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ACH550 User’s Manual ACH550-01 Drives (0.75…110 kW) ACH550-UH Drives (1…150 HP) ABB ACH550 Drive manuals GENERAL MANUALS ACH550-01/UH User's Manual (0.75…110 kW) / (1…150 HP) 3AFE68258537 (English) ACH550-02/U2 User's Manual (110… 355 kW) / (150… 550 HP) 3AFE68262674 (English) • Safety • Installation • Start-up • Diagnostics • Maintenance • Technical data HVAC Info Guide CD 3AFE68338743 (English) • Detailed product description – Technical product description including dimensional drawings – Cabinet mounting information including power losses – Software and control – 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 (delivered with optional equipment) Embedded Fieldbus (EFB) Control Manual 3AFE68320658 (English) Embedded Fieldbus (EFB) Control/BACnet Manual 3AFE68404550 (English) OHDI-01 115/230 V Digital Input Module User's Manual 3AUA0000003101 (English) OREL-01 Relay Output Extension Module User's Manual 3AUA0000001935 (English) RLON-01 LonWorks Adapter Module User’s Manual 3AFE64798693 (English) Typical contents • Safety • Installation • Programming/Start-up • Fault tracing • Technical data MAINTENANCE MANUALS Guide for Capacitor Reforming in ACS50/150/350/550 3AFE68735190 (English) Contents of this manual Preparing for installation Installing the drive Start-up and control panel Application macros and wiring Real-time clock and timed functions Serial communications Parameter listing and descriptions Diagnostics and maintenance 3AFE68258537 REV C EN EFFECTIVE: 24.05.2006 10 Technical data ACH550 User's Manual Table of contents Contents of this manual What this chapter contains Compatibility Intended use Intended audience Use of warnings and notes Safety instructions Drive package 11 Lifting the drive 12 Preparing for installation 13 What this chapter contains 13 Drive identification 14 Frame size 17 Motor identification 19 Motor compatibility 21 Suitable environment and enclosure 22 Suitable mounting location 23 Wiring and EMC considerations 26 Cabling instructions 29 Motor cables 29 Control cables 33 Tools required 36 Checklist for installation preparations 37 Installing the drive 39 What this chapter contains 39 Preparing the mounting location 39 Removing front cover (IP54) 40 Removing front cover (IP21) 41 Mounting the drive (IP54) 42 ACH550 User's Manual Mounting the drive (IP21) 43 Overview of wiring installation (R1…R4) 44 Overview of wiring installation (R5…R6) 45 Power wiring (IP54) 46 Control wiring (IP54) 49 Power wiring (IP21) 50 Control wiring (IP21) 53 Check installation 55 Re-install cover (IP54) 57 Re-install cover (IP21) 58 Apply power 59 Start-up and control panel 61 What this chapter contains 61 Control panel compatibility 61 HVAC control panel (ACH-CP-B) features 61 Start-up 62 Modes 65 Standard display mode 66 Parameters mode 68 Start-up assistant mode 70 Changed parameters mode 73 Drive parameter backup mode 74 Clock set mode 80 I/O settings mode 83 Fault logger mode 84 Application macros and wiring 85 What this chapter contains 85 Applications 85 Selecting an application macro 86 Restoring defaults 87 HVAC default 88 Supply fan 90 Return fan 92 Cooling tower fan 94 Condenser 96 ACH550 User's Manual Booster pump 98 Pump alternation 100 Internal timer 102 Internal timer with constant speeds / Powered roof ventilator 104 10 Floating point 106 11 Dual setpoint PID 108 12 Dual setpoint PID with constant speeds 110 13 E-bypass (USA only) 112 14 Hand control 114 Connection example of a two-wire sensor 116 Real-time clock and timed functions 117 What this chapter contains 117 Real-time clock and timed functions 117 Using the timer 118 Enabling the timer 120 Setting the time period 121 Creating a timer 122 Connecting parameters 124 Example of timer use 125 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 (EXT FBA) module 134 Drive control parameters 136 Fieldbus control interface 146 Generic Drive Profile 160 ACH550 User's Manual Parameter listing and descriptions 165 What this chapter contains 165 Parameter groups 165 Overview of PID controllers 264 Complete parameter list 314 Diagnostics and maintenance 347 What this chapter contains 347 Diagnostics displays 348 Correcting faults 349 Fault resetting 358 History 359 Correcting alarms 359 Maintenance intervals 364 Heatsink 365 Main fan replacement 365 Internal enclosure fan replacement 368 Capacitors 369 Control panel 370 10 Technical data 371 What this chapter contains 371 Ratings 371 Input power (mains) cable and fuses 378 Cable terminals 383 Input power (mains) connection 383 Motor connection 384 Control connections 387 Efficiency 391 Cooling 391 Dimensions and weights 393 Ambient conditions 409 Materials 410 Applicable standards 411 CE marking 411 C-Tick marking 412 ACH550 User's Manual UL marking 412 IEC/EN 61800-3 (2004) Definitions 413 Compliance with the IEC/EN 61800-3 (2004) 413 Equipment warranty and liability 415 Product protection in the USA 416 Contact information 417 Index 421 ACH550 User's Manual ACH550 User's Manual internal enclosure, replacement 368 main, replacement 365 replacement intervals 364 fault codes 350 correcting 349 current at, history parameter 179 digital input status at, history parameter 179 frequency at, history parameter 179 functions, parameter group 236 history 359 history, parameter group 179 indication 348 last, history parameter 179 logger mode 84 previous, history parameter 179 reset select, parameter 143, 206 resetting 358 speed at, history parameter 179 status at, history parameter 179 time of, history parameters 179 torque at, history parameter 179 voltage at, history parameter 179 words, data parameters 177 FBA, fieldbus adapter 130 feedback multiplier (PID), parameter 273 select (PID), parameter 273 fieldbus command words, data parameters 175 control interface 146 CPI firmware revision, parameter 136, 283 fault codes 162 module’s application program revision, parameter 136, 283 parameter refresh, parameter 135, 282 parameters 135, 282 profile 148, 160 status words, data parameters 176 status, parameter 136, 283 type, parameter 135, 282 firmware test date, parameter 248 firmware version, parameter 248 first environment 413 first start, alarm code 363 floating point application macro 106 flux braking, parameter 232 flux optimization, parameter 232 force trip, fault code 353 frame errors (count), parameter 285 428 Index ACH550 User's Manual frame size 17 frequency at fault, history parameter 179 max limit, parameter 216 limit, parameter 216 switching, parameter 233 fuses input power (mains) 378 208 240 volt drives 380 380 480 volt drives 379 G gain (PID), parameter 267 H hand control see HAND mode hand control application macro 114 HAND mode 66, 67 hardware description 388 heatsink maintenance 365 maintenance interval 364 hood 11 HVAC default application macro 88 I I/O settings mode 83 id run alarm code 362 fail, fault code 351 identification drive 14 motor 19 incompatible sw, fault code 354 information, parameter group 248 input phase loss, alarm code 363 installation 39 checklist 55 preparing for 13 checklist 37 see also mounting integration time (PID), parameter 268 integration time, parameter 226 interlock function 289 interlocks, parameter 301 internal setpoint (PID), parameter 272 Index 429 ACH550 User's Manual internal timer application macro 102 internal timer with constant speeds application macro 104 IO communication, alarm code 360 IP code 22 IR compensation frequency, parameter 233 parameters 233 voltage, parameter 233 IT system K keypad reference select, parameter 184 see also control panel kWh counter, data parameter 171 L labels 14 language, parameter 167 LED 61, 348 green 349 red 348, 358 lifting the drive 12 limits, parameter group 215 load package version, parameter 248 local control see HAND mode local control (HAND mode) lock, parameter 208 low frequency (PFA), parameters 292 M macro 85 booster pump 98 condenser 96 cooling tower fan 94 dual setpoint PID 108 dual setpoint PID with constant speeds 110 e-bypass 112 floating point 106 hand control 114 HVAC default 88 internal timer 102 internal timer with constant speeds 104 powered roof ventilator 104 pump alternation 100 return fan 92 supply fan 90 maintenance 347 430 Index ACH550 User's Manual battery 370 capacitors 369 heatsink 365 internal enclosure fan 368 intervals 364 main fan 365 triggers, parameter group 235 manual compatibility with control panel (operator keypad) 61 with drive firmware manuals materials 410 maximum frequency, parameter 216 torque limit, parameters 218 torque select, parameter 217 minimum frequency, parameter 216 torque limit, parameters 218 torque select, parameter 217 mode 65 changed parameters 73 clock set 80 drive parameter backup 74 fault logger 84 I/O settings 83 parameters 68 standard display 66 start-up assistant 70 motor aux start delay (PFA), parameter 293 aux stop delay (PFA), parameter 293 compatibility 21 control mode, parameter 167 id run, parameter 169 identification 19 load curve break point frequency 239 load curve max., fault parameter 238 load curve zero speed load 238 maintenance trigger, parameter 235 nominal current, parameter 168 nominal frequency, parameter 168 nominal power, parameter 168 nominal speed, parameter 168 nominal voltage, parameter 168 number of aux., parameter 294 overtemperature, alarm code 361 overtemperature, fault code 351 phase, fault code 354 revolution (counter), parameter 235 Index 431 ACH550 User's Manual revolution counter, data parameter 173 revolution trigger, parameter 235 stall, alarm code 361 stall, fault code 352 temperature alarm limit, parameter 257 temperature fault limit, parameter 257 temperature measurement, parameter group 254 temperature sensor selection, parameter 257 temperature sensor type, parameter 256 temperature, data parameter 174 thermal protection, fault parameter 237 thermal time, fault parameter 238 motor control IR compensation, parameters 233 parameter group 232 motors (PFA) parameter 311 mounting control panel (operator keypad) 396 template 396 mounting drive 39 dimensions 394 IP21 43 IP54 42 location, preparing 39 screws 395 suitable location 23 template 11, 39 mounting EXT FBA 132 MWh counter, data parameter 173 drive power consumption (counter), parameter 235 drive power consumption trigger, parameter 235 N noise smoothing, parameter 234 NPN 390 O off button, alarm code 362 offset (PID), parameter 280 OK messages (count), parameter 284 operating data, parameter group 170 operating drive 67 operator keypad 61 see control panel OPEX link, fault code 352 power, fault code 352 432 Index ACH550 User's Manual options, parameter group 312 output frequency, data parameter 170 output voltage, data parameter 170 output wiring, fault code 354 overcurrent alarm code 359 automatic reset, parameter 243 fault code 350 override alarm code 362 mode 213 parameter group 212 parameter set 75, 167 overspeed, fault code 353 overvoltage alarm code 359 automatic reset, parameter 244 P package 11 panel display variables, parameter group 249 see also control panel panel loss alarm code 361 fault code 351 parameter analog input scale, fault code 355 analog output scale, fault code 355 change lock 205 external relay output, fault code 356 fieldbus miss, fault code 356 groups 165 hz rpm, fault code 355 override, fault code 357 PCU (power control unit), fault code 356 PCU (power control unit), fault code 356 PFA and override, fault code 356 PFA IO, fault code 357 PFA mode, fault code 356 PFA ref neg., fault code 355 save changes, parameter 143, 208 sets 74 parameters complete list 314 list and descriptions 165 mode 68 parity (RS-232), parameter 284 parity errors (count), parameter 284 Index 433 ACH550 User's Manual patents 416 PE earth earth fault, parameter 242 PELV (protective extra low voltage) 390 PFA acceleration time, parameter 310 aux motor start delay, parameter 293 aux motor stop delay, parameter 293 aux start order, parameter 311 control, parameter group 289 deceleration time, parameter 310 enable, parameter 309 interlock, alarm code 362 low frequency, parameters 292 motors, parameter 311 number of aux motors, parameter 294 reference step, parameters 290 start delay, parameter 308 start frequency, parameters 291 PID 0% (actual signal), parameter 270 100% (actual signal), parameter 271 actual input select, parameters 274 actual value max., parameters 275 actual value min., parameters 275 adjustment procedure 267 controllers, overview 264 correction source, parameter 281 decimal point (actual signal), parameter 270 derivation filter, parameter 269 derivation time, parameter 269 deviation, data parameter 173 error feedback inversion, parameter 270 external / trimming, parameter group 280 external source activate, parameter 280 feedback multiplier, parameter 273 feedback select, parameter 273 feedback, data parameters 172 gain, parameter 267 integration time, parameter 268 internal setpoint, parameter 272 offset, parameter 280 output, data parameters 172 parameter set select, parameter 279 process sets, parameter groups 267, 279 scaling (0% 100%), parameters 270 setpoint maximum, parameter 272 setpoint minimum, parameter 272 setpoint select, parameter 144, 271 setpoint, data parameters 172 434 Index ACH550 User's Manual sleep delay, parameter 278 sleep level, parameter 277 sleep selection, parameter 276 sleep, alarm code 362 trim mode, parameter 281 trim scale, parameter 281 units (actual signal), parameter 270 wake-up delay, parameter 278 wake-up deviation, parameter 278 PNP 390 power data parameter 170 drive consumption (counter), parameter 235 drive MWh consumption trigger, parameter 235 powered roof ventilator application macro 104 previous faults, history parameters 179 process PID sets, parameter groups 267, 279 process variables, data parameters 173 profile 148, 160 proportional gain, parameter 225 protection, degree of (IP code) 22 PT100 temperature sensor 256 PTC temperature sensor 256 pump alternation application macro 100 R ramp pair (accel/decel), parameter 222 ratings 371 IEC, 208 240 V drives 374 IEC, 380 480 V drives 372 NEMA, 208 240 V drives 375 NEMA, 380 480 V drives 373 real-time clock 80, 117 reference analog input corrections 188 corrections for parameter values 188 keypad control, parameter 184 maximum, parameters 189 minimum, parameters 188 select source, parameters 137, 186 select, parameter group 184 reference step (PFA), parameters 290 reforming capacitors 369 regulator by-pass control, parameter 307 relay output activation condition parameters 139, 197 connections 388 off-delay, parameters 200 Index 435 ACH550 User's Manual on-delay, parameters 200 parameter group 197 status, data parameters 172 remote control see AUTO mode replacement battery 370 capacitors 369 internal enclosure fan 368 intervals 364 main fan 365 reset, automatic analog input less than min., parameter 244 delay time, parameter 243 external fault, parameter 244 number of trials, parameter 243 overcurrent, parameter 243 overvoltage, parameter 244 parameter group 243 trial time, parameter 243 undervoltage, parameter 244 resonance (avoiding) select, parameter 230 restore the default factory setting 65 return fan application macro 92 revolution, motor (counter), parameter 235 counter, data parameter 173 trigger, parameter 235 RS-232 baud rate, parameter 284 panel, parameter group 284 parity, parameter 284 station id, parameter 284 RS-232 counts buffer overruns, parameter 285 CRC errors, parameter 285 frame errors, parameter 285 OK messages, parameter 284 parity errors, parameter 284 RS485 391 run enable source select, parameter 143, 205 run time cooling fan (counter), parameter 235 cooling fan trigger, parameter 235 drive (counter), parameter 235 drive trigger, parameter 235 run time, data parameter 171, 173 436 Index ACH550 User's Manual S safety instructions 7, scalar control mode 167 screws, mounting 395 s-curve ramp, parameter 223 second environment 413 sensor type, parameter 256 sensorless vector control mode 167 serial error, fault code 353 serial communications 129 serial number 16 setpoint maximum (PID), parameter 272 setpoint minimum (PID), parameter 272 setpoint select (PID), parameter 144, 271 sets 74 short circuit, fault code 350 sleep selection (PID), parameter 276 slip compensation ratio, parameter 234 speed at fault, history parameter 179 data parameter 170 max limit, parameter 215 limit, parameter 215 speed control acceleration compensation, parameter 228 automatic tuning, parameter 229 derivation time, parameter 227 integration time, parameter 226 parameter group 225 proportional gain, parameter 225 speed, constant digital input selection parameter 191 parameter 194 parameter group 191 timer-activated mode selection, parameter 194 stall frequency, fault parameter 240 function, fault parameter 240 region 240 time, fault parameter 240 standard display mode 66 standards 411 start aux order (PFA), parameter 311 aux motor (PFA), parameters 291 aux motor delay (PFA), parameter 293 day, parameters 260 DC magnetizing time, parameter 220 Index 437 ACH550 User's Manual delay (PFA), parameter 308 frequency (PFA), parameters 291 function, parameter 219 inhibit, parameter 220 parameter group 219 time, parameters 260 torque boost current, parameter 221 start enable missing, alarm codes 362 source select, parameters 209 start mode automatic 219 automatic torque boost 219 DC magnetizing 219 flying start 219 start/stop, parameter group 219 start/stop/dir, parameter group 181 starting order counter 300 start-up 62 assistant 70 by changing the parameters individually 64 by using the start-up assistant 62 start-up data, parameter group 167 station id (RS-232), parameter 284 status at fault, history parameter 179 status information of drive 66 status word, serial communication bit definition 152 stop aux motor (PFA), parameters 292 aux motor delay (PFA), parameter 293 day, parameters 260 DC brake time, parameter 220 DC current braking selection, parameter 220 DC current ref., parameter 220 emergency select, parameter 221 emergency, alarm code 363 flux braking, parameter 232 function, parameter 220 parameter group 219 time, parameters 260 supervision parameter group 245 parameter high limit, parameters 246 parameter low limit, parameters 246 parameter selection, parameters 245 supply fan application macro 90 supply phase, fault code 353 switching frequency control, parameter 234 438 Index ACH550 User's Manual switching frequency, parameter 233 system controls, parameter group 205 T template control panel (operator keypad) mounting 396 drive mounting 11, 39 terminal layout R1 R4 44 R5 R6 45 terminals cable 383 terminals, I/O 388 test date, parameter 248 thermal fail, fault code 352 time period start day, parameters 260 start time, parameters 260 stop day, parameters 260 stop time, parameters 260 timed autochange, parameter 311 timed functions 117 boost select, parameter 261 boost time, parameter 262 parameter group 258 start day, parameters 260 start time, parameters 260 stop day, parameters 260 stop time, parameters 260 timer source, parameters 262 timers enable, parameter 259 timer 118 enable, parameter 259 example 125 source, parameters 262 TN system torque at fault, history parameter 179 boost current, parameter 221 data parameter 170 max limit select, parameter 217 max limit, parameters 218 limit select, parameter 217 limit, parameters 218 trim mode (PID), parameter 281 trim scale (PID), parameter 281 two-wire sensor, connection example 116 Index 439 ACH550 User's Manual type code 16 U U/f ratio, parameter 233 UL marking 412 underload alarm code 361 curve, fault parameter 241 fault code 352 function, fault parameter 241 time, fault parameter 241 undervoltage alarm code 360 automatic reset, parameter 244 control enable, parameter 216 units (PID), parameter 270 uploading parameters 74 user parameter set change control, parameter 207 V version, drive firmware, parameter 248 voltage at fault, history parameter 179 voltage/frequency ratio, parameter 233 W wake-up delay (PID), parameter 278 wake-up deviation (PID), parameter 278 warranty 415 weights 393, 395 wiring 26 control 49, 53 fault, parameter 242 power 46, 50 terminals 44, 45 XYZ zero speed load, fault parameter 238 440 Index 3AFE68258537 REV C / EN EFFECTIVE: 24.05.2006 © 2006 ABB Oy All rights reserved ABB Inc Automation Technologies Drives & Motors 16250 West Glendale Drive New Berlin, WI 53151 USA Telephone 262 785-3200 800-HELP-365 Fax 262 780-5135 ABB Limited Daresbury Park Daresbury Warrington Cheshire WA4 4BT UNITED KINGDOM Telephone +44 1925 741111 Fax +44 1925 741212 ABB Oy AC Drives P.O Box 184 FI-00381 HELSINKI FINLAND Telephone +358 10 22 11 Fax +358 10 22 22681 Internet http://www.abb.com ABB Beijing Drive Systems Co Ltd No 1, Block D, A-10 Jiuxianqiao Beilu Chaoyang District Beijing, P.R China, 100015 Telephone +86 10 5821 7788 Fax +86 10 5821 7618 Internet http://www.abb.com .. .ACH550 Drive manuals GENERAL MANUALS ACH550- 01/UH User'' s Manual (0.75…110 kW) / (1…150 HP) 3AFE68258537 (English) ACH550- 02/U2 User'' s Manual (110… 355 kW) / (150…... the USA 416 Contact information 417 Index 421 ACH550 User'' s Manual ACH550 User'' s Manual Contents of this manual What this chapter contains This chapter contains the safety... Digital Input Module User'' s Manual 3AUA0000003101 (English) OREL-01 Relay Output Extension Module User'' s Manual 3AUA0000001935 (English) RLON-01 LonWorks Adapter Module User? ??s Manual 3AFE64798693