ABB ACH550 series Bedienungsanleitung

User’s Manual

E-Bypass Configurations (BC, BD, VC, or VD) for

ACH550 Drives (1…400 HP)

ii E-Bypass Configurations for ACH550 Drives

ACH550 Drive Manuals

GENERAL MANUALS

ACH550-UH HVAC User's Manual (1…550 HP)

• Safety

• Installation

• Start-Up

• Embedded Fieldbus

• Fieldbus Adapter

• Diagnostics

• Maintenance

• Technical Data

Input Disconnect Configurations (PC or PD) for

ACH550 Drives (1…550 HP)

• Safety

• Installation

• Start-Up

• Technical Data

E-Bypass Configurations (BC, BD, VC or VD) for

ACH550 Drives (1…400 HP)

• Safety

• Installation

• Start-Up

• Technical Data

E-Bypass Configurations for ACH550 Drives 1

Safety

WARNING! The ACH550 adjustable speed AC drive with E-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

ACH550, 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 ACH550 will start up automatically after an input voltage

interruption if the external run command is on.

WARNING! When the ACH550 with E-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 ACH550 with E-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 E-Bypass Configurations for ACH550 Drives

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.

E-Bypass Configurations for ACH550 Drives 3

Table of Contents

Safety

Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table of Contents

Installation

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

E-Bypass Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Preparing for Installation (Supplement to ACH550-UH User’s Manual) . . . . . . . 7

Installing the Wiring (Supplement to ACH550-UH User’s Manual) . . . . . . . . . . 8

Check E-Bypass Jumpers, Switches and Pots . . . . . . . . . . . . . . . . . . . . . . . . 19

Start-up

Bypass Control Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Bypass Control Board Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

ACH550 Drive Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

The Bypass Application Macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Technical Data

Input Power Connections (Supplement to ACH550-UH User’s Manual) . . . . . 37

Motor Connections (Supplement to ACH550-UH User’s Manual) . . . . . . . . . . 44

E- Bypass Control Panel Connections

(Supplement to ACH550-UH User’s Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Dimensions and Weights (Supplement to ACH550-UH User’s Manual) . . . . . 46

Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Index

4 E-Bypass Configurations for ACH550 Drives

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 ACH550 with E-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 ACH550 with E-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 ACH550-UH User’s Manual and documents

E-Bypass configurations.

E-Bypass Features and Functions

The ACH550 with E-Bypass is an ACH550 AC adjustable frequency drive in an

integrated UL type 1 or UL type 12 package with a bypass motor starter. The

ACH550 with E-Bypass provides:

• Disconnect switch or circuit breaker with door mounted control lever. The lever

can be padlocked in the OFF position (padlock not supplied).

• Bypass starter.

• Motor overload protection.

• Local operator keypad with indicating lights.

• Provisions for external control connections.

• Optional drive service switch (drive input disconnect), the functional equivalent of

a three-contactor bypass arrangement.

E-Bypass Configurations for ACH550 Drives 5

Installation

The following shows the front view of the ACH550 E-Bypass vertical configuration,

and identifies the major components.

The following shows the front view of the ACH550 E-Bypass standard

configurations, and identifies the major components.

BP0091 E-Bypass

Bypass Keypad

Operating Handle

for Disconnect Switch

or Circuit Breaker

ACH-CP-B

Control Panel

ACH550 Drive

BP0092

ACH-CP-B

Bypass Keypad

Operating Handle

ACH550 Drive

Control Panel

for Disconnect Switch

or Circuit Breaker

E-Bypass

(R1 … R6)

(R7, R8)

6 E-Bypass Configurations for ACH550 Drives

Installation

The following is a typical power diagram.

Installation Flow Chart

The installation of E-Bypass Configurations for ACH550 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 ACH550-UH

User’s Manual

“Installation” section Reference in this Manual

PREPARE for

installation “Preparing for Installation” "Drive Identification" on page 7.

"Suitable Mounting Location

(Supplement to ACH550-UH User’s

Manual)" on page 8

PREPARE the Mounting

Location “Prepare the Mounting

Location” --

REMOVE the front cover “Remove Front Cover” --

MOUNT the drive “Mount the Drive” --

INSTALL wiring “Wiring Overview” and

“Install the Wiring” "Installing the Wiring (Supplement

to ACH550-UH User’s Manual)"

starting on page 8.

CHECK jumpers,

switches and pots -- "Check E-Bypass Jumpers,

Switches and Pots" on page 19.

CHECK installation “Check Installation” "Keypad Control Tests" on page 16.

RE-INSTALL the cover “Re-install Cover” --

APPLY power “Apply Power” --

START-UP “Start-Up” "Start-up" on page 24.

ACH550

Drive with E-Bypass

Motor

3 Phase Drive 3

Disconnect Switch

or Circuit Breaker

Service Switch

(Optional)

Input Power

Bypass

Contactor

Bypass

Control Drive Output

Contactor

E-Bypass Configurations for ACH550 Drives 7

Installation

Preparing for Installation (Supplement to ACH550-UH User’s Manual)

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.

Type Code

Use the following chart to interpret the type code found on either label.

Ser. no.

ACH550-BC-316A-4

*2030700001*

I2N

PN 100 A

400

3~ 200...280 V

2042500001

Input

Voltage (U1)

Current (I1ND)

3 Phase 48…63 Hz

200…240 V

100 A

1 Phase 48…63 Hz

200…240 V

100 A

Output

Voltage (U2)

Current (I2ND)

3 Phase 48…63 Hz

0…Input Voltage (U1)

100 A

1 Phase 48…63 Hz

0…Input Voltage (U1)

100 A

ULType 12 / IP54

ACH550–BC–100A–2+K454+L502+L503+N661+P901

Nominal Motor

Power (PND)

Short Circuit Rating Mfg. Date: June 10, 2004 Org. Firmware: V.2.03B

ABB Inc.

Made in USA with foreign parts

OEM Part Number

15 HP

100 kAIC

400 HP

100 kAIC

ACH550-BC-316A-4+…+…

AC, HVAC Drive – 550 product series

4 = 380…480 VAC

BC = E-Bypass with circuit breaker

2 = 208…240 VAC

Construction

Output current rating (See Ratings chart for details)

Voltage rating

UH = Base drive

Enclosure protection class

No specification = IP 21 / UL type 1

+B055 = IP 54 / UL type 12

BD = E-Bypass with disconnect switch

PC = Drive with circuit breaker

PD = Drive with disconnect switch

VC = Vertical E-Bypass with circuit breaker

VD = Vertical E-Bypass with disconnect switch

Line reactor

+E213 = Line Reactor

Service Switch

+F267 = Service switch

Fieldbus Adapters

+K451 = DeviceNet Adapter

+K452 = LonWorks Adapter

+K454 = Profibus Adapter

6 = 500…600 VAC

8 E-Bypass Configurations for ACH550 Drives

Installation

Ratings and Frame Size

The chart in the “Ratings” section of the ACH550-UH User’s Manual 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 (see

above). Also, when using the Ratings tables, note that there are two tables based on

the drive’s “Voltage rating”.

Suitable Mounting Location (Supplement to ACH550-UH User’s Manual)

In selecting a suitable mounting location for E-Bypass configurations, refer to the

Technical Data in this manual for the appropriate information on:

• Branch circuit protection

• Dimensions and weights

Installing the Wiring (Supplement to ACH550-UH User’s Manual)

WARNING!

• 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 ACH550 User’s Manual. The

requirements apply to all ACH550 drives. In particular:

• Use separate, metal conduit runs to keep these three classes of wiring apart:

– Input power wiring.

– Motor wiring.

– Control/communications wiring.

• Properly and individually ground the drive, the motor and cable shields.

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