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.