2. ABB
  3. ACS550-U2
ACS550-U2

ABB ACS550-U2, ACS550-02 User manual

  • Hello! I am an AI chatbot trained to assist you with the ABB ACS550-U2 User manual. I’ve already reviewed the document and can help you find the information you need or explain it in simple terms. Just ask your questions, and providing more details will help me assist you more effectively!
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
© 2007 ABB Oy. All Rights Reserved.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
ACS550-02/U2 User’s Manual 5
Safety
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
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
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
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
ACS550-02/U2 User’s Manual 15
Planning the electrical installation
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.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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 >
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
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.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
/