ABB ACH 400 User Manual
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ABB ACH 400 User Manual

ABB ACH 400 User Manual

With electronic bypass
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ACH 400 with Electronic Bypass

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Summary of Contents for ABB ACH 400

  • Page 1 ACH 400 Users Manual ACH 400 with Electronic Bypass...
  • Page 3 ACH 400 with Electronic Bypass User’s Manual ACH400-US-08EB 3AUA489002B4233 R0101 Rev. D EFFECTIVE: 4/20/01 SUPERSEDES: 5/15/00  2001 ABB Inc. All Rights Reserved.

  • Page 4: Safety Instructions

    This symbol informs you of high voltage conditions, situations, and locations that may cause death or serious injury if you do not follow precautions and proper steps. This warning symbol indicates a general warning. This warning symbol indicates an electrostatic discharge hazard. ACH 400 with Electronic Bypass Users Manual...

  • Page 5: Warnings, Cautions, And Notes

    Dangerous external control voltages may be present on the relay outputs of the Electronic Bypass control board. CAUTION: Electrostatic Discharge (ESD) can damage electronic circuits. Do not handle any components without following the proper ESD precautions. ACH 400 with Electronic Bypass Users Manual...

  • Page 6: Table Of Contents

    NEMA Type 12, Size R1 - R4 ..........3-6 ACH 400 Side By Side NEMA Type 1/12, Size R1 - R4 ......3-7 NEMA Type 1/12, Size R5 - R6 .
  • Page 7 Motor Connected to the Electronic Bypass ........4-5 ACH 400 with Electronic Bypass Users Manual...

  • Page 8: Chapter 1 - Introduction

    The ACH 400 with Electronic Bypass user documentation also includes the ACH 400 AC Drives User’s Manual for 3 to 50 Hp drives or the ACH 400 AC Drives User’s Manual for 60 to 400 Hp drives, depending on the model of your drive.

  • Page 9: Warranty And Liability Information

    Your local ABB Drives company or distributor may have a different warranty period, which is specified in their sales terms, conditions, and warranty terms. If you have any questions concerning your ACH 400 with Electronic Bypass, contact your local distributor or ABB Drives office.

  • Page 10: Chapter 2 - Overview Of Ach 400 With Electronic Bypass

    The ACH 400 with Electronic Bypass is a packaging arrangement that provides space for mounting factory installed options as designated by the type code characters following a plus sign (+) after the ACH 400 base unit type code. Locate the Control Nameplate on the Electronic Bypass and use Figure 2-1 to verify the model number.

  • Page 11: Electronic Bypass Features And Functions

    Features and Functions frequency drive in an integrated NEMA Type 1 or NEMA Type 12 package with a bypass motor starter. The ACH 400 with Electronic Bypass provides a disconnect switch or circuit breaker with door mounted operator (padlockable in the OFF position), a bypass starter, motor overload protection, a local operator keypad with indicating lights, and provisions for external control connections.
  • Page 12 170M5013 ACH40264003x 170M6012 Note: Fuses listed are similar in function to fuses listed in the ACH 400 User’s Manual, physical characteristics may differ. Fuses from other manufacturers can be used if they meet the ratings given in the table. The fuses recommended in the table are UL recognized.

  • Page 13: Bypass Contactors

    ACH 400 is out of service. The other contactor is the ACH 400 output contactor (1M for R1 through R4 and 3M for R5 through R9) that disconnects the ACH 400 from the motor when the motor is operating in the Bypass mode.

  • Page 14: Detailed Description Of Operation

    The LED is red when the overload has tripped or the bypass control board has faulted. Drive Run LED The Drive Run LED is illuminated green when the ACH 400 drive is running. Drive Fault LED The Drive Fault LED is illuminated red when the motor or drive protection functions have shut down the ACH 400.

  • Page 15: Operating Modes

    Reset Key The Reset key resets the bypass fault. Drive Select Key The Drive Select key selects the ACH 400 drive as the power source for the motor. Bypass Select Key The Bypass Select key selects the bypass as the power source for the motor.

  • Page 16: Bypass Control Board Inputs And Outputs

    If the bypass is switched to the Bypass mode, the motor will stop. Bypass/Drive If the ACH 400 is in the Auto mode and the motor is running in the Drive mode transfers mode, the motor will transfer to bypass operation if the bypass is switched to the Bypass mode and the bypass is in the Auto mode.

  • Page 17: Ach 400 Drive Inputs And Outputs

    ACH 400 is deenergized or if a fault has occurred. The Inverter Run relay is energized when the ACH 400 is running. The N.O. contact of this relay is connected in parallel with the N.O. contact of the Bypass Run relay to provide an output that is closed when the motor is running whether powered by the ACH 400 drive or the bypass.
  • Page 18 “actual” signal. Refer to the ACH 400 User’s Manual for additional information. The Output Frequency analog output of the ACH 400 provides a 4 to 20 mA signal proportional to the drive output frequency or motor speed. ACH 400 with Electronic Bypass User’s Manual...
  • Page 19 Chapter 2 – Overview of ACH 400 with Electronic Bypass 2-10 ACH 400 with Electronic Bypass User’s Manual...

  • Page 20: Chapter 3 - Installation Instructions

    Chapter 3 – Installation Instructions This chapter explains how to install the ACH 400 with Electronic Bypass and connect all power, motor, and control wiring. It also explains the initial inspection procedures. Pre-Installation Before beginning installation, review the installation instructions in this chapter and make sure that the installation requirements can be met.
  • Page 21 If the cooling air contains dust, clean the cooling surfaces of the unit regularly using compressed air and a brush. If the ACH 400 is in a NEMA 1 enclosure, cover the vents during cleaning to prevent the dust from entering the unit.
  • Page 22 Refer to Electrical Installation on page 3-13 for detailed wiring information. Initial Inspection As you unpack the ACH 400 with Electronic Bypass, check for any signs of Procedure damage and verify that the delivery is complete by examining the contents for items such as the user’s manual, keypad, etc.

  • Page 23: Mechanical Installation

    Chapter 3 – Installation Instructions Mechanical Installation Securely mount the ACH 400 with Electronic Bypass on a wall in a vertical position. Use the four mounting notches at the top and bottom of the unit. Before mounting the unit, verify that the environmental conditions conform to the specifications listed in Pre-Installation Planning in this chapter.
  • Page 24 Dimensions Reference Frame Size, IP21/NEMA 1 (in/mm) 5.28/134 5.28/134 8.66/220 8.66/220 3.96/101 3.96/101 6.34/161 6.34/161 43.67/1114 47.80/1214 54.93/1395 58.47/1485 41.68/1059 45.62/1159 52.47/1133 56.01/1423 10.28/261 10.20/259 1176/299 11.76/299 34/16 41/19 108/49 127/58 Mass (lb/kg) ACH 400 with Electronic Bypass User’s Manual...

  • Page 25: Nema Type 12, Size R1 - R4

    Dimensions Reference Frame Size, IP54/NEMA 12 (in/mm) 8.43/214 8.43/214 10.09/256 10.09/256 3.96/101 3.96/101 6.34/161 6.34/161 48.63/1235 52.51/1334 59.71/1517 63.65/1617 45.97/1168 50.37/1279 57.29/1455 61.19/1554 10.20/259 10.20/259 11.76/299 12.45/316 36/17 44/20 112/51 131/60 Mass (lb/kg) ACH 400 with Electronic Bypass User’s Manual...

  • Page 26: Ach 400 Side By Side Nema Type 1/12, Size R1 - R4

    Chapter 3 – Installation Instructions ACH 400 Side By Side NEMA Type 1/12, Size R1 - R4 ACH 400 with Electronic Bypass User’s Manual...

  • Page 27: Nema Type 1/12, Size R5 - R6

    Chapter 3 – Installation Instructions NEMA Type 1/12, Size R5 - R6 ACH 400 with Electronic Bypass User’s Manual...

  • Page 28: Ach 401 Nema Type 1, Size R7

    Chapter 3 – Installation Instructions ACH 401 NEMA Type 1, Size R7 ACH 400 with Electronic Bypass User’s Manual...

  • Page 29: Ach 402 Nema Type 12, Size R7

    Chapter 3 – Installation Instructions ACH 402 NEMA Type 12, Size R7 Conduit Connection Cutout Area 3-10 ACH 400 with Electronic Bypass User’s Manual...

  • Page 30: Ach 402 Nema Type 1, Size R8 - R9

    294-169 294-169 3AUA294001B169 3AUA294001B169 F642-F 3AF3 10026423 3AF3 10026423 XT700-LS XT700-LS Dimensions Reference Frame Size, IP21/NEMA 1 (in/mm) 56.30/1430 56.30/1430 81.14/2061 81.14/2061 27.05/687 27.05/687 Mass (lb/kg) 660/300 1130/515 ACH 400 with Electronic Bypass User’s Manual 3-11...

  • Page 31: Ach 402 Nema Type 12, Size R8 - R9

    294-169 3AUA294001B169 3AUA294001B169 F642-F 3AF3 10026423 3AF3 10026423 XT700-LS XT700-LS Dimensions Reference Frame Size, IP54/NEMA 12 (in/mm) 56.30/1430 56.30/1430 91.33/2320 91.33/2320 27.05/687 27.05/687 Mass (lb/kg) 660/300 1130/515 3-12 ACH 400 with Electronic Bypass User’s Manual...

  • Page 32: Electrical Installation

    Chapter 3 – Installation Instructions Electrical Installation Cable Entries Most ACH 400 Electronic Bypass drives are configured for wiring access from the bottom only. Types ACH 401612032 and ACH 401614032 are configured for wiring access from the top only. At least three separate conduits are required, one for input power, one for output power to the motor and one for control signals.

  • Page 33: Connection Points

    Figure 3-1 shows the Electronic Bypass wiring connection points for R1 - R4 frame sizes. Other frames sizes are addressed in the section Connection Points on page 3-16. Refer to the ACH 400 User’s Manual for control connections to the drive.

  • Page 34: Input Wiring

    Chapter 3 – Installation Instructions Input Wiring The ACH 400 with Electronic Bypass is designed for use on a three-phase system. Four wires (three phase wires plus a ground wire) are required for the input wiring. All field power wiring shall be copper, rated for 60°C if rated for less than 100 amps or 75°C if rated 100 amps or more.

  • Page 35: Output Wiring

    WARNING! Check the motor and motor wiring insulation before connecting the ACH 400 to line power. Follow the procedure provided below. Before proceeding with the insulation resistance measurements, check that the ACH 400 is disconnected from incoming line power. Failure to disconnect line power could result in death or serious injury.

  • Page 36: Control Wiring

    Motor Run contact to an external status indicating circuit. For a detailed description of the control circuit functions, refer to the section entitled Detailed Description of Operation on page 2-5. ACH 400 with Electronic Bypass User’s Manual 3-17...
  • Page 37 X2 on the Electronic Bypass control board. Figure 3-1 shows the location of X2. Refer to the ACH 400 User’s Manual for the location of X1. X1 accepts one wire per terminal in wire sizes ranging from 22 AWG to 16 AWG and X2 accepts one wire per terminal in wire sizes ranging from 26 AWG to 14 AWG.
  • Page 38 The analog inputs can accept a voltage signal (0 – 10 VDC) or a current signal (0 – 20 mA). Jumper J1, located on the ACH 400 control board (J1 is used for both AI1 and AI2), determines the signal type. J1 can be set in either the voltage or current position according to the type of external signal that will be connected.
  • Page 39 The shield connection must be terminated at the ground terminal provided (X1:1). The other end of the shield should be cut and taped back at the signal source. 3-20 ACH 400 with Electronic Bypass User’s Manual...

  • Page 40: Chapter 4 - Start-Up Procedure

    • Control cable connections, wire shield grounding, and control cable location away from the power wires. • Quantity and quality of cooling air for the ACH 400 with Electronic Bypass. Connect the ACH 400 with Electronic Bypass to supply voltage. Check that the voltage between L –...

  • Page 41: Electronic Bypass Jumper, Switch And Pot Settings

    User Override position. When the jumper is in the User Override position, the Drive contactor is energized and the Bypass contactor is deenergized. The contactors are not controlled by the Electronic Bypass keypad when the bypass is in the User Override mode. ACH 400 with Electronic Bypass User’s Manual...

  • Page 42: Relay Output Jumpers

    308 - 480 VAC Switch Code ACH401x0042x ACH401x0043x ACH401x0053x ACH401x0063x ACH401x0052x ACH401x0093x ACH401x0062x ACH401x0113x ACH401x0163x ACH401x0203x ACH401x0112x ACH401x0253x ACH401x0162x ACH401x0303x ACH401x0202x ACH401x0413x ACH401x0302x ACH40160603x ACH401x0412x ACH40160703x ACH40160601x ACH40161003x ACH40160701x ACH40x61203x ACH40x61403x ACH40262103x ACH40262603x ACH40263203x ACH40264003x ACH 400 with Electronic Bypass User’s Manual...

  • Page 43: Macros And Parameter Settings

    7. For Steps 8 through 13, set Parameter 9904 MOTOR CONTROL MODE to “SCALAR” for drive units above 50 Hp. Refer to the ACH 400 User’s Manual for details on setting parameters. After successful completion of Step 12, return Parameter 9904 to “DTC”.

  • Page 44: Motor Connected To The Electronic Bypass

    Chapter 4 – Start-up Procedure 9. Press the HAND key on the ACH 400 keypad. Note that the bottom line of the display indicates “HAND” and “RUN” and a Right Arrow. The Drive Run LED on the Bypass keypad should be illuminated.
  • Page 45 Do not swap the motor leads. If the drive does not operate according to these steps, refer to the ACH 400 User’s Manual. If the drive operates according to these steps, your ACH 400 with Electronic Bypass is ready to use with preset or modified macro settings.
  • Page 46 Disconnect switch mounting planning Installation planning Electronic Bypass cooling definition environment features Installation, inspection 3-17 functions Insulation resistance illustration Electrostatic Discharge (ESD) warning Environment Jumpers relay output user override ACH 400 with Electronic Bypass User’s Manual I - 1...
  • Page 47 3-16 3-20 conduits motor protection 3-17 3-20 control reset key 3-15 input power trip current adjustment 3-16 output Override, user 3-20 shielded cable 3-13 terminal sizes wiring requirements Parameter settings I - 2 ACH 400 with Electronic Bypass User’s Manual...
  • Page 48 ABB Inc. Drives & Power Electronics 16250 W. Glendale Drive New Berlin, WI 53151 Telephone:(262) 785-8378 (800) 243-4384 Fax: (262) 780-5135 All specifications and instructions are subject to change without notice from the manufacturer.

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