ABB ACQ550-U1-015A-4 Series User manual

User’s Manual
ACQ550-CC Packaged Drive with Bypass
Supplement for ACQ550-U1 Drives User’s Manual

ii ACQ550-CC Packaged Drive with Bypass
ACQ550 Drive Manuals
GENERAL MANUALS
ACQ550-U1 Drives User's Manual (1…550 HP)
• Safety
•Installation
• Start-Up
• Embedded Fieldbus
• Fieldbus Adapter
• Diagnostics
• Maintenance
• Technical Data
ACQ550-PC/PD Drive with Disconnect
Supplement to ACQ550-U1 User’s Manual
• Safety
•Installation
• Start-Up
• Technical Data
ACQ550-CC Packaged Drive with Bypass
Supplement for ACQ550-U1 User’s Manual
• Safety
•Installation
• Start-Up
• Maintenance
• Technical Data
© 2007 ABB Inc. All Rights Reserved.

ACQ550-CC Packaged Drive with Bypass 1
Safety
Safety
WARNING! The ACQ550 adjustable speed AC drive with Bypass should ONLY
be installed by a qualified electrician.
WARNING! Even when the motor is stopped, dangerous voltage is present at
the Power Circuit terminals U1, V1, W1 and U2, V2, W2 and, depending on the
frame size, UDC+ and UDC-, or BRK+ and BRK-.
WARNING! Dangerous voltage is present when input power is connected.
After disconnecting the supply, wait at least 5 minutes (to let the intermediate
circuit capacitors discharge) before removing the cover.
WARNING! Even when power is removed from the input terminals of the
ACQ550, 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 ACQ550 will start up automatically after an input voltage
interruption if the external run command is on.
WARNING! When the ACQ550 with 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 ACQ550 with 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 ACQ550-CC Packaged Drive with Bypass
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.

ACQ550-CC Packaged Drive with Bypass 3
Table of Contents
Table of Contents
Safety
Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents
Installation
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bypass Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing the Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance
Maintenance Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Technical Data
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power Connection Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Motor Connection Specifications – R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cooling – R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Index

4 ACQ550-CC Packaged Drive with Bypass
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 ACQ550 with 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 ACQ550 with 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 ACQ550-U1 User’s Manual and documents
Bypass configurations.
Bypass Features and Functions
The ACQ550 with Bypass is an ACQ550 AC adjustable frequency drive in an
integrated UL Type/NEMA 1, UL Type/NEMA 12, or UL Type/NEMA 3R package
with a bypass function configured entirely of standard industrial control components.
The ACQ550 with Bypass provides:
• Main circuit breaker with door mounted control lever. The lever can be padlocked
in the OFF position (padlock not supplied).
• Electrically interlocked Bypass and drive output contactors
• Class 20 motor overload protection.
• ACQ-CP-AQ drive control panel
– Cover mounted - UL Type/NEMA 1 and 12 enclosures
– Drive mounted - UL Type/NEMA 3R enclosures
• Bypass cover mounted control
– Drive-Off-Bypass selector switch
• Provisions for external control connections.
• Optional drive service switch (drive input disconnect), the functional equivalent of
a three-contactor bypass arrangement.

ACQ550-CC Packaged Drive with Bypass 5
Installation
The following shows the front view of a typical ACQ550 Bypass wall mount
configuration, and identifies the major components.
The following shows the front view of a typical ACQ550 Bypass floor mount
configuration, and identifies the major components.
l
ACQ-CP-AQ
Control Panel
Operating handle for
Circuit Breaker
Cover Control
ACQ-CP-AQ
Control Panel
Operating handle for
Circuit Breaker
Cover Control

6 ACQ550-CC Packaged Drive with Bypass
Installation
The following is a typical power diagram.
Installation Flow Chart
The installation of Bypass Configurations for ACQ550 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 ACQ550-U1
User’s Manual
“Installation” section
Reference in this Manual
PREPARE for
installation
“Preparing for Installation” Floor Mounted: “Lifting the Drive”
on page 7.
“Drive Identification” on page 8.
“Suitable Mounting Location
(Supplement to ACQ550-U1 User’s
Manual)” on page 8.
PREPARE the Mounting
Location
“Prepare the Mounting
Location”
“Prepare the Mounting Location –
Floor Mounted Enclosures” on
page 9.
“Dimensions and Weights” on
page 27.
REMOVE the front cover “Remove Front Cover” --
MOUNT the drive “Mount the Drive” --
INSTALL wiring “Wiring Overview” and
“Install the Wiring”
“Installing the Wiring” starting on
page 10.
CHECK installation “Check Installation” --
RE-INSTALL the cover “Re-install Cover” --
APPLY power “Apply Power” --
START-UP “Start-Up” –
ACQ550
Drive with Bypass
3 Phase
Drive
Circuit Breaker
Input Power
Service Switch
(Optional)
Drive Output
Contactor
Motor
Bypass
Contactor

ACQ550-CC Packaged Drive with Bypass 7
Installation
Preparing for Installation
Lifting the Drive
Floor Mounting
Warning! Handle and ship floor mounted enclosures
only in the upright position. These units are not
designed to be laid on their backs.
1. Use a pallet truck to move the package/enclosure to the
installation site.
2. Remove andy bolts that secure the cabinet to the shipping
pallet.
Warning! Use the lifting lugs/bars at the top of the unit
to lift floor mounted drives.
3. Use a hoist to lift the drive. (Do not place drive in final
position until mounting site is prepared.)
PC00005
PC00003
30o

8 ACQ550-CC Packaged Drive with Bypass
Installation
Preparing for Installation
Drive Identification
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 the enclosure.
• Enclosure with hinged cover/door – label on inside surface of the cover/door.
Type Code Number
Use the following to interpret the type code found on the identification label.
ACQ550-U1-015A-4 +…+…
AC Drive = 550 Product Series
Construction
U1 = Base Drive
CC = Bypass with circuit breaker
PC = Drive with circuit breaker
PD = Drive 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/NEMA 1
+B055 = UL Type/NEMA 12
+B058 = UL Type/NEMA 3R
Power options
+F267 = Service switch
Input/Output option modules
+L511 = Relay output extension
+L512 = 115/230 V digital input interface
Fieldbus adaptors
+K451 = DeviceNet Adapter
+K457 = CANopen Adapter
+K462 = ControlNet Adapter
+K466 = Ethernet Adapter
+K467 = PROFINET IO Adapter
Miscellaneous Options
+P191 = Bypass Cover Control Option
Suitable Mounting Location (Supplement to ACQ550-U1 User’s Manual)
For selecting a suitable mounting location for Drive with Bypass units, refer to:
• Preparing for installation in the ACQ550-U1 User’s Manual, and
• The Technical Data section of this manual for information on dimensions and
weights.

ACQ550-CC Packaged Drive with Bypass 9
Installation
Installing the Drive
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.
Prepare the Mounting Location – Floor Mounted Enclosures
The ACQ550 should only be mounted where all of the requirements defined in
“Preparing for Installation” are met.

10 ACQ550-CC Packaged Drive with Bypass
Installation
Installing the Wiring
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 ACQ550-U1 User’s Manual. The
requirements apply to all ACQ550 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.

ACQ550-CC Packaged Drive with Bypass 11
Installation
Wiring Overview
Connection Diagrams —
ACQ550-CC units are configured for wiring access from the top or the bottom. The
following figures show the wiring connection points. Refer to the ACQ550-U1 User's
Manual for control connections to the drive.
Control Transformer
Grounding
Connection
Circuit
Breaker
Drive Control
Unit
RDCU (RMIO)
Drive
Contactor
Bypass
Contactor
Overload
Grounding
Connection
Terminals
Thermostats
Relay
VFD Fuses
VFD
Grounding Lug
Main Circuit
Breaker
Service Switch
Drive Contactor
Bypass Contactor
Overload Relay
Control Relay
Terminal Blocks
Grounding Lug
VFD Fuses
VFD
Control Circuit
Transformer
VFD
Typical Wall Mount Typical Floor Mount

12 ACQ550-CC Packaged Drive with Bypass
Installation
Install the Line Input Wiring
Line Input Connections – Bypass Configurations
Connect input power to the terminals of the circuit breaker. Connect the equipment
grounding conductor to the ground lug at the top of the enclosure. The figures below
show the connection points for typical configurations. Units are configured for wiring
access from the top or the bottom.
WARNING! Check the motor and motor wiring insulation before connecting
the ACQ550 to line power. Follow the procedure in the ACQ550-U1 User’s
Manual. Before proceeding with the insulation resistance measurements,
check that the ACQ550 is disconnected from incoming line power. Failure to
disconnect line power could result in death or serious injury.
Typical Wall Mount Typical Floor Mount

ACQ550-CC Packaged Drive with Bypass 13
Installation
Install the Motor Wiring
Motor Connections – Bypass Configurations
Connect the motor cables to the motor overload relay output terminals; see the
figures below. The motor grounding conductor can be connected to the ground lug
near the motor overload relay.
Install the Control Wiring (Supplement to ACQ550-U1 User’s Manual)
Connect control wiring to the terminal block 1TB located on the back panel toward
the bottom of the enclosure and terminal block x1 inside the drive.
Control Wiring
The control wiring includes connections to an analog speed command signal and
start/stop relay contact for controlling the drive in the AUTO mode. There may also
be connections to external run enable interlock contacts and a connection from the
Motor Run contact to an external status indicating circuit.
Wiring Practices
The external control wiring must not be run in the same conduit or raceway with any
high power wiring. The external speed reference signal must be wired using a
shielded, twisted pair cable. The shield connection must be terminated at the ground
terminal provided (x1:3). The other end of the shield should be cut and taped back at
the signal source.
Typical Wall Mount Typical Floor Mount
Overload
Relay Output
Terminals
Motor
Ground Lug
Overload Relay
Output Terminals
Motor
Ground Lug

14 ACQ550-CC Packaged Drive with Bypass
Installation
Terminal Block 1TB
Connection Points
Basic control connections are made to 1TB, which is a din-rail terminal block on the
back panel at the bottom of the enclosure. 1TB includes screw clamp terminals rated
for #22-10 AWG stranded or solid wire. Recommended tightening torque is 4.4 - 7.1
in-lbs.
Terminals 1TB:7 and 1TB:8 are 120 VAC control circuit terminals connected to 120
VAC control power supplied by the control circuit transformer provided. Terminals
1TB:9 and 1TB:10 are powered at 24VDC to accept an external contact closure to
start the drive. Terminals 1TB:13 and 1TB:14 are connected to un-powered relay
contacts provided for use with externally powered customer control circuits.
Additional Connections
The low voltage speed reference signal input, analog outputs, additional relay
outputs, and additional digital input connections are available on Terminal Block X1
inside the ACQ550. Note that the Bypass control circuitry uses inputs and outputs
DI1, DI4 and R02. These inputs are not available for any other purpose and must not
be reconfigured. Output RO2 is wired to the terminal block, 1TB. AI1, AI2, DI3, DI5,
DI6, RO1, and R03 are available for use. Refer to the ACQ550-U1 User’s Manual for
information about control connections on Terminal Block X1. When making
connections to Terminal Block X1, be careful not to disturb the factory installed wiring
between X1 and the Bypass control circuitry.
Analog Input
The external “Auto” speed reference is to be connected to ACQ550 analog input AI1.
The analog input can accept a voltage signal (0 – 10 VDC) or a current signal (0 – 20
mA). Jumper J1, located on the Control Board in the ACQ550, determines the signal
type. J1 can be set in either the voltage or current position according to the type of
external signal that will be connected. Refer to the ACQ550-U1 User’s Manual.
Run Enable Interlocks
Run Enable interlocks are normally closed un-powered contacts connected in series
between 1TB:7 and 1TB:8. When any of these contacts opens, the motor will stop,
whether in DRIVE or BYPASS. The unit is shipped with a jumper installed from
1TB:7 to 1TB:8. This jumper must be removed before connecting external contacts.
REMOTE RUN
MOTOR RUN
Replace Jumper with customer run enable
interlock contacts

ACQ550-CC Packaged Drive with Bypass 15
Installation
Auto Start Contact
To start the ACQ550 by means of an external un-powered contact (maintained),
connect the contact to 1TB:9 and 1TB:10. Closing this contact will start the motor
when the drive is in the AUTO mode.
Relay Contact Output
A “Motor Running” relay contact output is provided at terminals 1TB:13 and 1TB:14
for external indication of the motor status. The output consists of a normally open
auxiliary contact on the bypass contactor and a normally open “Drive Running”
contact from the ACQ550. The two contacts are connected in parallel so that a
contact closure is provided whenever the motor is running.
Refer to “Control Connections” in the ACQ550-U1 User’s Manual Technical Data
where relay contacts are used to control inductive loads.

16 ACQ550-CC Packaged Drive with Bypass
Installation
Motor Overload Relay
The ACQ550 with Bypass includes a motor overload relay to provide thermal motor
protection. It is connected in both drive and bypass modes of operation. For motor
full load currents up to 80 amperes, the Motor Overload Relay is an adjustable trip,
bimetallic overload relay with a class 20 trip characteristic. Above 80 amperes, the
Motor Overload Relay is an adjustable trip, electronic overload relay with selectable
class 10, 20 or 30 trip characteristic.
Suggested Settings
Current
Set the current adjustment to the value of the full load current shown on the motor
nameplate.
Auto/Man
It is recommended the overload relay be set to the Manual Reset mode of operation.
In the Auto Reset mode, the Overload Relay contacts re-close automatically when
the bi-metals of bi-metallic versions cool or when the timer function within the
electronic versions times out. If power is applied and the switches and contacts in
the control circuit are commanding the motor to run, the motor will start as soon as
the overload relay resets.
Class
The class 20 setting on the electronic overload relays would be the appropriate
choice for the majority of the motors used in North America.
Resetting the Overload Relay
In the event an overload relay set in the Manual Reset mode trips, it is necessary to
open the door of the enclosure and push the Reset button on the front of the
overload relay to reset it.
WARNING! If power is applied and the switches and contacts in the control
circuit are commanding the motor to run, the motor will start as soon as the
overload relay resets. Use caution when manually resetting the overload relay
to make sure it is safe to start the motor.

ACQ550-CC Packaged Drive with Bypass 17
Maintenance
Maintenance
Maintenance Interval
If installed in an appropriate environment, the drive requires very little maintenance.
The table lists the routine maintenance intervals recommended by ABB. The
information shown below is supplemental and in addition to that shown in the
ACQ550-U1 User’s Manual.
Maintenance Configuration Interval
Check/replace enclosure inlet air
filter
UL Type/NEMA 12 and 3R
enclosures
Check every 3 months.
Replace as needed.
Check/replace enclosure
exhaust air filter
UL Type/NEMA 12 and 3R
enclosures
Check every 6 months.
Replace as needed.
Replace enclosure vent fan(s) UL Type/NEMA 12 and 3R
enclosures
Every three years.
Replace enclosure air circulation
fan
Frames R4 through R6 in UL
Type/NEMA 1 enclosures
Every three years.

18 ACQ550-CC Packaged Drive with Bypass
Technical Data
Technical Data
Ratings
Note! The ratings listed below are exceptions to the ratings listed in the ACQ550-U1
User’s Manual.
Ratings, 380…480 Volt Drives
Input Power Connections
Branch Circuit Protection
Input power is connected to the ACQ550 with Bypass through a circuit breaker that
provides the branch circuit short circuit and ground fault protection for the motor
operating in the bypass mode.
Fuses
Drive input fuses are provided to disconnect the drive from power in the event that a
component fails in the drive’s input power circuitry. The drive’s electronic protection
circuitry is designed to clear drive output short circuits and ground faults without
blowing the drive input fuses. Drive input fuses are shown in the following tables.
Note! Although fuses listed are similar in functional characteristics to fuses listed in
the ACQ550-U1 User’s Manual, physical characteristics may differ. Fuses from other
manufacturers can be used if they meet the functional characteristics of those shown
in the tables.
Type Code Valid up to 40°C (104 °F)
Frame Size
Normal Use Heavy-Duty Use
ACQ550-Cx-
see below
I2N
A
PN
HP
I2hd
A
Phd
HP
-316A-4 316 250 240 200 R8
-368A-4 368 300 302 250 R8
-414A-4 414 350 368 300 R8
-486A-4 486 400 414 350 R8