| Вид документа | Технічний документ |
|---|---|
| Виробник | ABB |
| Код документа | ACH580-E-Clipse_3AXD50000289554 |
| Сторінок | 260 |
| Мова документа | англійська |
| Розмір файлу | 14.8 МБ |
О чём документ
Руководство по монтажу, вводу в эксплуатацию, диагностике и обслуживанию частотных преобразователей ABB серии ACH580 для систем HVAC в конфигурациях с байпасом E-Clipse (1…200 HP) и пакетных преобразователей с разъединителем (Packaged Drives with Disconnect, 1…200 HP). Документ дополняет руководство пользователя ACH580-01 и описывает подключение силовых и управляющих цепей, настройку связи с BMS (BACnet, N2, Modbus), макросы приложений и устранение неисправностей. Пригодится монтажникам, наладчикам и инженерам по автоматизации зданий.
Ключевые характеристики
| Параметр | Значение |
|---|---|
| Мощность | 1…200 HP |
| Напряжение питания | 440…480 Vac (вариант 2 = 208…240 VAC; вариант 6 = 575…600 VAC) |
| Входная частота | 50…60 Hz |
| Выходная частота | 0…500 Hz |
| Ток короткого замыкания (пример шильдика) | 100 kA |
| Степень защиты корпуса | UL (NEMA) Type 1; +B056 = Type 12; +B058 = Type 3R |
| Конструкции | BCR/BDR — байпас E-Clipse с автоматическим выключателем/разъединителем; VCR/VDR — вертикальный байпас; PCR/PDR — пакетное исполнение с разъединителем |
| Встроенная связь с BMS | BACnet, Johnson Controls N2, Modbus |
| Опциональные адаптеры полевой шины | LonWorks, Ethernet/IP, DeviceNet, PROFINET (+K451…+K475) |
| Опции | +E213 линейный реактор, +F267 сервисный выключатель, +J429 панель с Bluetooth® |
| Защита двигателя | Motor overload protection (встроена) |
| Отключение после снятия питания | ожидание ≥ 5 минут для разряда конденсаторов промежуточной цепи |
Что внутри документа
- Инструкции по безопасности: электрическая безопасность, заземление, функции безопасности, приводы с двигателями на постоянных магнитах, кибербезопасность.
- Монтаж конфигураций E-Clipse Bypass: подготовка, схемы подключения, прокладка проводки, проверка установки.
- Панель управления и пуск: проверки панели, восстановление Drive Link, системная проверка с подключённым двигателем.
- Обзор функций байпаса E-Clipse: режимы работы, релейные входы/выходы, Energy Savings Estimator.
- Макросы приложений: E-Clipse HVAC Default, Damper, Retrofit, Smoke Control.
- Список и описание параметров.
- Встроенная полевая шина (EFB): установка, настройка, протоколы N2, BACnet, Modbus, профили ABB.
- Адаптер полевой шины (FBA): монтаж, настройка, диагностика, технические данные профилей.
- Диагностика: дисплеи, исправление аварий и предупреждений.
- Обслуживание и технические данные: присоединения двигателя, размеры, массы, применимые стандарты.
Быстрый старт
- Подготовьте место монтажа и смонтируйте блок; снимите переднюю крышку вертикального исполнения.
- Подключите входное питание к клеммам разъединителя/автоматического выключателя, заземляющий проводник — к заземляющему зажиму у точки ввода. Используйте отдельные металлические кабелепроводы для силовых, моторных и контрольных цепей.
- Подключите кабели двигателя к выходным клеммам, заземление двигателя — к ближайшему заземляющему зажиму. Перед подачей питания проверьте сопротивление изоляции двигателя при отключённом питании.
- Подключите управление к клеммам X1 платы ACH580 и X2 платы байпаса (аналоговые входы AI1/AI2, цифровые входы DI1…DI6, реле RO1…RO6).
- Проверьте перемычки и переключатели, установите крышки, подайте питание.
- При аварии PHASE SEQ снимите питание, выждите ≥ 5 минут и поменяйте местами любые две фазы входа.
- Настройте параметры пусковых данных двигателя, затем выполните системную проверку: режим Drive, клавиша Hand, плавное увеличение скорости, проверка направления вращения.
Частые вопросы
- Какие протоколы связи поддерживаются встроенно?
- Встроенная связь поддерживает основные протоколы BMS: BACnet, Johnson Controls International N2 и Modbus. Дополнительно через опциональные адаптеры — LonWorks, Ethernet/IP, DeviceNet и PROFINET.
- Как настроить связь с системой автоматизации здания?
- Все настройки внешней связи между ACH580 с E-Clipse Bypass и BAS выполняются только с панели оператора E-Clipse Bypass — не пытайтесь настраивать её с панели ACH580. Внутренняя связь между приводом и байпасом сконфигурирована на заводе.
- Можно ли использовать функцию Safe Torque Off в режиме байпаса?
- Нет. Конфигурации байпаса (ACH580-VxR и ACH580-BxR) не поддерживают функцию Safe Torque Off в режиме байпаса.
- Что делать при ошибке «Drive Link Fault» или «Drive Setup»?
- На клавиатуре привода установите бит 5 параметра 95.21 в значение «Bypass present». Если бит уже равен 1, измените его на 0, циклически отключите питание привода и верните бит 5 в 1.
- Через сколько времени после отключения питания можно работать с оборудованием?
- Не менее 5 минут — за это время конденсаторы промежуточной цепи должны разрядиться. Клеммы двигателя T1/T2/T3 находятся под опасным напряжением при подключённом сетевом питании даже при неработающем двигателе.
- Какие настройки фиксируются при включении байпаса (параметр 95.21, бит 5)?
- Устанавливаются и защищаются от записи: 20.01 Ext1 commands = 14 (Embedded fieldbus), 20.02 Ext1 start trigger type = 1 (Level), 20.06 Ext2 commands = 14, 20.07 Ext2 start trigger type = 1, 20.40 Run permissive = 15, 20.41 Start interlock 1 = 15, 20.42–20.44 Start interlock 2–4 = 1 (Not used), 58.01 Protocol = 1 (Modbu[us]).
Текст документа
ACH580
E-Clipse bypass and packaged drive user manual
ACH580-BCR/BDR/VCR/VDR E-Clipse Bypass Drives 1…200 HP
ACH580-PCR/PDR Packaged Drives with Disconnect 1…200 HP
Table of Contents
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Use of warnings and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . 6
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . 7
Additional instructions for Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . 9
General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ACH580 BCR/BDR/VCR/VDR E-Clipse Bypass Drives . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
E-Clipse bypass features and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installing the wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
E-Clipse bypass functions overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Relay contact (digital) inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Relay contact outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Energy Savings Estimator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Application macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
E-Clipse HVAC Default macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Damper macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Retrofit macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Smoke Control macro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Parameter list and descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Table of Contents
Embedded fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Mechanical and electrical installation – Embedded Fieldbus (EFB) . . . . . . . . . 91
Communication setup – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Activate drive control functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Feedback from the drive – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Activate bypass control functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Feedback from the ABB E-Clipse Bypass – EFB . . . . . . . . . . . . . . . . . . . . . . 107
Diagnostics – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
N2 protocol technical data – system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
BACnet protocol technical data – system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
BACnet Protocol Implementation Conformance Statement . . . . . . . . . . . . . . 145
Modbus protocol technical data – Drive only . . . . . . . . . . . . . . . . . . . . . . . . . 151
ABB control profiles technical data – Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Modbus protocol technical data - system mode . . . . . . . . . . . . . . . . . . . . . . . 170
Fieldbus adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Mechanical and electrical installation – FBA . . . . . . . . . . . . . . . . . . . . . . . . . 179
Communication setup – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Activate drive control functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Feedback from the drive – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Activate bypass control functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Diagnostics – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
ABB drives profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Generic profile technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Diagnostic displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Correcting faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Correcting warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Motor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
E-Clipse Bypass control unit connections (RBCU) . . . . . . . . . . . . . . . . . . . . . 223
Dimensional references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Dimensions and weights 580-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Table of Contents
ACH580-PCR/PDR Packaged Drives with Disconnect 1…200 HP . . . . . . . . 234
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Installation flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Installing the wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Table of Contents
6 ACH580 Installation, Operation and Maintenance Manual
Safety instructions
These are the safety instructions which you and long sleeves. Some parts have sharp
must obey when you install and operate the edges.
drive and do maintenance on the drive. If • Handle the drive carefully.
you ignore the safety instructions, injury,
death or damage can occur. • Frames R5…R9: Lift the drive with a
lifting device. Use the lifting eyes of
the drive.
Use of warnings and notes in • Frames R5…R9: Do not tip the drive
this manual over. The drive is heavy and its center
of gravity is high. An overturning drive
Warnings tell you about conditions which
can cause physical injury.
can cause injury or death, or damage to the
equipment. They also tell you how to
prevent the danger. Notes draw attention to
a particular condition or fact, or give
information on a subject.
The manual uses these warning symbols:
Electricity warning tells about
hazards from electricity which can
cause injury or death, or damage to the
equipment.
General warning tells about
conditions, other than those caused
by electricity, which can cause injury or
death, or damage to the equipment.
Electrostatic sensitive devices
warning tells you about the risk of
electrostatic discharge which can cause
damage to the equipment. • Beware of hot surfaces. Some parts, such
as heatsinks of power semiconductors,
remain hot for a while after
General safety in installation, disconnection of the electrical supply.
start-up and maintenance • Keep the drive in its package or protect it
These instructions are for all personnel that otherwise from dust and burr from
install the drive and do maintenance work drilling and grinding until you install it.
on it. • Vacuum clean the area below the drive
WARNING! Obey these instructions. If before the start-up to prevent the drive
you ignore them, injury or death, or cooling fan from drawing the dust inside
damage to the equipment can occur. the drive.
• Use safety shoes with a metal toe cap to • Do not cover the air inlet and outlet when
avoid foot injury. Wear protective gloves the drive runs.
Safety instructions
ACH580 Installation, Operation and Maintenance Manual 7
• Make sure that there is sufficient cooling. mode disable has value Off button
See the ACH580 Hardware Manual disabled), the stop key on the control
(3AXD50000044839) for more panel will not stop the drive.
information. • Frames R1…R5: Do not attempt to repair
• Before you connect voltage to the drive, a malfunctioning drive; contact your local
make sure that the drive covers are on. representative for replacement or repair
Keep the covers on during the operation. by authorized persons.
• Before you adjust the drive operation • Frames R6…R9: Can be repaired by
limits, make sure that the motor and all authorized persons.
driven equipment can operate
throughout the set operation limits.
Electrical safety in
• Before you activate the automatic fault
reset or automatic restart functions of installation, start-up and
the drive control program, make sure that maintenance
no dangerous situations can occur. These
functions reset the drive automatically Precautions before electrical
and continue operation after a fault or work
supply break. If these functions are
activated, the installation must be clearly These warnings are for all personnel who do
marked as defined in IEC/EN 61800-5-1, work on the drive, motor cable or motor.
subclause 6.5.3, for example, “THIS WARNING! Frames R1 … R9: Obey these
MACHINE STARTS AUTOMATICALLY”. instructions. If you ignore them, injury
• The maximum number of drive power- or death, or damage to the equipment can
ups is five in ten minutes. Too frequent occur. If you are not a qualified electrical
power-ups can damage the charging professional, do not do electrical
circuit of the DC capacitors. installation or maintenance work. Go
• If you have connected safety circuits to through these steps before you begin any
the drive (for example, emergency stop installation or maintenance work.
and Safe torque off), validate them at the 1. Clearly identify the work location.
start up. For the validation of the Safe 2. Disconnect all possible voltage sources.
torque off, see ACH580 HVAC control Lock and tag.
program firmware manual
(3AXD50000027537 [English]). For the • Open the main disconnector at the
validation of other safety circuits, see the power supply of the drive.
instructions provided with them. • Make sure that reconnection is not
Note: possible.
• If you select an external source for start • Disconnect any external power
command and it is on, and the start sources from the control circuits.
command is level-triggered, the drive will
start immediately after fault reset. See • After you disconnect the drive, always
parameters 20.02 Ext1 start trigger type wait for 5 minutes to let the
and 20.07 Ext2 start trigger type in intermediate circuit capacitors
ACH580 HVAC control program firmware discharge before you continue.
manual (3AXD50000027537 [English]).
• When the control location is not set to
Local (text Hand is not shown on the top
row of the panel and parameter 19.19 Off
Safety instructions
8 ACH580 Installation, Operation and Maintenance Manual
3. Protect any other energized parts in the phase varistor are connected (metal
work location against contact. screws should not be installed).
Connections with metal screws in these
4. Take special precautions when close to
systems can cause danger or damage.
bare conductors.
See section Checking the compatibility
5. Measure that the installation is with IT (ungrounded) and corner-
de-energized. grounded TN systems (North America) in
• Use a multimeter with an impedance the ACH580 Installation, Operation and
of at least 1 Mohm. Maintenance Manual
(3AXD50000049127).
• Make sure that the voltage between
the drive input power terminals (L1, L2, Note: For other systems, connecting the
L3) and the grounding terminal (PE) is internal EMC filter will reduce the
close to 0 V. conducted emission.
• If the drive will be connected on a corner-
Frames R1…R3: Measure the voltage
grounded TN system, make sure the EMC
between the drive UDC+ terminal and
filter is not connected (metal screws
grounding terminal (PE) with one
should not be installed). Connections
multimeter. As there is no UDC-
with metal screws in these systems can
terminal, measure the voltage
cause danger or damage. See section
between the drive T1/U terminal and
Checking the compatibility with IT
grounding terminal (PE) with another
(ungrounded) and corner-grounded TN
multimeter. Make sure that the voltage
systems (North America) in the ACH580
difference between the multimeters is
Installation, Operation and Maintenance
close to 0 V.
Manual (3AXD50000049127).
Frames R4…R9: Measure the voltage
Note: For other systems, connecting the
between the drive DC terminals (UDC+
internal EMC filter (using metal screws)
and UDC-) and the grounding terminal
will reduce the conducted emission.
(PE) and make sure that it is close to
0 V. • Use all ELV (extra low voltage) circuits
connected to the drive only within a zone
6. Install temporary grounding as required of equipotential bonding, that is, within a
by the local regulations. zone where all simultaneously accessible
7. Ask for a permit to work from the person conductive parts are electrically
in control of the electrical installation connected to prevent hazardous voltages
work. appearing between them. You can
accomplish this by a proper factory
If the drive does not operate according to grounding, that is, make sure that all
these steps, refer to the ACH580-01 simultaneously accessible conductive
Hardware Manual (3AXD50000044839). parts are grounded to the protective
Additional instructions and notes earth (PE) bus of the building.
• Do not do insulation or voltage withstand
WARNING! Obey these instructions. If
tests on the drive or drive modules.
you ignore them, injury or death, or
damage to the equipment can occur. Note:
• If the drive will be connected on an IT • The motor cable terminals of the drive
system (ungrounded or high-resistance- are at a dangerous voltage when the
grounded [over 30 ohms]), make sure input power is on, regardless of whether
neither the EMC filter nor the ground-to- the motor is running or not.
Safety instructions
ACH580 Installation, Operation and Maintenance Manual 9
• The DC and brake resistor terminals • Connect the power cable shields to the
(UDC+, UDC-, R+ and R-) are at a protective earth (PE) terminals of the
dangerous voltage. drive.
• External wiring can supply dangerous • Standard IEC/EN & UL 61800-5-1 (section
voltages to the terminals of relay outputs 4.3.5.5.2.) requires that as the normal
(RO1, RO2 and RO3). touch current of the drive is higher than
• The Safe torque off function does not 3.5 mA AC or 10 mA DC, you must use a
remove the voltage from the main and fixed protective earth (PE) connection. In
auxiliary circuits. The function is not addition,
effective against deliberate sabotage or • install a second protective earth
misuse. conductor of the same cross-sectional
WARNING! Use a grounding wrist band area as the original protective earthing
when you handle the printed circuit conductor,
boards. Do not touch the boards or
unnecessarily. The boards contain
• install a protective earth conductor
components sensitive to electrostatic
with a cross-section of at least 7 AWG
discharge.
(10 mm2) Cu,
Grounding or
These instructions are for all personnel who • install a device which automatically
are responsible for the electrical installation, disconnects the supply if the
including the grounding of the drive. protective earth conductor breaks.
WARNING! Obey these instructions. If Additional instructions for
you ignore them, injury or death, or
equipment malfunction can occur, and Safety Functions
electromagnetic interference can increase. WARNING! Bypass configurations
• If you are not a qualified electrical (ACH580-VxR & ACH580-BxR) do not
professional, do not do grounding work. support Safe Torque Off (STO) functionality
• Always ground the drive, the motor and in bypass mode.
adjoining equipment to the protective
earth (PE) bus of the power supply. This Additional instructions for
is necessary for the personnel safety.
Proper grounding also reduces permanent magnet motor
electromagnetic emission and drives
interference.
• In a multiple-drive installation, connect Safety in installation, start-up
each drive separately to the protective and maintenance
earth (PE) bus of the power supply.
These are additional warnings concerning
• Make sure that the conductivity of the permanent magnet motor drives. The other
protective earth (PE) conductors is safety instructions in this chapter are also
sufficient. See section Power cable valid.
terminal and lead-through data in the
ACH580 Installation, Operation and WARNING! Obey these instructions. If
Maintenance Manual you ignore them, injury or death and
(3AXD50000049127). Obey the local damage to the equipment can occur.
regulations. • Do not work on a drive when a rotating
permanent magnet motor is connected
Safety instructions
10 ACH580 Installation, Operation and Maintenance Manual
to it. A rotating permanent magnet General safety in operation
motor energizes the drive including its
power terminals. These instructions are for all personnel that
Before installation, start-up and operate the drive.
maintenance work on the drive: WARNING! Obey these instructions. If
• Stop the motor. you ignore them, injury or death, or
damage to the equipment can occur.
• Disconnect the motor from the drive with
a safety switch or by other means. • Do not control the motor with the line
side disconnect at the drive power
• If you cannot disconnect the motor, make supply; instead, use the control panel
sure that the motor cannot rotate during start and stop keys or commands
work. Make sure that no other system, through the I/O terminals of the drive.
like hydraulic crawling drives, can rotate
the motor directly or through any • Give a stop command to the drive before
mechanical connection like felt, nip, rope, you reset a fault. If you have an external
etc. source for the start command and the
start is on, the drive will start
• Measure that the installation is de- immediately after the fault reset, unless
energized. you configure the drive for pulse start.
• Use a multimeter with an impedance See the firmware manual.
of at least 1 Mohm. • Before you activate automatic fault reset
• Make sure that the voltage between functions of the drive control program,
the drive output terminals (T1/U, T2/V, make sure that no dangerous situations
T3/W) and the grounding (PE) busbar can occur. These functions reset the drive
is close to 0 V. automatically and continue operation
after a fault.
• Make sure that the voltage between
the drive input power terminals (L1, L2, Note: When the drive is not in the Hand
L3) and the grounding (PE) busbar is mode, the Off key on the control panel will
close to 0 V. not stop the drive.
• Make sure that the voltage between
the drive DC terminals (UDC+, UDC-)
and the grounding (PE) terminal is
close to 0 V.
• Install temporary grounding to the drive
output terminals (T1/U, T2/V, T3/W).
Connect the output terminals together as
well as to the PE.
Start-up and operation:
• Make sure the motor is not run over the
rated speed with dynamic/positive
displacement loads.
Safety instructions
ACH580 Installation, Operation and Maintenance Manual 11
Cybersecurity disclaimer
This product is designed to be connected to
and to communicate information and data
via a network interface. It is Customer’s sole
responsibility to provide and continuously
ensure a secure connection between the
product and Customer network or any other
network (as the case may be). Customer
shall establish and maintain any appropriate
measures (such as but not limited to the
installation of firewalls, application of
authentication measures, encryption of
data, installation of anti-virus programs,
etc) to protect the product, the network, its
system and the interface against any kind of
security breaches, unauthorized access,
interference, intrusion, leakage and/or theft
of data or information. ABB and its affiliates
are not liable for damages and/or losses
related to such security breaches, any
unauthorized access, interference,
intrusion, leakage and/or theft of data or
information.
Safety instructions
ACH580 BCR/BDR/VCR/VDR
E-Clipse Bypass Drives
1…200 HP
ACH580 BCR/BDR/VCR/VDR E-Clipse Bypass Drives 1…200 HP
ACH580 E-Clipse bypass and packaged drive user manual 13
Installation
Study these installation instructions carefully before proceeding. Failure to observe the
warnings and instructions may cause a malfunction or personal hazard.
WARNING! Before you begin read Safety instructions on page 6.
WARNING! When the ACH580 with E-Clipse Bypass is connected to the line
power, the Motor Terminals T1, T2, and T3 are live even if the motor is not
running. Do not make any connections when the ACH580 with E-Clipse Bypass
is connected to the line. Disconnect and lock out power to the drive before
servicing the drive. Failure to disconnect power may cause serious injury or
death.
Application
This manual is a supplement to the ACH580-01 User’s Manual and documents E-Clipse Bypass
configurations.
E-Clipse bypass features and functions
The ACH580 with E-Clipse Bypass is an ACH580 AC adjustable frequency drive in an integrated
UL (NEMA) Type 1, UL (NEMA) Type 12, or UL (NEMA) Type 3R package with a bypass motor
starter. The ACH580 with E-Clipse Bypass provides:
• Disconnect switch or circuit breaker with door mounted handle mechanism. The handle
can be padlocked in the OFF position (padlock not supplied).
• Bypass starter.
• Motor overload protection.
• Local operator panel with indicating lights and multifunction display.
• Provisions for external control connections.
• Embedded communications for major BMS protocols including BACnet, Johnson Controls
International N2 and Modbus.
• Optional field bus adapters for connection to additional BMS protocols including
LonWorks, Ethernet/IP, DeviceNet, and PROFINET.
• Optional drive service switch (drive input disconnect), the functional equivalent of a three-
contactor bypass arrangement.
Installation
14 ACH580 E-Clipse bypass and packaged drive user manual
The following shows the front view of the ACH580 E-Clipse Bypass vertical configuration, and
identifies the major components.
ACH580 Drive
ACH-AP-H
Control Panel
E-Clipse Bypass Control Panel
Operating Handle
for Disconnect Switch
or Circuit Breaker
E-Clipse Bypass
VxR
The following shows the front view of the ACH580 E-Clipse Bypass standard configurations,
and identifies the major components.
E-Clipse Bypass
Control Panel
ACH-AP-H
Control Panel
BYPASS CONTROL
ESC ENTER
ENABLE
SELECTED HAND
FAULTED
DRIVE BYPASS
OFF/RESET
AUTO
MOTOR RUN
Operating Handle
for Disconnect Switch
or Circuit Breaker
BxR
Installation
ACH580 E-Clipse bypass and packaged drive user manual 15
The following is a typical power diagram.
Disconnect Switch Drive with E-Clipse Bypass
Bypass Drive Output
or Circuit Breaker Contactor
Control
3 Phase ACH580
Drive Motor
Input Power 3 3
Service Switch Bypass
(Optional) Contactor
Drive Input Fuse
Installation flow chart
The installation of E-Clipse Bypass Configurations for ACH580 drives follows the outline
below. The steps must be carried out in the order shown. At the right of each step are
references to the detailed information needed for the correct installation of the unit.
Reference in ACH580-01
Hardware Manual
Task Reference in this Manual
(3AXD50000044839)
Installation section
PREPARE for Preparing for installation in Preparing for installation on
installation the ACH580-01 Hardware page 18.
Manual Suitable mounting location on
(3AXD50000044839) page 19
PREPARE the mounting PREPARE the mounting —
location location
MOUNT the unit MOUNT the drive —
REMOVE the covers REMOVE the front cover —
from Vertical E-Clipse
Bypass Unit
INSTALL wiring Wiring overview and Install Installing the wiring starting on
the wiring page 19.
CHECK jumpers and — Check jumpers and switches on
switches page 37.
CHECK installation Check installation Check installation – Bypass on
page 32.
RE-INSTALL the covers Re-install cover —
APPLY power Apply power —
START-UP Start-up —
For more details, refer to the ACH580-01 Hardware Manual (3AXD50000044839).
Installation
16 ACH580 E-Clipse bypass and packaged drive user manual
Preparing for installation
Drive identification
Drive labels
To determine the type of drive you are installing, refer to either:
• Serial number label attached on upper part of the chokeplate
between the mounting holes. ACH580-BCR-316A-4
• Type code label attached on the heat sink – on the right side
of the unit cover. S/N 2090501769
VFD Rating
ABB Inc.
Input 3PH 50...60 Hz Output 3PH 0...500 Hz
Made in the USA of foreign parts MTR OL INCL: SEE MANUAL
Voltage(U1) 440...480 Vac Voltage(U2) 0...U1 Vac
Mfg. Date: xx-xxxx-20xx Orig. Drive Firmware: V.2.05.0.0
Current(I1n) 240 A Current(I2n) 240 A
Orig. Bypass Firmware: V.1.01B
Short Circuit 100 kA
E-Clipse Package Rating
Power(Pn) 200 Hp S/N 2090501769
Schematic: 3AUA0000014954
ACH580–BCR–240A-4
Type code
Use the following chart to interpret the type code found on either label.
ACH580-BCR-012A-4 +…+…
AC, HVAC Drive = 580 Product Series
Construction
01 = Base Drive
BCR = E-Clipse Bypass with circuit breaker
BDR = E-Clipse Bypass with disconnect switch
PCR = Packaged Drive with circuit breaker
PDR = Packaged Drive with disconnect switch
VCR = Vertical bypass with circuit breaker
VDR = Vertical bypass with disconnect switch
VFD output current rating (See ratings chart for details)
Voltage rating
2 = 208…240 VAC
4 = 440…480 VAC
6 = 575…600 VAC
Enclosure protection class
No specification = UL (NEMA) Type 1
+B056 = UL (NEMA) Type 12
+B058 = UL (NEMA) Type 3R
Power options
+E213 = Line reactor (PxR or BxR Configurations)
+F267 = Service switch (VxR or BxR Configurations)
Input/Output option modules
+L501 = Ext 24V DC/AC and digital I/O Extension
+L512 = 115/230 V digital input interface
+L523 = Ext 24V and isolated PTC Interface
Fieldbus adaptors
+K451 = DeviceNet Adapter
+K452 = LonWorks Adapter
+K454 = Profibus Adapter
+K462 = ControlNet Adapter
+K465 = BACnet/IP (2-port) Adapter (PxR or -01 configurations)
+K475 = Ethernet Adapter
Keypad
+J429 = Control panel with Bluetooth® interface
Installation
ACH580 E-Clipse bypass and packaged drive user manual 17
Ratings and frame size
For ratings and frame size information refer to the chart in the Ratings section of the ACH580-
01 Hardware Manual (3AXD50000044839). This section lists technical specifications, and
identifies the drive’s frame size, which is significant, since some instructions in this document
vary, depending on the drive’s frame size. To read the Ratings table, you need the “Output
current rating” entry from Type code on page 18. Also, when using the Ratings tables, note
that there are three tables based on the drive’s “Voltage rating”.
Suitable mounting location
In selecting a suitable mounting location for E-Clipse Bypass configurations, refer to the
Technical data on page 215 in this manual for the appropriate information on:
• Branch circuit protection
• Dimensions and weights
• UL (NEMA) Type 3R, Bx3R-1...Bx3R-4 enclosures are designed to be mounted on a wall.
Installing the wiring
WARNING!
•Metal shavings or debris in the enclosure can damage electrical equipment
and create a hazardous condition. Where parts, such as conduit plates require
cutting or drilling, first remove the part. If that is not practical, cover nearby
electrical components to protect them from all shavings or debris.
•Do not connect or disconnect input or output power wiring, or control wires,
when power is applied.
•Never connect line voltage to drive output Terminals T1, T2, and T3.
•Do not make any voltage tolerance tests (Hipot or Megger) on any part of the
unit. Disconnect motor wires before taking any measurements in the motor or
motor wires.
•Make sure that power factor correction capacitors are not connected between
the drive and the motor.
Wiring requirements
Refer to the Wiring requirements in the ACH580-01 Hardware Manual (3AXD50000044839).
The requirements apply to all ACH580 drives. In particular:
• Use separate, metal conduit runs to keep these three classes of wiring apart:
– Input power wiring.
– Motor wiring.
Installation
18 ACH580 E-Clipse bypass and packaged drive user manual
– Control/communications wiring.
• Properly and individually ground the drive, the motor and cable shields.
• Use wire ties to permanently affix control/communications wiring to the hooked wire race
tie points provided maintaining a minimum 6 mm (1/4 in.) spacing from power wiring.
• Use a separate motor conduit run for each motor.
Installation
ACH580 E-Clipse bypass and packaged drive user manual 19
Wiring overview
Connection and wiring diagrams – Vertical E-Clipse Bypass
ACH580 Vertical E-Clipse Bypass units are configured for wiring access from the bottom only.
The following figures show the layout and wiring connection points. For drive control wiring,
see page 54. Maintain appropriate separation of control and power wires.
Drive Control Panel
ACH580 Drive
E-Clipse Bypass
Control Panel
E-Clipse Bypass
Control Board
Terminals (X2)
Fuses Motor
Terminals
Service Switch Motor Ground
(Optional) Lug
Disconnect Switch
or Circuit Breaker
Input
Terminals Input
Ground Lug
V1/V2
(Vx1-1, Vx1-2)
Installation
20 ACH580 E-Clipse bypass and packaged drive user manual
Drive Control Panel
ACH580 Drive
E-Clipse Bypass
Control Panel
E-Clipse Bypass
Control Board
Terminals (X2)
Disconnect Switch
or Circuit Breaker
Input
Ground Lug
Motor
Terminals
Motor Ground
Input Lug
Terminals
Service Switch
(Optional)
Fuses
V3/V4
(Vx1-3, Vx1-4)
Installation
ACH580 E-Clipse bypass and packaged drive user manual 21
Connection and wiring diagrams – Box E-Clipse Bypass
ACH580 Box E-Clipse Bypass units are configured for wiring access from the top (for UL
(NEMA) Type 1 and 12) and from the bottom (for UL (NEMA) Type 3R). The following figures
show the layout and wiring connection points. For drive control wiring, see page 54. Maintain
appropriate separation of control and power wires.
User Power
Cable Guides
ACH580 Drive
E-Clipse Bypass
Control Board Motor
Terminals (X2) Terminals
Fuses Motor Ground
Lug
Service Switch
(Optional) Input Ground
Lug
Disconnect Switch
or Circuit Breaker
Input Terminals
MOV and
Line Reactor
(Optional)
B1
(Bx1-1, Bx12-1)
Installation
22 ACH580 E-Clipse bypass and packaged drive user manual
User Power
Cable Guides
ACH580 Drive
E-Clipse Bypass
Control Board
Terminals (X2)
Disconnect Switch
or Circuit Breaker
Input Terminals
Input Ground
Lug
Motor Ground
Lug
Motor Terminals MOV and
Line Reactor
Fuses (Optional)
Service Switch
(Optional)
B2
(Bx1-2, Bx12-2)
Installation
ACH580 E-Clipse bypass and packaged drive user manual 23
Motor
Ground Lug
Input
Ground Lug
Motor
Terminals
Fuses ACH580 Drive
Service Switch
(Optional)
Input
Terminals
Disconnect
Switch or
Circuit Breaker
E-Clipse Bypass
Control Board
Terminals X2
B3
600V, 41A - 77A
(Bx1-3, Bx12-3*)
*Hood and filter kit not shown
Installation
24 ACH580 E-Clipse bypass and packaged drive user manual
Motor
Ground Lug
Input
Ground Lug ACH580 Drive
Motor
Terminals
Input
Terminals
Disconnect
Switch or
Circuit Breaker
E-Clipse Bypass
Control Board
Terminals X2
Fuses
Service Switch
(Optional)
B3
Units above 77A
(Bx1-3, Bx12-3*)
*Hood and filter kit not shown
Installation
ACH580 E-Clipse bypass and packaged drive user manual 25
RHTR Temperature Heater ON Heater OFF
HI/LO Jumper (X1) Temperatur Temperatur
e e
Default Setting 14.4 °C 21.4 °C
(X1 jumper in LO 58 °F 70.5 °F
position)
E-Clipse Bypass Alternate Setting 17.8 °C 24.4 °C
Control Board (X1 jumper in HI 64 °F 76.5 °F
Terminals X2 position)
The alternate (HI) setting further reduces the likeli-
Disconnect hood of condensate in high humidity environments.
Switch or
Circuit Breaker ACH580 Drive
Input
Terminals
Input
Ground Lug
Motor
Ground Lug
Motor
Terminals
Fuses
Service Switch
(Optional)
B2
(Bx3R-2)
Installation
26 ACH580 E-Clipse bypass and packaged drive user manual
Install the line input wiring
Line input connections – Vertical E-Clipse Bypass
configurations
Connect the input power to the terminals at the bottom
of the disconnect switch or circuit breaker as shown
below. Also see Connection and wiring diagrams –
Vertical E-Clipse Bypass on page 21. Connect the
equipment grounding conductor to the ground lug near Ground
the input power connection point.
Line input connections – Standard E-Clipse Bypass Input Power Cables
configurations (wall mounted)
Connect input power to the terminals of the disconnect
switch or circuit breaker. Connect the equipment grounding conductor to the ground lug at
the top of the enclosure. For connection points for Standard E-Clipse Bypass configurations,
refer to Connection and wiring diagrams – Vertical E-Clipse Bypass on page 21 and Connection
and wiring diagrams – Box E-Clipse Bypass on page 23.
Note: Route cables through the cable guides on the left side of the enclosure. Use separate
conduits for input power and motor cables. Follow the guides to separate the cables from
each other.
Power connections – Vertical E-Clipse Bypass configurations
Line input connections
Connect the input power to the terminals at the bottom of the disconnect switch or circuit
breaker. Also see Connection and wiring diagrams – Vertical E-Clipse Bypass on page 21.
Connect the equipment grounding conductor to the ground lug near the input power
connection point.
Motor connections
Connect the motor cables to the terminals at the bottom of the bypass section. Also see
Connection and wiring diagrams – Vertical E-Clipse Bypass on page 21. Connect the motor
grounding conductor to the ground lug near the motor cable terminal block connection point.
Power connections – Standard E-Clipse Bypass configurations (wall mounted)
Line input connections
Connect input power to the terminals of the disconnect switch or circuit breaker. Connect the
equipment grounding conductor to the ground lug at the top of the enclosure. The figure
below shows the connection points for Standard E-Clipse Bypass configurations. Also see
Connection and wiring diagrams – Box E-Clipse Bypass on page 23.
Motor connections
Installation
ACH580 E-Clipse bypass and packaged drive user manual 27
Connect the motor cables to the output terminal block as shown on page 30. Also see
Connection and wiring diagrams – Box E-Clipse Bypass on page 23. The motor grounding
conductor can be connected to the ground lug near the terminal block.
Note: Route cables through the cable guides on the left side of the enclosure. Use separate
conduits for input power and motor cables. Follow the guides to separate the cables from
each other.
WARNING! Check the motor and motor wiring insulation before connecting the
ACH580 to line power. Refer to the ACH580-01 Hardware Manual
(3AXD50000044839). Before proceeding with the insulation resistance
measurements, check that the ACH580 is disconnected from incoming line power. Failure to
disconnect line power could result in death or serious injury.
Install the control wiring
Connect control wiring to terminal block X1 on the ACH580 control board and to terminal block
X2 on the E-Clipse Bypass control board. For more information on these connections, refer to
the following:
• X1 terminal block location and terminal data are defined in the Installation instructions for
the drive on page 5.
• X2 terminal block location is illustrated in the figures starting with Connection and wiring
diagrams – Vertical E-Clipse Bypass on page 21.
• X2 terminal data are provided in Basic control connections for E-Clipse HVAC Default on
page 31.
• Basic connections are described in the following paragraphs. Alternate configurations
using the E-Clipse Bypass macro are described in the ACH580 HVAC control program
firmware manual (3AXD50000027537).
• On Terminal Block X1 inside the ACH580, analog inputs and outputs and additional digital
input and relay output connections (AI1, AI2, AO1, AO2, DI1…DI6 and RO1…RO6) are
available for use.
Note: The E-Clipse Bypass control circuitry uses serial communications connections
(X1:29…X1:31) inside the ACH580. These connections are not available for any other purpose
and must not be reconfigured.
Installation
28 ACH580 E-Clipse bypass and packaged drive user manual
Basic connections
The figure on page 30 shows the basic control
connections for use with the E-Clipse Bypass
HVAC Default macro. These connections are
BYPASS CONTROL
ESC ENTER
described in the following paragraphs.
ENABLED
HAND
SELECTED
FAULTED
DRIVE BYPASS
OFF/RESET In typical installations, only analog input wires
connect to the ACH580 terminal block, with other
AUTO
MOTOR RUN
control connections made on the E-Clipse Bypass
control board.
Use wire ties to permanently affix control/
Digital I/O communications wiring to the hooked wire race
control EIA-485
terminals tie points provided, maintaining a minimum 6 mm
port
control (1/4 in.) spacing from power wiring.
terminals
Drive’s power connection terminals
Refer to the tables in the Technical data section
from pages 215 – 232, which list the maximum
J7
J2
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