adapter
+K452 = LonWorks Adapter
+K454 = Profibus Adapter
6 = 500…600 VAC

8 E-Bypass Configurations for ACH550 Drives
Installation
Ratings and Frame Size
The chart in the “Ratings” section of the ACH550-UH User’s Manual lists technical
specifications, and identifies the drive’s frame size – significant, since 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). Also, when using the Ratings tables, note that there are two tables based on
the drive’s “Voltage rating”.
Suitable Mounting Location (Supplement to ACH550-UH User’s Manual)
In selecting a suitable mounting location for E-Bypass configurations, refer to the
Technical Data in this manual for the appropriate information on:
• Branch circuit protection
• Dimensions and weights
Installing the Wiring (Supplement to ACH550-UH User’s Manual)
WARNING!
• Do not connect or disconnect input or output power wiring, or control
wires, when power is applied.
• Never connect line voltage to drive output Terminals T1, T2, and T3.
• Do not make any voltage tolerance tests (Hi Pot or Megger) on any part of
the unit. Disconnect motor wires before taking any measurements in the
motor or motor wires.
• Make sure that power factor correction capacitors are not connected
between the drive and the motor.
Wiring Requirements
Refer to the “Wiring Requirements” Section in the ACH550 User’s Manual. The
requirements apply to all ACH550 drives. In particular:
• Use separate, metal conduit runs to keep these three classes of wiring apart:
– Input power wiring.
– Motor wiring.
– Control/communications wiring.
• Properly and individually ground the drive, the motor and cable shields.