ABB ACS550-02 User manual

ACS550

User’s Manual

ACS550-02 Drives (132…355 kW)

ACS550-U2 Drives (250…550 hp)

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS550-02/U2 Drive Manuals

GENERAL MANUALS

ACS550-02/U2 User's Manual (132…355 kW) /

(250…550 hp)

3AFE64804626 (English)

•Safety

• Planning electrical installation

•Installation

• Start-up, control with I/O and ID Run

• Control panels

• Application macros

• Parameters

• Embedded fieldbus

• Fieldbus adapter

• Diagnostics

• Maintenance

• Technical data

ACS550-U2 Installation Supplement

3AUA0000004067 (English)

OPTION MANUALS

(delivered with optional equipment)

OHDI-01 115/230 V Digital Input Module User's Manual

3AUA0000003101 (English)

OREL-01 Relay Output Extension Module User's

Manual

3AUA0000001935 (English)

OTAC-01 User’s Manual Pulse Encoder Interface

Module User’s Manual

3AUA0000001938 (English).

RCAN-01 CANopen Adapter User's Manual

3AFE64504231 (English)

RCNA-01 ControlNet Adapter User's Manual

3AFE64506005 (English)

RDNA-01 DeviceNet Adapter User's Manual

3AFE64504223 (English)

RETA-01 Ethernet Adapter User's Manual

3AFE64539736 (English)

RETA-02 Ethernet Adapter User's Manual

3AFE68895383 (English)

RLON-01 LonWorks Adapter Module User’s Manual

3AFE64798693 (English)

RPBA-01 PROFIBUS-DP Adapter User's Manual

3AFE64504215 (English)

Typical contents

•Safety

•Installation

• Programming/Start-up

• Diagnostics

• Technical data

MAINTENANCE MANUALS

Guide for Capacitor Reforming in ACS50, ACS55,

ACS150, ACS350, ACS550 and ACH550

3AFE68735190 (English)

The Industrial

IT

wordmark and Product names in the form

Drive

IT

are registered or pending trademarks of ABB.

CANopen is a registered trademark of CAN in Automation e.V

.

ControlNet is a registered trademark of ControlNet

International.

DeviceNet is a registered trademark of Open DeviceNet

Vendor Association.

Ethernet/IP is a registered trademark of Open DeviceNet

Vendor Association.

DRIVECOM is a registered trademark of DRIVECOM User

Organization.

Interbus is a registered trademark of Interbus Club.

LonWorks is a registered trademark of Echelon Corp.

Metasys is a registered trademark of Johnson Controls Inc.

Modbus, Modbus Plus and Modbus/TCP are registered

trademarks of Schneider Automation Inc.

PROFIBUS is a registered trademark of Profibus Trade Org.

PROFIBUS-DP is a registered trademark of Siemens AG.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS550-02/U2 Drives

132…355 kW

250…550 hp

User’s Manual

3AFE64804626 Rev C

EN

EFFECTIVE: 17.09.2007

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS550-02/U2 User’s Manual 5

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.

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 UDC+, UDC-.

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 switched off from the input terminals of the

ACS550, there may be dangerous voltage (from external sources) on the terminals

of the relay outputs RO1

…RO3 and, if the relay extension board is included in the

installation, RO4…RO6, as well as terminals X1:19…X1:27 on the control board.

WARNING! When the control terminals of two or more drives 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 drives or an external supply.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

6 ACS550-02/U2 User’s Manual

Safety

WARNING! Disconnect the EMC filter (frame size R7) and the varistor network

(frame sizes R7 and R8) when installing the drive on an IT system [an ungrounded

power system or a high resistance-grounded (over 30 ohm) power system],

otherwise the system will be connected to earth potential through the EMC filter

capacitors or varistor network. This may cause danger or damage the drive.

Disconnect the EMC filter (frame size R7) and the varistor network (frame sizes R7

and R8) when installing the drive on a corner grounded TN system, otherwise the

drive will be damaged.

WARNING! Do not control the motor with the disconnecting device (disconnecting

means); instead, use the control panel start and stop keys and , or

commands via the I/O board of the drive. The maximum allowed number of charging

cycles of the DC capacitors (i.e. power-ups by applying power) is five in ten minutes.

WARNING! The ACS550-02/U2 is a field repairable drive. In case of service or

repair of malfunctioning drive, 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! The heat sink will reach a high temperature. See chapter Technical data

on page 293.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS550-02/U2 User’s Manual 7

Safety

WARNING! The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt the

drive. The drive will overturn from a tilt of about 6 degrees. Use extreme caution

when manoeuvring a drive that runs on wheels. An overturning drive can cause

physical injury.

Note: For more technical information, contact the factory or your local ABB

representative.

Do not tilt!

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS550-02/U2 User’s Manual 9

Table of contents

ACS550-02/U2 Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety

Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Table of contents

Installation and commissioning flowchart

Planning the electrical installation

Checking the compatibility of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installation

Moving the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Checking the insulation of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Start-up, control with I/O and ID Run

How to start up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

How to control the drive through the I/O interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

How to perform the ID Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Control panels

About control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Assistant Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

10 ACS550-02/U2 User’s Manual

Table of contents

Basic Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Application macros

ABB Standard macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3-wire macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Alternate macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Motor Potentiometer macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Hand-Auto macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

PID Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

PFC macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Torque Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Connection example of a two-wire sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

User parameter sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Macro default values for parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Parameters

Complete parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Complete parameter descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Embedded fieldbus

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Mechanical and electrical installation – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Communication set-up – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Activate drive control functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Feedback from the drive – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Diagnostics – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Modbus protocol technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

ABB control profiles technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Fieldbus adapter

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Mechanical and electrical installation – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Communication set-up – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Activate drive control functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Feedback from the drive – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Diagnostics – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

ABB Drives profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Generic profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Diagnostics

Diagnostic displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Correcting faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS550-02/U2 User’s Manual 11

Table of contents

Correcting alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Maintenance

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Technical data

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Fuses and circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Input power (mains) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

C-Tick marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

UL markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

IEC/EN 61800-3 (2004) Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Compliance with the IEC/EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Equipment warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Product protection in the USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Contact ABB

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS550-02/U2 User’s Manual 13

Installation and commissioning flowchart

Task See

Identify the frame size of your drive, R7 or R8. Technical data: Ratings on page 293 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.

Planning the electrical installation on page 15

Technical data on page 293

For compliance with the EU EMC Directive,

see Technical data: CE marking on page 305.

Option manual (if optional equipment is

included)

Unpack and check the drive.

Check that all necessary optional modules and

equipment are present and correct.

Only intact drive may be started up.

Installation: Moving the drive on page 29 and

Delivery check on page 31

If the drive has been non-operational for more

than one year, the drive DC link capacitors

need to be reformed, see Reforming on page

289.

Check the installation site. Installation: Requirements for the installation

site on page 33

Technical data: Ambient conditions on page

303

Check the insulation of the motor and the motor

cable.

Installation: Checking the insulation of the

installation on page 35

If the drive is about to be connected to an IT

(ungrounded) system or corner grounded TN system,

check that the EMC filter (in frame size R7) and the

varistor (in frame sizes R7 and R8) are disconnected.

Installation: Drive identification on page 31 and

instructions for disconnecting the EMC filter

and varistor, starting from page 44

Route the cables. Routing the cables on page 27

Install the drive. Connect the power cables. Connect

the control and the auxiliary control cables.

Installation on page 29

Check the installation. Installation checklist on page 59

Commission the drive. Start-up, control with I/O and ID Run on page

61

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ACS550-02/U2 User’s Manual 15

Planning the electrical installation

Note: The installation must always be designed and made according to applicable

local laws and regulations. ABB does not assume any liability whatsoever for any

installation which breaches the local laws and/or other regulations. Furthermore, if

the recommendations given by ABB are not followed, the drive may experience

problems that the warranty does not cover.

Note: ACS550-U2 Installation Supplement [3AUA0000004067 (English)] provides

more information about the installation of ACS550-U2 drives.

Checking the compatibility of the motor

1. Select the motor according to the needs of the application.

2. Select the drive according to the rating tables in chapter Technical data on page 293.

Use the DriveSize PC tool if the default load cycles are not applicable.

3. Check that the motor ratings lie within the allowed ranges of the drive control

program:

• motor nominal voltage is 1/2 … 2 · U

N

of the drive

• motor nominal current is 1/6 … 2 · I

2hd

of the drive in vector control and

0…2·I

2hd

in scalar control. The control mode is selected by parameter 9904

MOTOR CTRL MODE.

4. Consult the motor manufacturer before using a motor in a drive system where the

motor nominal voltage differs from the AC power source voltage.

5. Ensure that the motor insulation system withstands the maximum peak voltage in the

motor terminals. See section Requirements table on page 16 for the required motor

insulation system and drive filtering.

Example 1: When the supply voltage is 440 V, the maximum peak voltage in the

motor terminals can be approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check

that the motor insulation system withstands this voltage.

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.

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16 ACS550-02/U2 User’s Manual

Planning the electrical installation

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-drive end) bearings are

recommended according to the following table. In addition, the cables must be

selected and installed according to the instructions given in this manual.

ACS550-02/U2 devices are equipped with a common mode filter (CMF) which is

adequate to prevent bearing currents at voltages less than 500 V.

The common mode filter is composed of toroidal cores installed onto the output

busbars inside the drive at the factory.

Requirements table

The following table shows how to select the motor insulation system and when

external du/dt limitation and insulated N-end (non-drive 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 fulfill the following requirements or improper installation may

shorten motor life or damage the motor bearings. ACS550-02/U2 devices have

common mode filters as standard accessories.

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ACS550-02/U2 User’s Manual 17

Planning the electrical installation

The abbreviations used in the table are defined below.

* Common mode filter (CMF) is included in ACS550-02/U2 as standard.

Random wound ABB motors and generators of series M2_ and M3_

Random wound

standard motors (non-

Ex) and generators

U

N

< 500 V P

N

< 100 kW P

N

> 100 kW or

IEC 315 < frame size <

IEC 355

P

N

> 350 kW or

IEC 400 < frame size <

IEC 450

Standard

motor

Standard motor

+ insulated N-bearing

Standard motor

+ insulated N-bearing

+ common mode filter *

Random wound high-

output motors and

other non-harmonized

designs

U

N

< 500 V P

N

< 55 kW P

N

> 55 kW P

N

> 200 kW

Standard

motor

Standard motor

+ insulated N-bearing

Standard motor

+ insulated N-bearing

+ common mode filter *

Random wound motors

for hazardous

environments

(Ex-motors)

U

N

< 500 V < IEC 250 > IEC 280 > IEC 355

Standard

motor

Standard motor

+ insulated N-bearing

Standard motor

+ insulated N-bearing

+ common mode filter *

Random wound ABB motors and generators of series HX_ and AM_

0 < U

N

< 500 V Winding type Protective measures

Enamelled wire with fibre glass taping + insulated N-bearing

Form wound low voltage ABB motors of series AM_ and HX_

Protective measures

• insulated bearing construction

• common mode filter (CMF)

Non-ABB motors, random wound and form wound windings

Insulation level Protective measures

P

N

< 100 kW 100 kW < P

N

< 350 kW P

N

> 350 kW

Standard Û

LL

= 1300 V 0 < U

N

< 420 V - + insulated N-bearing + insulated N-bearing

Standard Û

LL

= 1300 V 420 V < U

N

< 500 V + du/dt + du/dt + du/dt

+ insulated N-bearing

Reinforced 0.2 V/us 420 V < U

N

< 500 V - - + insulated N-bearing

Abbreviation Definition

U

N

nominal voltage of the supply network

Û

LL

peak line-to-line voltage at motor terminals which the motor insulation must withstand

P

N

motor nominal power

du/dt du/dt filter at the output of the drive or internal du/dt limitation. Contact ABB.

N N-end bearing: insulated motor non-drive end bearing

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18 ACS550-02/U2 User’s Manual

Planning the electrical installation

Supply connection

Disconnecting device (means)

Install a hand-operated input disconnecting device between the AC power source

(MCC) and the drive. The disconnecting device must be of a type that can be locked

to the open position for installation and maintenance work.

EU

To meet the European Union Directives, according to standard EN 60204-1, Safety

of Machinery, the disconnecting device must be one of the following types:

• a switch-disconnector of utilization category AC-23B (EN 60947-3)

• a disconnector that has an auxiliary contact that in all cases causes switching

devices to break the load circuit before the opening of the main contacts of the

disconnector (EN 60947-3)

• a circuit breaker suitable for isolation in accordance with EN 60947-2.

US

The disconnecting means must conform to the applicable safety regulations.

Fuses

See section Fuses and circuit breakers on page 295.

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ACS550-02/U2 User’s Manual 19

Planning the electrical installation

Thermal overload and short-circuit protection

Thermal overload protection of the drive and the input and motor cables

The drive protects itself and the input and motor cables against thermal overload

when the cables are dimensioned according to the nominal current of the drive. No

additional thermal protection devices are needed.

WARNING! If the drive is connected to multiple motors, a separate thermal overload

switch or a circuit breaker must be used for protecting each cable and motor. These

devices may require a separate fuse to cut off the short-circuit current.

Thermal overload protection of the motor

According to regulations, the motor must be protected against thermal overload and

the current must be switched off when overload is detected. The drive includes a

motor thermal protection function that protects the motor and switches off the current

when necessary. Depending on a drive parameter value, the function either monitors

a calculated temperature value (based on a motor thermal model) or an actual

temperature indication given by motor temperature sensors. The user can tune the

thermal model further by feeding in additional motor and load data.

The most common temperature sensors are:

• motor sizes IEC180…225: thermal switch (e.g. Klixon)

• motor sizes IEC200…250 and larger: PTC or Pt100.

See Group 30: FAULT FUNCTIONS on page 170 for more information on the motor

thermal protection by the software and Group 35: MOTOR TEMP MEAS on page

180 for the connection and use of the temperature sensors.

Protection against short-circuit in the motor and motor cable

The drive protects the motor cable and motor in a short-circuit situation when the

motor cable is dimensioned according to the nominal current of the drive. No

additional protection devices are needed.

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20 ACS550-02/U2 User’s Manual

Planning the electrical installation

Protection against short-circuit inside the drive or in the supply cable

Arrange the protection according to the following guidelines.

1) Size the fuses according to instructions given in section Fuses and circuit breakers

on page 295. The fuses will protect the input cable in short-circuit situations, restrict

drive damage and prevent damage to adjoining equipment in case of a short-circuit

inside the drive.

2) Circuit breakers which have been tested by ABB with the ACS550 can be used.

Fuses must be used with other circuit breakers. See section Fuses and circuit

breakers on page 295.

The protective characteristics of circuit breakers depend on the type, construction

and settings of the breakers. There are also limitations pertaining to the short-circuit

capacity of the supply network.

WARNING! Due to the inherent operating principle and construction of circuit

breakers, independent of the manufacturer, hot ionized gases may escape from the

breaker enclosure in case of a short-circuit. To ensure safe use, special attention

must be paid to the installation and placement of the breakers. Follow the

manufacturer’s instructions.

Note: Circuit breakers must not be used without fuses in the USA.

Ground fault protection

The drive is equipped with an internal ground fault protective function to protect the

drive against ground faults in the motor and the motor cable. This is not a personal

safety or a fire protection feature. The ground fault protective function can be

disabled with parameter 3017

EARTH FAULT.

The EMC filter of the drive includes capacitors connected between the main circuit

and the frame. These capacitors and long motor cables increase the ground leakage

current and may cause fault current circuit breakers to function.

Circuit diagram Short-circuit

protection

Protect the drive and

input cable with fuses

or a circuit breaker.

See footnotes 1) and

2).

~

M

3~

Distribution

board

Input cable

~

M

3~

Drive

1)

2)

I >

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ACS550-02/U2 User’s Manual 21

Planning the electrical installation

Emergency stop devices

For safety reasons, install the emergency stop devices at each operator control

station and at other operating stations where emergency stop may be needed.

Note: Pressing the stop key ( ) on the control panel of the drive does not

generate an emergency stop of the motor or separate the drive from dangerous

potential.

Selecting the power cables

General rules

Dimension the mains (input power) and motor cables according to local

regulations:

• The cable must be able to carry the drive load current. See section Ratings on

page 293 for the rated currents.

• The cable must be rated for at least 70

°C maximum permissible temperature of

conductor in continuous use. For US, see Additional US requirements on page

22.

• The inductance and impedance of the PE conductor/cable (grounding wire) must

be rated according to permissible touch voltage appearing under fault conditions

(so that the fault point voltage will not rise excessively when a ground fault

occurs).

• 600 V AC cable is accepted for up to 500 V AC covering the whole ACS550

range.

Symmetrical shielded cables must be used for the input and motor cables (see the

figure below). A four-conductor system cannot be used.

Compared to a four-conductor system, the use of symmetrical shielded cable

reduces electromagnetic emission of the whole drive system as well as the stress on

motor insulation, bearing currents and wear.

The motor cable and its PE pigtail (twisted shield) should be kept as short as

possible in order to reduce electromagnetic emission (see details in section Power

cable connection diagram on page 36).

Motor cable shield

To effectively suppress radiated and conducted radio-frequency emissions, the

shield conductivity must be at least 1/10 of the phase conductor conductivity. The

requirements are easily met with a copper or aluminium shield. The minimum

requirement of the motor cable shield of the drive is shown below. It consists of a

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22 ACS550-02/U2 User’s Manual

Planning the electrical installation

concentric layer of copper wires. The better and tighter the shield, the lower the

emission level and bearing current.

Additional US requirements

Type MC continuous corrugated aluminum armor cable with symmetrical grounds or

shielded power cable must be used for the motor cables if metallic conduit is not

used. For the North American market, 600 V AC cable is accepted for up to 500

V AC. For drives rated over 100 amperes, the power cables must be rated for 75

°C

(167

°F).

Conduit

Where conduits must be coupled together, bridge the joint with a ground conductor

bonded to the conduit on each side of the joint. Bond the conduits also to the drive

enclosure. Use separate conduits for input power, motor and control wiring. Do not

run motor wiring from more than one drive in the same conduit.

Armored cable / shielded power cable

The motor cables can be run in the same cable tray as other 460 V power wiring.

Control and signal cables must not be run in the same tray as power cables. Six

conductor (3 phases and 3 ground) type MC continuous corrugated aluminum armor

cable with symmetrical grounds is available from the following suppliers (trade

names in parentheses):

• Anixter Wire & Cable (Philsheath)

• BICC General Corp (Philsheath)

• Rockbestos Co. (Gardex)

• Oaknite (CLX).

Shielded power cables are available from Belden, Lapp Kabel (ÖLFLEX) and Pirelli.

Insulation jacket

Copper wire screen

Cable core

Inner insulation

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ACS550-02/U2 User’s Manual 23

Planning the electrical installation

Power factor compensation capacitors

Power factor compensation is not needed with AC drives. However, if a drive is to be

connected in a system with compensation capacitors installed, note the following

restrictions.

WARNING! Do not connect power factor compensation capacitors or surge

absorbers to the motor cables (between the drive and the motor). They are not

meant to be used with AC drives and can cause permanent damage to the drive or

themselves.

If there are power factor compensation capacitors in parallel with the three phase

input of the drive:

1. Do not connect a high-power capacitor to the power line while the drive is

connected. The connection will cause voltage transients that may trip or even

damage the drive.

2. If capacitor load is increased/decreased step by step when the AC drive is

connected to the power line: Ensure that the connection steps are low enough not to

cause voltage transients that would trip the drive.

3. Check that the power factor compensation unit is suitable for use in systems with AC

drives, i.e. harmonic generating loads. In such systems, the compensation unit

should typically be equipped with a blocking reactor or harmonic filter.

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24 ACS550-02/U2 User’s Manual

Planning the electrical installation

Equipment connected to the motor cable

Installation of safety switches, contactors, connection boxes, etc.

To minimize the emission level when safety switches, contactors, connection boxes

or similar equipment are installed in the motor cable (i.e. between the drive and the

motor):

• EU: Install the equipment in a metal enclosure with 360 degrees grounding for the

screens of both the incoming and outgoing cable, or connect the screens of the

cables otherwise together.

• US: Install the equipment in a metal enclosure in a way that the conduit or motor

cable shielding runs consistently without breaks from the drive to the motor.

Bypass connection

WARNING! Never connect the supply power to the drive output terminals U2, V2

and W2. If frequent bypassing is required, employ mechanically connected switches

or contactors. Mains (line) voltage applied to the output can result in permanent

damage to the drive.

Before opening a contactor, sensorless vector control (SVC) mode selected

If an output isolator or contactor is used, supply either stop signal or RUN ENABLE

(see parameter 1601) signal from an auxiliary contact of the isolator to the drive, in

order to make sure that the drive will coast to stop immediately when the isolator

opens. Improper use of the isolator may damage the drive and the isolator itself.

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