ABB ACH550-01 User manual

DriveIT Low Voltage AC Drives
User’s Manual
ACH550-01 Drives (0.75…90 kW)
ACH550-UH Drives (1…150 Hp)
ABB
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ACH550 Drive Manuals
GENERAL MANUALS
ACH550-01/UH User's Manual
(0.75…90 kW) / (1…150 HP)
• Safety
• Installation
• Start-Up
• Diagnostics
• Maintenance
• Technical Data
ACH550-02/UH User's Manual
(110... 355 kW) / (150... 550 HP)
• Safety
• Installation
• Start-Up
• Diagnostics
• Maintenance
• Technical Data
ACH550 Technical Reference
Manual
• Detailed Product Description
– Technical product description
including dimensional
drawings
– Cabinet mounting information
including power losses
– Softwareandcontrol including
complete parameter
descriptions
– User interfaces and control
connections
– Complete options descriptions
– Spare parts
–Etc.
• Practical Engineering Guides
– PID & PFA 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
• Programming
• Fault tracing
• Technical data
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1. Contents of this manual
2. Preparing for installation
3. Installing the drive
4. Start-up & control panel
5. Wiring and applications
6. Real-time clock and timer functions
7. Serial communications
8. Parameter listing and descriptions
9. Diagnostics and maintenance
10. Appendix and available options
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ACH550 User's Manual
Table of Contents 1
Table of Contents
Table of Contents ......................................... 1
Contents of this manual ............................... 7
What this chapter contains ......................... 7
To which products this chapter applies ...... 7
Intended use .............................................. 7
Intended audience ...................................... 7
Use of warnings and notes .........................8
Drive package .......................................... 10
Lifting the drive ......................................... 11
Preparing for installation ........................... 13
What this chapter contains ....................... 13
Drive identification, IP 21 ......................... 14
Drive identification, IP 54 ......................... 15
Frame size ............................................... 16
Motor identification ................................... 18
Motor compatibility ................................... 20
Suitable environment and enclosure ........ 21
Suitable mounting location ....................... 22
Wiring and EMC considerations ............... 25
Cabling instructions .................................. 28
Motor cables ............................................. 28
Control cables .......................................... 32
Tools required .......................................... 35
Checklist for installation preparations ......36
Installing the drive ...................................... 37
What this chapter contains ....................... 37
Preparing the mounting location ..............37
Removing front cover (IP 54) ................... 38
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2 Table of Contents
ACH550 User's Manual
Removing front cover (IP 21) ...................39
Mounting the drive (IP 54) ........................40
Mounting the drive (IP 21) ........................41
Overview of wiring installation(R1...R4) ...42
Overview of wiring installation(R5...R6) ...43
Power wiring (IP54) ..................................44
Control wiring (IP 54) ................................46
Power wiring (IP 21) .................................47
Control wiring (IP 21) ................................50
Check installation .....................................52
Re-install cover (IP 54) .............................54
Re-install cover (IP 21) .............................55
Apply power ..............................................56
Start-up & control panel .............................59
What this chapter contains .......................59
HVAC control panel (ACS-CP-B) features 59
Start-up .....................................................60
Modes .......................................................63
Standard display mode .............................64
Parameters mode .....................................66
Start-up assistant mode ...........................68
Changed parameters mode ......................71
Drive parameter backup mode .................72
Clock set mode .........................................77
I/O settings mode .....................................80
Wiring and applications .............................83
What this chapter contains .......................83
Applications ..............................................83
Selecting an application macro ................84
Restoring defaults ....................................85
1. HVAC default ........................................86
2. Supply fan ............................................88
3. Return fan .............................................90
4. Cooling tower fan .................................92
5. Condenser ............................................94
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ACH550 User's Manual
Table of Contents 3
6. Booster pump .......................................96
7. Pump alternation .................................. 98
8. Internal timer ...................................... 100
9. Internal timer with constant speeds/
Powered roof ventilator ......................... 102
10. Floating point .................................... 104
11. Dual setpoint with PID ...................... 106
12. Dual setpoint with PID and constant
speeds .................................................... 108
13. E-bypass (USA only) ........................ 110
14. Hand Control .................................... 112
Real-time clock and timer functions ....... 115
What this chapter contains ..................... 115
Real-time clock and timer features ......... 115
Using the timer .......................................116
1. Enabling the timer ..............................118
2. Setting the time period .......................119
3. Creating a timer .................................. 121
4. Connecting parameters ...................... 122
Example of timer use .............................124
Serial communications ............................ 129
What this chapter contains ..................... 129
System overview .................................... 130
Mechanical and electrical installation of the
plug-in fieldbus ....................................... 132
Setting up communication through a plug-in
fieldbus adapter module ......................... 134
Drive control parameters ........................ 136
Fieldbus control interface ....................... 145
Generic Drive Profile .............................. 159
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4 Table of Contents
ACH550 User's Manual
Parameter listing and descriptions .........165
What this chapter contains .....................165
Parameter Groups ..................................166
Overview of PID-controllers in ACH550 .266
Complete parameter list for ACH550 .....316
Diagnostics and maintenance .................349
What this chapter contains .....................349
Diagnostics displays ...............................350
Correcting faults .....................................351
Fault resetting .........................................360
History ....................................................361
Correcting alarms ...................................361
Maintenance intervals ............................365
Heatsink .................................................366
Main fan replacement .............................366
Internal enclosure fan replacement ........369
Capacitors ..............................................370
Control panel ..........................................371
Appendix and available options ..............373
What this chapter contains .....................373
Technical data ........................................373
Input power (mains) cables and fuses ....380
Cable terminals ......................................385
Input power (mains) connection .............385
Motor connection ....................................386
Control connection .................................387
Hardware description .............................388
Efficiency ................................................391
Cooling ...................................................391
Dimensions and weights ........................393
Frame size R1 (IP54/NEMA12) ..............394
Frame size R2 (IP54/NEMA12) ..............395
Frame size R3 (IP54/NEMA12) ..............396
Frame size R4 (IP54/NEMA12) ..............397
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ACH550 User's Manual
Table of Contents 5
Frame size R5 (IP54/NEMA12) .............. 398
Frame size R6 (IP54/NEMA12) .............. 399
Frame size R1 (IP21/NEMA1) ................ 400
Frame size R2 (IP21/NEMA1) ................ 401
Frame size R3 (IP21/NEMA1) ................ 402
Frame size R4 (IP21/NEMA1) ................ 403
Frame size R5 (IP21/NEMA1) ................ 404
Frame size R6 (IP21/NEMA1) ................ 405
Ambient conditions ................................. 406
Materials ................................................. 407
Applicable standards .............................. 408
EMC instructions (Europe, Australia and
New Zealand) ......................................... 409
Equipment warranty and liability ............ 411
Contact information ................................ 412
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6 Table of Contents
ACH550 User's Manual
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Contents of this manual 7
ACH550 User's Manual
Contents of this manual
What this chapter contains
This chapter contains the safety instructions which you must
follow when installing, operating and servicing the drive. If
ignored, physical injury or death may follow, or damage may
occur to the drive, the motor or driven equipment. Read the
safety instructions before you work on the unit. This chapter also
contains an introduction to the contents of this manual.
To which products this chapter applies
This chapter applies to the ACH550-01/UH.
Intended use
The ACH550 and the instructions in this manual are intended for
use in HVAC applications. The macros should only be applied to
the applications defined in the respective section.
Intended audience
This manual is intended for personnel who install, commission,
operate and service the drive. Read the manual before working
on the drive. The reader is expected to know the fundamentals
of electricity, wiring, electrical components and electrical
schematic symbols.
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8 Contents of this manual
ACH550 User's Manual
Use of warnings and notes
There are two types of safety instructions throughout this
manual:
• Warnings caution you about conditions which can result in
serious injury and death and/or damage to the equipment.
They also tell you how to avoid the danger.
• Notes draw attention to a particular condition or fact, or give
information on a subject.The warning symbols are used as
follows:
Dangerous voltage warning warns of high voltage which may
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.
Warning! The ACH550 adjustable speed AC drive should ONLY
be installed by a qualified technician.
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-.
Warning! Dangerous voltage is present when input power is
connected. After disconnecting the supply, wait at least 5
minutes before removing the cover. To check, measure for zero
voltage at the DC terminals, which are, depending on the frame
size, UDC+ and UDC-.
Warning! Even when the power is switched off from the input
terminals of the ACH550, there may be dangerous voltage (from
external sources) on the terminals of the relay outputs
R01...R03.
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Contents of this manual 9
ACH550 User's Manual
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 ACH550-01/UH is not a field repairable unit.
Never attempt to repair a malfunctioning unit; contact the factory
or your local Authorized Service Center for replacement.
Warning! The ACH550 will start up automatically after an input
voltage interruption if the external run command is on.
Warning! The heat sink may reach a high temperature. See
section "Technical data".
Warning! If the drive will be used in a floating network, see
“Warning! For floating networks remove screws at EM1 and
EM2 (R1-R4), F1 and F2(R5-R6) in the section "Installing the
drive".”
Note! For more technical information, contact the factory or your
local ABB sales representative.
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10 Contents of this manual
ACH550 User's Manual
Drive package
After opening the package, check that the following items are
included:
• ACH550 drive (1)
• Box containing clamps and connection box (IP21) (2)
• Control panel ACS-CP-B (3)
• Cardboard mounting template (4)
• User’s manual (5)
• Warning stickers in this manual
The following figure shows the contents of the drive package.
1
2
3
4
5
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Contents of this manual 11
ACH550 User's Manual
Lifting the drive
The following figure shows how to lift the drive.
Note! Lift the drive only from the metal chassis.
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12 Contents of this manual
ACH550 User's Manual
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Preparing for installation 13
ACH550 User's Manual
Preparing for installation
What this chapter contains
This chapter contains the instructions for preparing for the
installation of the drive. It contains the drive identification, wiring
and EMC guidelines and a list of tools necessary for the
installation.
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14 Preparing for installation
ACH550 User's Manual
Drive identification, IP 21
Drive labels
The location and the contents of the labels for the IP 21
protection are shown in the following figure.
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Preparing for installation 15
ACH550 User's Manual
Drive identification, IP 54
Drive labels
The location and the contents of the labels for the IP 54
protection are shown in the following figure.
Note! The location of the labels can vary between different
frame sizes.
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16 Preparing for installation
ACH550 User's Manual
The following figure shows the contents of the drive type code.
Frame size
Type Code I2N
APN kW Frame size
ACH550-x1-
see below
Three-phase supply voltage, 380...480 V
-02A4-4 2.4 0.75 R1
-03A3-4 3.3 1.1 R1
-04A1-4 4.1 1.5 R1
-05A4-4 5.4 2.2 R1
-06A9-4 6.9 3 R1
-08A8-4 8.8 4 R1
-012A-4 11.9 5.5 R1
-015A-4 15.4 7.5 R2
-023A-4 23 11 R2
-031A-4 31 15 R3
-038A-4 38 18.5 R3
-044A-4 44 22 R4
ACH550-01-08A8-4+...
AC, HVAC Drive – 550 product series
08A8 = 8.8 A, See the following table for details
4 = 380…480 VAC
UH = Setup and parts specific to US installation and NEMA compliance
2 = 208…240 VAC
Construction (region specific)
Output current rating
Voltage rating
01 = Setup and parts specific to IEC installation and compliance
Enclosure protection class
No specification = IP 21
B056 = IP 54
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