ABB ACS550-02 User manual

User’s Manual
ACS550-02 Drives (110...355 kW)
ACS550-U2 Drives (150...550 HP)

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

Safety
1
Safety
General
ACS550 in this manual refers, unless otherwise stated, to types ACS550-02 and
-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 UC+, UC-.
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 to RO3.
Warning! The ACS550-02/-U2 is a field repairable unit. In case of
service or repair of malfunctioning unit, contact your local
Authorized Service Centre for service.
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 from a single source which can either
be one of the units or an external supply.
Warning! The heat sink may reach a high temperature, see
Technical Data chapter.

Safety
2
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

Table of Contents
3
Table of Contents
Safety
Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents
Installation
Installation and Commissioning Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Start-Up
Complete Parameter List for ACS550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Complete Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Diagnostics
Diagnostic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Correcting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Maintenance
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Technical Data
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Input Power Cables and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Cable Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Input Power (Mains) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Control Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Dimensions, Weights and Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Degrees of Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Table of Contents
4
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187

Installation
5
Installation
Installation and Commissioning Flowchart
Task See
Identify the frame size of your drive, R7 or R8. Technical Data: Ratings on page 180 vs
application requirements
Plan the installation.
Check the ambient conditions, ratings, required
cooling air flow, input power connection, compatibility
of the motor, motor connection, and other technical
data.
Select the cables.
Installation
For compliance with the European Union EMC
Directive, see
Technical Data : CE / UL
Markings / C-Tick
on page 186
Option manual (if optional equipment is
included)
Unpack and check the units.
Check that all necessary optional modules and
equipment are present and correct.
Only intact units may be started up.
Installation : Moving the Unit on page 19.
If the converter has been non-operational for
more than one year, the converter DC link
capacitors need to be reformed. Ask ABB for
instructions.
Check the installation site.
Installation: Before Installation on page 21
Technical Data
Check the insulation of the motor and the motor
cable.
Installation: Checking the Insulation of the
Assembly
on page 23
If the drive is about to be connected to an IT
(ungrounded) system, check that the EMC filter is not
connected to the ground.
Delivery Check : Type code. For instructions on
how to disconnect the EMC filtering, contact
ABB.
Route the cables.
Routing Instructions:
Routing the cables installation on page 17
Install the drive. Connect the power cables. Connect
the control and the auxiliary control cables. Resistor Braking (external), contact your local ABB.
Check the installation.
Installation Checklist on page 37
Commission the drive. User Manual

Installation
6
Preparing for Installation
Checking the Compatibility of the Motor
See
Technical data for the drive ratings and the motor connection data.
WARNING! Operation is not allowed if the motor nominal voltage is less than 1/2 of
the drive nominal input voltage, or the motor nominal current less than 1/6 of the
drive nominal output current.
Protecting the Motor Winding and Bearings
The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the mains network voltage with a very short rise time. This
is the case with all drives employing modern IGBT inverter technology.
The voltage of the pulses can be almost double at the motor terminals, depending on
the motor cable properties. This in turn can cause additional stress on the motor
insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can cause current pulses through the motor bearings which can
gradually erode the bearing races.
To avoid damage to motor bearings, insulated N-end (non-driven end) bearings and
output filters from ABB are recommended according to the following table. In
addition, the cables must be selected and installed according to the instructions
given in this manual. Three types of filters are used individually or in combinations:
• optional du/dt limitation (protects motor insulation system and reduces bearing
currents).
• common mode filter (reducing bearing currents)
The common mode filter is composed of toroidal cores installed onto the output
busbars inside the drive at the factory.

Installation
7
Requirements Table
The following table shows how to select the motor insulation system and when external du/dt limitation
and insulated N-end (non-driven end) motor bearings are required. The motor manufacturer should be
consulted regarding the construction of the motor insulation and additional requirements for explosion-
safe (EX) motors. Failure of the motor to fulfil the following requirements or improper installation may
shorten motor life or damage the motor bearings. ACS550-02/U2 devices have common mode filters
(CMF) as standard accessories.
* manufactured before 1992
Manufacturer
Motor type Nominal mains
voltage (AC line
voltage)
Requirement for
Motor insulation
system ABB du/dt limitation and insulated N-end bearing
P
N< 100 kW
and
frame size < IEC 315
100 kW < P
N< 350 kW
or
frame size > IEC 315
P
N> 350 kW
or
frame size > IEC 400
P
N< 134 HP
and frame size <
NEMA 500
134 HP <
P
N< 469 HP
or frame size >
NEMA 500
P
N> 469 HP
A
B
B
Random-
wound M2_
and M3_
U
N< 500 V Standard - + N + N
Form-wound
HXR and AM_ 380 V <
U
N< 480 V Standard n.a. + N + N
Old* form-
wound HX_
and modular
380 V <
U
N< 480 V Check with the
motor
manufacturer.
Random-
wound HXR
and AM_
380 V <
U
N< 480 V Check with the
motor
manufacturer.
N
O
N
-
A
B
B
Random-
wound and
form-wound
U
N< 420 V Standard:
Û
LL =
1300 V - + N + N
420 V <
U
N< 500 V Standard:
Û
LL =
1300 V + du/dt + du/dt + N + du/dt + N
or
+ du/dt
or
Reinforced:
Û
LL =
1600 V, 0.2
microsecond rise
time
- + N + N

Installation
8
Note 1: The abbreviations used in the table are defined below.
Note 2: Explosion-safe (EX) motors
The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors.
Note 3:
HXR and AMA motors
All AMA machines (manufactured in Helsinki) to be supplied by a drive have form-wound windings. All
HXR machines manufactured in Helsinki since 1997 have form-wound windings.
Note 4:
ABB motors of types other than M2_, M3_, HX_ and AM_
Select according to non-ABB motors.
Note 5:
Resistor braking of the drive
When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC
voltage of the drive increases, the effect being similar to increasing the supply voltage by up to 20
percent. The voltage increase should be taken into consideration when determining the motor insulation
requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.
Abbreviation Definition
U
Nnominal voltage of the supply network
Û
LL peak line-to-line voltage at motor terminals which the motor insulation must withstand
P
Nmotor nominal power
du/dt du/dt filter at the output of the drive or internal du/dt limitation. Contact ABB.
CMF common mode filter toroidal cores, included in ACS550 R7 and R8.
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.

Installation
9
Supply Connection
Disconnecting Device (Means)
Install a hand-operated input disconnecting device between the AC power source
(MCC) and the drive. The disconnecting device must be of a type that can be locked
to the open position for installation and maintenance work.
EU
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 that has 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 60947-3)
• a circuit breaker suitable for isolation in accordance with EN 60947-2.
US
The disconnecting means must conform to the applicable safety regulations.
Fuses
See Technical Data: Input Power Cables and Fuses on page 182 .
Thermal Overload and Short-circuit Protection
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal overload
switch or a circuit breaker must be used for protecting each cable and motor. These
devices may require a separate fuse to cut off the short-circuit current.
The drive protects the motor cable and the motor in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive.
Mains Cable (AC line cable) Short-circuit Protection
Always protect the input cable with fuses. Standard gG (US: T or L) fuses will protect
the input cable in short-circuit situations and prevent damage to adjoining equipment
in case of a short-circuit inside the drive.
Size the fuses according to local safety regulations, appropriate input voltage and
the rated current of the drive. For fuse ratings, see
Technical Data .

Installation
10
WARNING! Circuit breakers are not capable of providing sufficient protection
because they are inherently slower than fuses. Always use fuses with circuit
breakers, if you are not sure of the circuit breaker braking capacity and mains short
circuit power.
Ground Fault Protection
The drive is equipped with an internal ground fault protective function to protect the
unit against ground faults in the motor and the motor cable. This is not a personal
safety or a fire protection feature. The ground fault protective function can be
disabled with a parameter contact ABB for more information.
The EMC filter of the drive includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the ground leakage
current and may cause fault current circuit breakers to function.
Emergency Off Devices
For safety reasons, install the emergency off devices at each operator control station
and at other operating stations where emergency off may be needed. Pressing the
stop key ( ) on the control panel of the drive does not generate an emergency off
of the motor or separate the drive from dangerous potential.
Selecting the Power Cables
General Rules
Dimension the mains (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter
Technical
Data
for the rated currents.
• The cable must be rated for at least 70 °C (158 °F) maximum permissible
temperature of conductor in continuous use. For US, follow local codes for cable
size
.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when an ground fault
occurs).
• 600 VAC cable is accepted for up to 500 VAC concerning the whole ACS550
range.
For frame sizes R7 and R8, symmetrical shielded motor cable must be used (figure
below). A four-conductor system used up to 30 kW motors cannot be used.
Compared to a four-conductor system, the use of symmetrical shielded cable
reduces electromagnetic emission of the whole drive system as well as motor
bearing currents and wear of bearings.

Installation
11
The motor cable and its PE pigtail (twisted screen) should be kept as short as
possible in order to reduce electromagnetic emission as well as capacitive current.
Motor Cable Shield
To effectively suppress radiated and conducted radio-frequency emissions, the
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminium shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires with an open helix of copper tape. The better and
tighter the shield, the lower the emission level and the bearing currents.
Additional US Requirements
Type MC continuous corrugated aluminum armor cable with symmetrical grounds or
shielded power cable must be used for the motor cables if metallic conduit is not
used. For the North American market, 600 VAC cable is accepted for up to 500 VAC.
For drives rated over 100 amperes, the power cables must be rated for 70 °C (158
°F).
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure.Use separate conduits for input power, motor, brake resistors, and control
wiring. Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
The motor cables can be run in the same cable tray as other 460 V power wiring.
Control and signal cables must not be run in the same tray as power cables. Six
conductor (3 phases and 3 ground) type MC continuous corrugated aluminum armor
cable with symmetrical grounds is available from the following suppliers (trade
names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and
Pirelli.
Insulation jacket Copper wire screen Helix of copper tape
Cable core
Inner insulation

Installation
12
Power Factor Compensation Capacitors
Do not connect power factor compensation capacitors or capacitive surge absorbers
to the motor cables (between the drive and the motor). They are not designed to be
used with drives, and will degrade motor control accuracy. They can cause
permanent damage to the drive or themselves due to the rapid changes in the drive
output voltage.
If there are power factor compensation capacitors in parallel with the three phase
input of the drive, ensure that the capacitors and the drive are not charged
simultaneously to avoid voltage surges which might damage the unit.
Equipment Connected to the Motor Cable
Installation of Safety Switches, Contactors, Connection Boxes, etc.
To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed in the motor cable (i.e. between the drive and the
motor):
• EU: Install the equipment in a metal enclosure with 360 degrees grounding for the
screens of both the incoming and outgoing cable, or connect the screens of the
cables otherwise together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor
cable shielding runs consistently without breaks from the drive to the motor.
Bypass connection
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.
Before Opening a Contactor, Sensorless Vector Control (SVC) Mode Selected
If an output isolator or contactor is used, supply either stop signal or RUN ENABLE
(see parameter 1601) signal from an auxiliary contact of the isolator to the ACS550,
in order to make sure that the ACS550 will coast to stop immediately when the
isolator opens. Improper use of the isolator may damage the ACS550 and the
isolator itself.

Installation
13
Protecting the Relay Output Contacts and Attenuating Disturbances in
Case of Inductive Loads
Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
It is highly recommended to equip inductive loads with noise attenuating circuits
[varistors, RC filters (AC) or diodes (DC)] in order to minimize the EMC emission at
switch-off. If not suppressed, the disturbances may connect capacitively or
inductively to other conductors in the control cable and form a risk of malfunction in
other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install protective components at the OMIO board terminal block.
24 VDC
230 VAC
19 RO1C
20 RO1A
21 RO1B
22 RO2C
23 RO2A
24 RO2B
25 RO3C
26 RO3A
27 RO3B
OMIO
230 VAC
Diode
Varistor
RC filter
Digital outputs
X1

Installation
14
Selecting the Control Cables
All control cables must be shielded.
Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by NK Cables,
Finland) for analogue signals. This type of cable is recommended for the pulse
encoder signals also. Employ one individually shielded pair for each signal. Do not
use common return for different analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (Figure b) is also usable.
Run analogue and digital signals in separate, shielded cables.
Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in
the same cables as digital input signals. It is recommended that the relay-controlled
signals be run as twisted pairs.
Never mix 24 VDC and 115 / 230 VAC signals in the same cable.
Relay Cable
The cable type with braided metallic screen (e.g. ÖLFLEX LAPPKABEL, Germany)
has been tested and approved by ABB.
Control Panel Cable
In remote use, the cable connecting the control panel to the drive must not exceed
3 metres (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.
Control Connections
To complete the control connections, use:
• Following tables
•
Application Macro: PFC on page 59
• Complete Parameter Descriptions on page 72
• Cable recommendations in Selecting the Control Cables on page 35
a
A double shielded twisted
pair cable
b
A single shielded twisted
multipair cable

Installation
15
1Digital input impedance 1.5 kΩ. Maximum voltage for digital inputs is 30 V.
2Default values depend on the macro used. Values specified are for the default macro. See
Application
Macros
on page 52 .
X1 Hardware Description
1 SCR Terminal for signal cable screen. (Connected internally to chassis ground.)
2 AI1 Analog input channel 1, programmable. Default2= frequency reference. Resolution
0.1%, accuracy ±1%.
J1:AI1 OFF: 0…10 V (Ri=312kΩ)
J1:AI1 ON: 0…20 mA (Ri=100Ω)
3 AGND Analog input circuit common. (Connected internally to chassis gnd. through 1 MΩ)
4 +10 V 10 V/10 mA reference voltage output for analog input potentiometer, accuracy ±2%.
5 AI2 Analog input channel 2, programmable. Default2= not used. Resolution 0.1%,
accuracy ±1%.
J1:AI2 OFF: 0…10 V (Ri=312kΩ)
J1:AI2 ON: 0…20 mA (Ri=100Ω)
6 AGND Analog input circuit common. (Connected internally to chassis gnd. through 1 MΩ)
7 AO1 Analog output, programmable. Default2= frequency. 0…20 mA (load < 500 Ω)
8 AO2 Analog output, programmable. Default2= current. 0…20 mA (load < 500 Ω)
9 AGND Analog output circuit common (Connected internally to chassis gnd. through 1 MΩ)
10 +24V Auxiliary voltage output 24 VDC / 250 mA (reference to GND). Short circuit
protected.
11 GND Auxiliary voltage output common. (Connected internally as floating.)
12 DCO
MDigital input common. To activate a digital input, there must be ≥+10 V (or ≤-10 V) between that input and DCOM. The 24 V may be provided by the
ACS550 (X1-10) or by an external 12…24 V source of either polarity.
13 DI1 Digital input 1, programmable. Default2= start/stop.
14 DI2 Digital input 2, programmable. Default2=fwd/rev.
15 DI3 Digital input 3, programmable. Default2= constant speed sel (code).
16 DI4 Digital input 4, programmable. Default2= constant speed sel (code).
17 DI5 Digital input 5, programmable. Default2= ramp pair selection (code).
18 DI6 Digital input 6, programmable. Default2= not used.
19 RO1C Relay output 1, programmable. Default2= Ready
Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)
20 RO1A
21 RO1B
22 RO2C Relay output 2, programmable. Default2= Running
Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)
23 RO2A
24 RO2B
25 RO3C Relay output 3, programmable. Default2= Fault
Maximum: 250 VAC / 30 VDC, 2 A
Minimum: 500 mW (12 V, 10 mA)
26 RO3A
27 RO3B
Analog I/O
ON
ON
ON
ON
Digital Inputs1
Relay Outputs

Installation
16
Note! Terminals 3, 6, and 9 are at the same potential.
Note! For safety reasons the fault relay signals a “fault” when the ACS550 is
powered down.
You can wire the digital input terminals in either a PNP or NPN configuration.
Communications
Terminals 28…32 are for RS485 modbus communications. Use shielded cables.
Do not directly ground the RS485 network at any point. Ground all devices on the
network using their corresponding earthing terminals.
As always, the grounding wires should not form any closed loops, and all the devices
should be earthed to a common ground.
Terminate the RS485 network using 120 Ωresistors at both ends of the network.
Use the DIP switch to connect or disconnect the termination resistors. See following
diagram and table.
1For functional descriptions, see
Application Macros on page 52 , Complete Parameter Descriptions on
page
72 , and Standard Serial Communication on page 150 .
X1 Identification Hardware Description1
28 Screen
29 B
30 A
31 AGND
32 Screen
NPN connection (sink)PNP connection (source) 10 +24V
11 GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
10 +24V
11 GND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
X1
X1
Terminated Terminated
Station Station Station Station
28 SCR
29 B
30 A
31 AGND
32 SCR
SCR
B
A
GND
B
A
GND
SCR
Other Modbus Devices
RS485 Multidrop application J2RS485 interface
Bus termination
ON
J5
ON
off position on position
J2
ON
J5
ON

Installation
17
Connection of a Motor Temperature Sensor to the Drive I/O
WARNING! IEC 664 requires double or reinforced insulation between live parts and
the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar
components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay from measuring
circuit to output contact must be rated for the same voltage level as the main
circuit of the drive.
Routing the Cables
Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables be installed on separate trays. Avoid
long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
Where control cables must cross power cables make sure they are arranged at an
angle as near to 90 degrees as possible.
The cable trays must have good electrical bonding to each other and to the
grounding electrodes. Aluminium tray systems can be used to improve local
equalizing of potential.

Installation
18
A diagram of the cable routing is below.
90 ° min 500 mm (20 in.)
Motor cable
Input power cable
Control cables
min 200 mm (8 in.)
min 300 mm (12 in.)
Motor cable
Power cable
Drive