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ABB ACH400 Series Retrofit Manual
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ABB ACH400 Series Retrofit Manual

Hvac drives. vertical electronic bypass to e-bypass, 1 - 25hp @ 208v, 1 - 50hp @ 480v (r1 ... r4 frame size drives)
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ABB HVAC Drives
ACH400 Vertical Electronic Bypass to ACH550 E-Bypass,
1 - 25Hp @ 208V, 1 - 50Hp @ 480V (R1 ... R4 Frame Size Drives)
Retrofit Guide
PRODUCTS

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Summary of Contents for ABB ACH400 Series

  • Page 1 ABB HVAC Drives ACH400 Vertical Electronic Bypass to ACH550 E-Bypass, 1 - 25Hp @ 208V, 1 - 50Hp @ 480V (R1 ... R4 Frame Size Drives) Retrofit Guide PRODUCTS...
  • Page 2 ACH550 NEMA 1 drive, reusing the existing electronic bypass (e-by- pass) can greatly increase the value to your company. ABB offers this step by step guide to help you easily install an ACH550 drive while maintaining the existing bypass components.

  • Page 3: Table Of Contents

    Contents Step 1: Verify that the correct replacement drive has been chosen....4 Step : Record existing parameter settings............5 Step : Deactivate the system ................5 Step 4: Remove and lockout all power from the ACH400........5 Step 5: Remove the cover from the bypass unit.

  • Page 4: Step 1: Verify That The Correct Replacement Drive Has Been Chosen

    Follow the steps for easiest conversion. Check off each step as you complete it. Step 1: Verify that the correct replacement drive has been chosen.  Locate the ACH400 Catalog Number at the top of the drive. Record the catalog # below. _____________________________________ ...

  • Page 5: Step : Record Existing Parameter Settings

    If it is still possible to power the existing unit, retrieve the programmed settings by performing Step 2. Otherwise, proceed to Step 3. Step 2: Record existing parameter settings.  With power applied to the existing unit, verify and record the parameter settings of the ACH400 in the table in the back of this document.

  • Page 6: Step 5: Remove The Cover From The Bypass Unit

     Confirm that the correct circuit has been locked out. The drive should have no active displays or status lights. Turn the disconnect / circuit breaker handle on the bypass unit to “OFF”. Warning! Dangerous voltages are present when input power is connected.

  • Page 7: Step 6: Verify Removal Of All Dangerous Voltages

    Step 6: Verify removal of all dangerous voltages.  If the metal option mounting bracket is present, carefully remove it. Remove and keep the two screws at the bottom of the shield. A magnetic screw driver is helpful for this step. ...

  • Page 8: Step 9: Remove The Front Cover From The Drive

    Step 9: Remove the front cover from the drive.  Insert a screwdriver into the slot and release the retaining lever. Then swing the cover away from the drive and remove it.  Use an appropriate meter to verify the absence of AC line voltage at the drive terminals (U1, V1,W1) and measure the DC voltage at terminals (Uc+, Uc-) before servicing the unit..

  • Page 9: Step 11: Disconnect Customer Installed Control Wiring

     Disconnect motor lead terminals U2, V2 and W2. Disconnect the green/yellow ground lead at terminal PE.  Step 11: Disconnect customer installed control wiring. You will need to know the type and level of signal produced and  the scaling to system units (e.g. 4-20 mA for 0-2.5 In. of H Also note the terminals from which the wiring was disconnected.

  • Page 10: Step 1: Remove The Ach400 Drive

    Bypass Unit Terminal Color Terminal 7 Green Terminal 8 Blue Terminal 9 Violet Terminal 10 Gray Terminal 14 Orange Terminal 1 Terminal 11 White Terminal 1 Black Step 13: Remove the ACH400 drive. (R1 frame shown)  Using a screwdriver with a blade length long enough to easily access the mounting screws, loosen (do not remove) the two bottom mounting screws.

  • Page 11: Step 14: Clean Up The Installation Area

    Step 14: Clean up the installation area.  Perform any general cleanup necessary. Use a brush, vacuum and other equipment to remove any dust and debris from the bypass unit, frame work and other areas. Step 15: Prepare the new ACH550 for installation. ...
  • Page 12 R3 Frame Size: Attach the top adapter bracket to the back panel with two of the  existing drive mounting screws as shown in the picture at the right. The adapter bracket has a lip and two (2) tabs that will point up when properly installed.
  • Page 13  Mount the ACH550 into the mounting channel by hooking the bottom mounting slots over the bolts and then tilting the top of the drive back into the channel. Lift the drive slightly to slip the top keyhole slots over the mounting screws, and then lower the drive fully.
  • Page 14  Mount the ACH550 into the mounting channel by hooking the bot- tom mounting slots over the bolts and then tilting the top of the drive back into the channel. Lift the drive slightly to slip the top keyhole slots over the mount- ing studs, and then lower the drive fully.

  • Page 15: Step 17: Reinstall The Power Wiring

    Step 17: Reinstall the Power Wiring. Important: Be careful that no loose strands are created when inserting the wires into the terminal block.  Reconnect ac input leads at terminals U1, V1 and W1.  Reconnect motor leads at terminals U2, V2 and W2. ...

  • Page 16: Step 19: Reinstall The Customer's Control Wires

     Tie wrap the cable and any other site-specific control wires to the top of the bypass unit as shown. Use only the tie slot shown (lower of the two). DO NOT wrap the cable to the top slot or cover interference may result.

  • Page 17: Step 1: Reinstall The Option Mounting Bracket

     Tighten the gold colored cover screw.  Reinstall the ACH550 Control Panel. Step 21: Reinstall the option mounting bracket.  If the metal bracket was removed in Step 6, reinstall the metal bracket and fasten it to the drive with the original 2 screws.

  • Page 18: Step : Reinstall The Bypass Unit Cover

    Step 22: Reinstall the bypass unit cover. R1 and R2 Frame Sizes: Prepare the cover by cleaning any dust or oil from the top of the  cover.  Apply the supplied gasket to the top of the cover by removing the backing and placing the gasket as shown.
  • Page 19 R3 and R4 Frame Sizes:  Prepare the cover by cleaning any dust or oil from the top inside edge of the cover.  Apply the supplied gasket material to the inside edges of the cover at the top by removing the backing and placing the gasket as shown. Note the top edge of the cover will match the edge of the gasket and the gasket will be snug against the inside bend of the cover.

  • Page 20: Step : Reapply Power To The Unit

    Step 23: Reapply power to the unit.  First, remove the safety tagout/lockout from the feeder device. Be certain to follow all designated safety procedures.  Close the branch device.  Now turn the disconnect handle on the bypass unit to the “On” position. Step 24: Verify that the signals and status are correct.

  • Page 21: Step 6: Test The Unit

    Step 26: Test the unit Start the system and verify correct operation in both Hand and Auto Modes.  Step 27: Drive Replacement Complete! Congratulations! If you followed these steps, your system is now running with the new ABB ACH550 drive.

  • Page 22: Parameter Conversion List

    Parameter Conversion List ACH400 ACH550 Parameter Par # HVAC Default Actual Par # Factory Desired Name Setting Default Setting LANGUAGE 9901 ENGLISH (AM) 9901 ENGLISH APPLIC MACRO 990 HVAC 990 HVAC DEFAULT E-BYPASS MOTOR CTRL MODE 9904 SCALAR: FREQ 9904 SCALAR: FREQ MOTOR NOM VOLT 9905...
  • Page 23 ACH400 ACH550 Parameter Par # HVAC Default Actual Par # Factory Desired Name Setting Default Setting MAXIMUM AI 105 100% 105 100.0 % FILTER AI 106 0.1 s 106 0.1 s RELAY OUTPUT 1 1401 FAULT (-1) 1401 READY STARTED RELAY OUTPUT  () 140 140...
  • Page 24 ACH400 ACH550 Parameter Par # HVAC Default Actual Par # Factory Desired Name Setting Default Setting DC MAGN TIME / 106 .0 s 10 0.0 s PREMAGN MAX TIME START INHIBIT 107 108 ACC/DEC 1/ SEL 01 NOT SEL 01 NOT SEL ACCELER TIME 1 0...
  • Page 25 ACH400 ACH550 Parameter Par # HVAC Default Actual Par # Factory Desired Name Setting Default Setting ZERO SPEED LOAD 007 008 70 % BREAK POINT FREQ 008 15 Hz 009 5 Hz STALL FUNCTION 009 NOT SEL 010 NOT SEL STALL CURRENT 010 8.8 A...
  • Page 26 ACH400 ACH550 Parameter Par # HVAC Default Actual Par # Factory Desired Name Setting Default Setting ACT1 INPUT 4007 4016 ACT INPUT 4008 4017 ACT1 MINIMUM 4009 4018 ACT1 MAXIMUM 4010 100% 4019 100 % ACT MINIMUM 4011 400 ACT MAXIMUM 401 100% 401...
  • Page 28 ABB Inc. ABB Inc. Low Voltage Drives Drives & LVC Canada 1650 W. Glendale Drive 99 J.B. Deschamps Blvd. New Berlin, WI 5151 Lachine, Quebec Telephone (800) 75-0696 H8T E4 (6) 785-097 Telephone (800) 15-006 Internet http://www.abb.com/motors&drives (514) 40-17 http://www.abb-drives.com Internet http://www.abb.com/motors&drives...

This manual is also suitable for:

Ach40160052Ach550 seriesAch40160042Ach40160062Ach40160112Ach40160162 ... Show all

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