ABB ACS550-01 User manual

DriveIT Low Voltage AC Drives
User’s Manual
ACS550-01 Drives (0.75…110 kW)
ACS550-U1 Drives (1…150 HP)

2ACS550 User’s Manual
ACS550 Drive Manuals
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GENERAL MANUALS
ACS550-01/U1 User's Manual (0.75…110 kW) /
(1…150 HP)
• Safety
•Installation
• Start-Up
• Embedded Fieldbus
• Fieldbus Adapter
• Diagnostics
• Maintenance
• Technical Data
ACS550-02/U2 User's Manual (110…355 kW) /
(150…550 HP)
• Safety
•Installation
• Start-Up
• Diagnostics
• Maintenance
• Technical Data
ACS550 Technical Reference Manual
(available in electronic format only)
• Detailed Product Description
– Technical product description including Dimensional
drawings
– Cabinet mounting information including power
losses
– Software and control including complete parameter
descriptions
– User interfaces and control connections
– Complete options descriptions
– Spare parts
–Etc.
• Practical Engineering Guides
– PID & PFC 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
• Start-Up
• Diagnostics
• Technical Data
© 2004 ABB Inc. All Rights Reserved.

ACS550 User’s Manual 3
Safety
Safety
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, 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
ACS550, there may be dangerous voltage (from external sources) on the
terminals of the relay outputs R01…R03.
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 ACS550-01/U1 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 ACS550 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 "Technical Data" on
page 215.
Warning! If the drive will be used in a floating network, remove screws at EM1
and EM3 (Frame size R1…R4), or F1 and F2 (Frame size R5 or R6). See
diagrams on page 15 and page 16 respectively. Also see "Unsymmetrically
Grounded Networks" and "Floating Networks" on page 221.
Warning! Do not attempt to install or remove EM1, EM3, F1 or F2 screws while
power is applied to the drive’s input terminals.
Note! For more technical information, contact the factory or your local ABB sales
representative.

4ACS550 User’s Manual
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

ACS550 User’s Manual 5
Table of Contents
Table of Contents
Safety
Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table of Contents
Installation
Installation Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Start-Up
Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assistant Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Basic Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Application Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Complete Parameter List for ACS550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Complete Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Embedded Fieldbus
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Mechanical and Electrical Installation – EFB . . . . . . . . . . . . . . . . . . . . . . . . . 149
Communication Set-up – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Activate Drive Control Functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Feedback from the Drive – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Diagnostics – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Modbus Protocol Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
ABB Control Profiles Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Fieldbus Adapter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Mechanical and Electrical Installation – FBA . . . . . . . . . . . . . . . . . . . . . . . . . 183
Communication Set-up – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Activate Drive Control Functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Feedback from the Drive – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Diagnostics – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
ABB Drives Profile Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Generic Profile Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Diagnostics
Diagnostic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Correcting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Correcting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

6ACS550 User’s Manual
Table of Contents
Maintenance
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Main Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Internal Enclosure Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Technical Data
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Degrees of Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Liability Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Index

ACS550 User’s Manual 7
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 3.
Installation Flow Chart
The installation of the ACS550 adjustable speed AC drive 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 See
PREPARE for installation "Preparing for Installation" on page 8.
PREPARE the Mounting Location "Prepare the Mounting Location" on page 11.
REMOVE the front cover "Remove Front Cover" on page 11.
MOUNT the drive "Mount the Drive" on page 12.
INSTALL wiring "Wiring Overview" on page 13 and
"Install the Wiring" on page 18.
CHECK installation "Check Installation" on page 23.
RE-INSTALL the cover "Re-install Cover" on page 24.
APPLY power "Apply Power" on page 25.
START-UP "Start-Up" on page 25.

8ACS550 User’s Manual
Installation
Preparing for Installation
Lifting the Drive
Lift the drive only by the metal
chassis.
Unpack the Drive
1. Unpack the drive.
2. Check for any damage and
notify the shipper immediately
if damaged components are
found.
3. Check the contents against
the order and the shipping label to verify that all parts have been received.
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.
IP2040
Ser. no.
ACS550-01-08A8-4
*2030700001*
U13~ 380...480 V
I2N / I2hd 8.8 A / 6.9 A
PN/Phd 4 / 3 kW
Ser. no.
ACS550-01-08A8-4
*2030700001*
Input U13~ 380...480 V
I1N 8.8 A
f148...63 Hz
Output U23~ 0...U1V
I2N / I2hd 8.8 A / 6.9 A
f20...500 Hz
Motor PN/Phd 4 / 3 kW

ACS550 User’s Manual 9
Installation
Type Code
Use the following chart to interpret the type code found on either label.
Ratings and Frame Size
The chart in "Ratings"on page 215 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. Also, when using the Ratings table, note
that the table is broken into sections based on the drive’s “Voltage rating”.
Motor Compatibility
The motor, drive, and supply power must be compatible:
Tools Required
To install the ACS550 you need the following:
• Screwdrivers (as appropriate for the mounting hardware used)
• Wire stripper
• Tape measure
•Drill
Motor
Specification Verify Reference
Motor type 3-phase induction motor –
Nominal current Motor value is within this
range: 0.2…2.0 * I2hd
(I2hd = drive heavy duty
current)
• Type code label on drive, entry for Output I2hd,
or
• Type code on drive and rating table in
"Technical Data" on page 215.
Nominal frequency 10…500 Hz –
Voltage range Motor is compatible with
the ACS550 voltage range. 208…240 V (for ACS550-X1-XXXX-2) or 380…480 V (for ACS550-X1-XXXX-4)
ACS550-01-08A8-4+...
AC, Standard Drive – 550 product series
See Ratings chart for details
4 = 380…480 VAC
U1 = 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 / UL type 1
B055 = IP 54 / UL type 12

10 ACS550 User’s Manual
Installation
• For installations involving ACS550-U1, frame sizes R5 or R6 and IP 54 / UL type
12 enclosures: A punch for creating conduit mounting holes.
• For installations involving ACS550-U1, frame size R6: The appropriate crimping
tool for power cable lugs. See "Power Terminal Considerations – R6 Frame Size".
• Mounting hardware: screws or nuts and bolts, four each. The type of hardware
depends on the mounting surface and the frame size:
Suitable Environment and Enclosure
Confirm that the site meets the environmental requirements. To prevent damage
prior to installation, store and transport the drive according to the environmental
requirements specified for storage and transportation. See "Ambient Conditions" on
page 240.
Confirm that the enclosure is appropriate, based on the site contamination level:
• IP 21 / UL type 1 enclosure. The site must be free of airborne dust, corrosive
gases or liquids, and conductive contaminants such as condensation, carbon
dust, and metallic particles.
• IP 54 / UL type 12 enclosure. This enclosure provides protection from airborne
dust and light sprays or splashing water from all directions.
Suitable Mounting Location
Confirm that the mounting location meets the following constraints:
• The drive must be mounted vertically on a smooth, solid surface, and in a suitable
environment as defined above.
• The minimum space requirements for the drive are the outside dimensions (see
"Outside Dimensions" on page 238), plus air flow space around the unit (see
"Cooling" on page 235).
• The distance between the motor and the drive is limited by the maximum motor
cable length. See either "Motor Connection Specifications"on page225, or "Motor
Cable Requirements for CE & C-Tick Compliance" on page 226.
• The mounting site must support the drive’s modest weight. See "Weight" on page
239.
Frame Size Mounting Hardware
R1…R4 M5 #10
R5 M6 1/4 in
R6 M8 5/16 in

ACS550 User’s Manual 11
Installation
Installing the Drive
Warning! Before installing the ACS550, ensure the input power supply to the
drive is off.
Prepare the Mounting Location
The ACS550 should only be mounted where all of the
requirements defined in "Preparing for Installation" on
page 8 are met.
1. Mark the position of the mounting holes.
2. Drill the holes.
Note! Frame sizes R3 and R4 have four holes along the top. Use only two. If
possible, use the two outside holes (to allow room to remove the fan for
maintenance).
Note! ACS400 drives can be replaced using the original mounting holes. For R1 and
R2 frame sizes, the mounting holes are identical. For R3 and R4 frame sizes, the
inside mounting holes on the top of ACS550 drives match ACS400 mounts.
Remove Front Cover
IP 21 / UL Type 1
1. Remove the control panel, if attached.
2. Loosen the captive screw at the top.
3. Pull near the top to remove the cover.
X0002
1
3
IP2000
1
2

12 ACS550 User’s Manual
Installation
IP 54 / UL Type 12
1. If hood is present: Remove screws (2) holding
hood in place.
2. If hood is present: Slide hood up and off of the
cover.
3. Loosen the captive screws around the edge of
the cover.
4. Remove the cover.
Mount the Drive
IP 21 / UL Type 1
1. Position the ACS550 onto the mounting screws
or bolts and securely tighten in all four corners.
Note! Lift the ACS550 by its metal chassis.
2. Non-English speaking locations: Add a warning
sticker in the appropriate language over the
existing warning on the top of the module.
IP 54 / UL Type 12
For the IP54 / UL Type 12 enclosures, rubber plugs are required in the holes
provided for access to the drive mounting slots.
1. As required for access, remove the rubber plugs.
Push plugs out from the back of the drive.
2. R5 & R6: Align the sheet metal hood (not shown)
in front of the drive’s top mounting holes. (Attach
as part of next step.)
3. Position the ACS550 onto the mounting screws
or bolts and securely tighten in all four corners.
Note! Lift the ACS550 by its metal chassis.
4. Re-install the rubber plugs.
5. Non-English speaking locations: Add a warning
sticker in the appropriate language over the existing warning on the top of the
module.
3
4
12
FM
IP2002
1
2
3
1, 4
FM

ACS550 User’s Manual 13
Installation
Wiring Overview
Conduit/Gland Kit
Wiring drives with the IP 21 / UL type 1 Enclosure requires a conduit/gland kit with
the following items:
• Conduit/gland box
• Five (5) cable clamps (ACS550-01 only)
•Screws
• Cover
The kit is included with IP 21 / UL type 1 Enclosures.
Wiring Requirements
Warning! Ensure the motor is compatible for use with the ACS550. The
ACS550 must be installed by a competent person in accordance with the
considerations defined in "Preparing for Installation" on page 8. If in doubt,
contact your local ABB sales or service office.
As you install the wiring, observe the following:
• There are four sets of wiring instructions – one set for each combination of drive
enclosure type (IP 21 / UL type and IP 54 / UL type 12), and wiring type (conduit
or cable). Be sure to select the appropriate procedure.
• Determine electro-magnetic compliance (EMC) requirements per local codes.
See "Motor Cable Requirements for CE & C-Tick Compliance" on page 226. In
general:
– Follow local codes for cable size.
– Keep these four classes of wiring separated: input power wiring, motor wiring,
control/communications wiring, and braking unit wiring.
• When installing input power and motor wiring, refer to the following, as
appropriate:
• To locate input power and motor connection terminals, see "Power Connection
Diagrams" starting on page 15. For specifications on power terminals, see
"Drive’s Power Connection Terminals" on page 223.
• For frame sizes R1…R4 in unsymmetrically grounded networks, see
"Unsymmetrically Grounded Networks" on page 221.
• For floating (or impedance grounded) networks, see "Floating Networks" on page
222.
Terminal Description Specifications and Notes
U1, V1, W1* 3-phase power supply input "Input Power Connections" on page 218.
PE Protective Ground "Ground Connections" on page 221.
U2, V2, W2 Power output to motor "Motor Connections" on page 225.
* The ACS550 -x1-xxxx-2 (208…240V series) can be used with a single phase supply, if output
current is derated by 50%. For single phase supply voltage, connect power at U1 and W1.

14 ACS550 User’s Manual
Installation
• For frame size R6, see "Power Terminal Considerations – R6 Frame Size" on
page 223 to install the appropriate cable lugs.
• For drives using braking (optional), refer to the following, as appropriate:
• When installing control wiring, refer to the following, as appropriate:
–"Control Terminals Table" on page 17.
–"Control Connections" on page 234.
–"Application Macros" on page 42.
–"Complete Parameter Descriptions" on page 65.
–"Embedded Fieldbus" on page 148.
–"Fieldbus Adapter" on page 180.
Frame Size Terminal Description Braking Accessory
R1, R2 BRK+, BRK- Braking resistor Braking resistor. See "Brake
Components" on page 230.
R3, R4, R5, R6 UDC+, UDC- DC bus Contact your ABB representative to
order either:
• Braking unit or
• Chopper and resistor

ACS550 User’s Manual 15
Installation
Power Connection Diagrams
The following diagram shows the terminal layout for frame size R3, which, in
general, applies to frame sizes R1…R6, except for the R5/R6 power and ground
terminals.
Warning! For floating, impedance grounded, or unsymmetrically grounded
networks, disconnect the internal RFI filter by removing:
- On ACS550-01: screws EM1 and EM3.
- On ACS550-U1: screw EM1 (drive is shipped with EM3 already removed).
See "Floating Networks" on page 222.
Panel Connector
Power LED (Green)
Fault LED (Red)
Optional Module 1
J2 – DIP Switch
X1 – Communications
Optional Module 2
GND
Power Output to Motor
Power Input
EM1
X1 – Analog Inputs and Outputs
X1 – Digital Inputs
X1 – Relay Outputs
J2
ON
off position on position
for RS485 Termination
(and 10 V Ref. Voltage Output)
(and 24 V Aux. Voltage Output)
EM3
PE
(U1, V1, W1) (U2, V2, W2)
Optional braking
Frame
Size Terminal Labels Brake Options
R1, R2 BRK+, BRK- Brake resistor
R3, R4 UDC+, UDC- • Braking unit
• Chopper and resistor
X0003
(RS485)
R5/R6 differ.
See
Frame Sizes
next page.
Diagram shows the R3 frame.
J2
ON
Other frames have similar layouts.
J1 – DIP Switches for Analog Inputs
J1 AI1: (in Voltage Position)
AI2: (in Current Position)
ON
ON

16 ACS550 User’s Manual
Installation
The following diagram shows the power and ground terminal layout for frame sizes
R5 and R6
Warning! For floating, impedance grounded, or unsymmetrically grounded
networks, disconnect the internal RFI filter by removing screws: F1 and F2.
See "Floating Networks" on page 222.
GND
Power Input
PE
(U1, V1, W1)
Optional braking
Frame
Size Terminal Labels Brake Options
R5, R6 UDC+, UDC- • Braking unit
• Chopper and resistor
X0011
F1
F2
Power Input
PE
(U1, V1, W1)
F1
F2
X0013
Power Output to Motor
(U2, V2, W2)
R5 R6
GND
GND
Power Output to Motor
(U2, V2, W2)

ACS550 User’s Manual 17
Installation
Control Terminals Table
The following provides information for connecting control wiring at X1 on the drive.
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 42.
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= 312 kΩ)
J1:AI1 ON: 0…20 mA (Ri= 100 Ω)
3 AGND Analog input circuit common (connected internally to chassis gnd. through 1 MΩ).
4 +10 V Potentiometer reference source: 10 V ±2%, max. 10 mA (1kΩ< R < 10kΩ).
5 AI2 Analog input channel 2, programmable. Default2= not used. Resolution 0.1%,
accuracy ±1%.
J1:AI2 OFF: 0…10 V (Ri= 312 kΩ)
J1:AI2 ON: 0…20 mA (Ri= 100 Ω)
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 DCOM Digital 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 (-1)
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

18 ACS550 User’s Manual
Installation
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.
Install the Wiring
Checking Motor and Motor Cable Insulation
Warning! Check the motor and motor cable insulation before connecting the
drive to input power. For this test, make sure that motor cables are NOT
connected to the drive.
1. Complete motor cable connections to the motor, but NOT to the drive output
terminals (U2, V2, W2).
2. At the drive end of the motor cable, measure the insulation
resistance between each motor cable phase and Protective
Earth (PE): Apply a voltage of 1 kV DC and verify that
resistance is greater than 1 Mohm.
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
PE
M
ohm

ACS550 User’s Manual 19
Installation
Wiring IP 21 / UL type 1 Enclosure with Cables
1. Open the appropriate knockouts in the conduit/gland
box. (See "Conduit/Gland Kit" above.)
2. Install the cable clamps for the power/motor cables.
3. On the input power cable, strip the sheathing back
far enough to route individual wires.
4. On the motor cable, strip the sheathing back far
enough to expose the copper wire screen so that the
screen can be twisted into a pig-tail. Keep the short
pig-tail short to minimize noise radiation.
5. Route both cables through the clamps.
6. Strip and connect the power/motor wires, and the
power ground wire to the drive terminals.
Note! For R5 frame size, the minimum power cable
size is 25 mm2(4 AWG).
For R6 frame size, refer to "Power Terminal
Considerations – R6 Frame Size" on page 223.
7. Connect the pig-tail created from the motor cable screen.
8. Install conduit/gland box and tighten the cable clamps.
9. Install the cable clamp(s) for the control cable(s).
(Power/motor cables and clamps not shown in
figure.)
10. Strip control cable sheathing and twist the copper
screen into a pig-tail.
11. Route control cable(s) through clamp(s) and tighten
clamp(s).
12. Connect the ground screen pig-tail for digital and
analog I/O cables at X1-1. (Ground only at drive
end.)
13. Connect the ground screen pig-tail for RS485 cables
at X1-28 or X1-32. (Ground only at drive end.)
14. Strip and connect the individual control wires to the
drive terminals. See "Control Terminals Table" on
page 17.
15. Install the conduit/gland box cover (1 screw).
1
2
X0004
6
3
IP2001
6
7
4
8
8
X0005
9X0006
12
IP2003
11
14

20 ACS550 User’s Manual
Installation
Wiring IP 21 / UL Type 1 Enclosure with Conduit
1. Open the appropriate knockouts in the conduit/gland
box. (See "Conduit/Gland Kit" above.)
2. Install thin-wall conduit clamps (not supplied).
3. Install conduit/gland box.
4. Connect conduit runs to box.
5. Route input power and motor wiring through conduits
(must be separate conduit runs).
6. Strip wires.
7. Connect power, motor, and ground wires to the drive
terminals.
Note! For R5 frame size, the minimum power cable
size is 25 mm2(4 AWG).
For R6 frame size, refer to "Power Terminal Considerations – R6 Frame Size" on
page 223.
8. Route the control cable through the conduit (must be
separate from input power and motor conduit runs).
9. Strip the control cable sheathing and twist the copper
screen into a pig-tail.
10. Connect the ground screen pig-tail for digital and
analog I/O cables at X1-1. (Ground only at drive end.)
11. Connect the ground screen pig-tail for RS485 cables
at X1-28 or X1-32. (Ground only at drive end.)
12. Strip and connect the individual control wires to the
drive terminals. See "Control Terminals Table" on
page 17.
13. Install the conduit/gland box cover (1 screw).
2X0007
3
X0005
4IP2004
7
7
5
10
8
IP2005
12