Changing E-Clipse Bypass Control Unit (RBCU) Replacement Instructions1.pdf · ABB Drive Services Status Revision C Page 1/14 Changing E-Clipse Bypass Control Unit (RBCU) WARNING!

ABB Inc

E-Clipse RBCU Replacement Instructions

3AUA0000032890 RBCU REPLACEMENT INSTRUCTIONS.DOC

Dept. Drive Services

Project

Date

6/6/2008 Author

ABB Drive Services Status

Revision

C Page

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Changing E-Clipse Bypass Control Unit (RBCU)

WARNING! The incoming power to the ACH550 adjustable speed AC drive with E-Clipse Bypass should be switched off before changing the Bypass Control Unit (RBCU).

Tools Required:

No. 1 Slotted Screwdriver (Control & Communication Cables)

No. T15 Torx Head Screwdriver or Bit (Fan, If installed)

Applies To:

All E-Clipse units

Introduction:

The following set of instructions will guide the technician with the proper replacement of the Bypass Control Unit (RBCU). Proper installation will require both hardware and software changes.

Steps:

1. If possible, document changes in existing Bypass Control Unit by

viewing the Changed Parameter section via the bypass keyboard.

2. Move the circuit breaker or disconnect handle to the “OFF” position to

remove incoming supply voltage from Bypass Unit.

3. Remove RS45J Wire from the J3 plug located on the top of Bypass

Control Unit (RBCU).

4. Remove Fan, if installed, by removing the two screws that hold the

fan in place and unplug the power connection by squeezing and gently

pulling upward on the J4 plug located on the top of Bypass Control Unit

(RBCU).

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Top of RBCU

5. Remove the following 4 wires from the bottom of the Bypass Control

Unit (RBCU) by squeezing the front and back of plug then pulling slightly

forward and down:

• Cable, Chassis Ground from the J6 Plug • RLIM Module, 3-phase AC from the J7 Power Plug • Cable, Contactor Coil from the J8 Plug • Cable, CT Harness from the J2 Plug

Note! RBCU units that are Rev. D (as denoted on the right side of the RBCU unit) or previous require an RLIM module installed in the J7 Power Connector. If an RLIM module is installed, make sure a module stays with the cable and not with the RBCU unit. If RLIM needs to be replaced, follow Steps 1-4 below. Use Steps 1-2 below to simply disconnect RLIM from RBCU

J4, External Fan Connection

J3,

RS-485 Connection from the Drive

Fan Mounting Screws

1

2

3

4

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Bottom of RBCU (RLIM Installed)

6. Remove digital input and digital output wires from front of Bypass

Control Unit (RBCU) using a small slotted screwdriver making sure wires

are properly identified for reinstallation.

7. Remove communication cables from front of Bypass Control Unit

(RBCU) using a small slotted screwdriver making sure wires are properly

identified for reinstallation. If optional communication module is used,

remove module by loosening screw that is held by the communication

module standoff.

J6

Ground Connection

J7

Power Connector

J2

Current Transducer Feedback

J8

Contactor

Control

RLIM Module

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8. Push in the lower tabs and pull out from the bottom of the Bypass


9. Push in the upper tabs and pull out from the top of the Bypass


Digital

Input Terminals

Digital Output Terminals

Communication Terminals

Communication Module Port

Communication Module Standoff

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10. Snap new RBCU into mounting holes

11. Reconnect Input, Output and Communication wires identified in step

6 & 7. If applicable, reinstall communication module. Terminals should be

tightened to 0.3 lb-ft(0.4 Nm).

12. Reinstall cables, and fan if installed, that were removed from RBCU

in steps 3, 4 and 5, making sure RLIM is reinstalled.

13. Reapply power to the Bypass Unit and make sure new Bypass

Control Unit (RBCU) initializes.

14. If the drive and Bypass power up normally, then proceed to Step 19.

Top Mounting Tabs

Bottom Mounting Tabs

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15. Drive and motor parameters should automatically transfer from the

drive to the new RBCU via the RS-485 link. If the drive does not function on

power up and/or the Bypass Keypad displays either:

Bypass Fault 3027: Invalid Subassembly

Bypass Fault 3038: No Drive Data

Alarm 4013: Drive Link Error

Fault 3019: Drive Link Fault

Parameters in Group 112 need to be entered manually.

From the operating screen of the bypass, press “Enter” on the Bypass

Keypad.

Operating Screen

Use the Up (▲) and Down (▼) arrow keys to get to the Parameter List

Menu Option

UP and Down Arrow Keys

“Enter” Button

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Parameter List Menu Option

Press “Enter” again to enter the Parameter List.

Parameter List

Press “Enter” again to enter a Parameter grouping.

“ESC” Key “ENTER” Key

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Parameter Grouping

From a Parameter group list, access to Parameters 112 is gained by

pressing the “Esc”, “Up” and “Down” keys at the same time. Stop pressing

the three keys as soon as the screen goes blank. When the screen display

returns, press “Esc” and scroll down to Group 112 and press “Enter”. Press

“Enter” again to verify first parameter value (11201). Use “Up” & “Down”

arrow keys to change value, then “Enter” to accept the value.

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Parameter Grouping 112

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Verify or enter the follow parameters:

112.01 = Drive type using format XXXY where:

XXX is current rating of drive (found in the column labeled “Current” on Pages 11-13 of this manual)

Y is voltage rating of drive: 2 for 208-240V,4 for 380V - 480V or 6 for 500V - 600V (a 023a-4 drive should be entered as a 0234)

(scroll up until the left most digit is correct, after a few seconds, the cursor will move to the right and flash the next digit, use the up/down arrows to modify, press “Enter” when drive type is correct)

112.02 = Motor rated voltage, V

112.03 = Motor rated current, A

112.04 = Motor rated power, Hp

16. Press “Esc” to turn to the Parameter List.

17. Scroll down to Parameter Group 105, press “Enter”, then scroll to

Parameter 105.09, press “Enter” and verify the corresponding 5 digit value

found in the tables below using the Drive type found in Parameter 112.01. If

105.09 displays a “0”, press the up arrow key to display the 5 digit value.

Press “Enter” then “Esc” when complete.

18. Set Parameter 105.11 to 3 to save all parameters, and then press the

Enter key.

19. Set Parameter 98.02 to “Not Sel” if E-Clipse will not be

communicating to a building system via Serial Communications.

20. Cycle Power on the Bypass and the unit should be ready to operate

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200 Volt Rating Table

HP Current Frame Ver

tica

l

Sta

nd

ard

Par

am.

1050

9

1 04A6-2 R1 x x 14826

1.5 06A6-2 R1 x x 14826

2 07A5-2 R1 x x 14826

3 012A-2 R1 x x 14826

5 017A-2 R1 x x 14829

7.5 024A-2 R2 x x 14829

10 031A-2 R2 x x 14830

15 046A-2 R3 x x 14831

20 059A-2 R3 x x 14831

25 075A-2 R4 x x 14831

30 088A-2 R4 x 15635

40 114A-2 R4 x 15637

50 143A-2 R6 x 15638

60 178A-2 R6 x 15639

75 221A-2 R6 x 15640

100 248A-2 R6 x 15641

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tica

l

Sta

nd

ard

Par

am.

1050

9

1.5 03A3-4 R1 x x 14826

2 04A1-4 R1 x x 14826

3 06A9-4 R1 x x 14826

5 08A8-4 R1 x x 14826

7.5 012A-4 R1 x x 14826

10 015A-4 R2 x x 14829

15 023A-4 R2 x x 14829

20 031A-4 R3 x x 14830

25 038A-4 R3 x x 14830

30 045A-4 R3 x x 14830

40 059A-4 R4 x x 14831

50 072A-4 R4 x x 14831

60 078A-4 R4 x x 14831

75 097A-4 R4 x 15636

100 125A-4 R5 x 15637

125 157A-4 R6 x 15638

150 180A-4 R6 x 15639

200 246A-4 R6 x 15641

250 316A-4 R8 x 15642

300 368A-4 R8 x 15642

350 414A-4 R8 x 15642

400 486A-4 R8 x 15642

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tica

l

Sta

nd

ard

Par

am.

1050

9

2 02A7-6 R2 x x 14829

3 03A9-6 R2 x x 14829

5 06A1-6 R2 x x 14829

7.5 09A0-6 R2 x x 14829

10 011A-6 R2 x x 14829

15 017A-6 R2 x x 14829

20 022A-6 R3 x x 14830

25 027A-6 R3 x x 14830

30 032A-6 R4 x x 14831

40 041A-6 R4 x x 14831

50 052A-6 R4 x x 14831

60 062A-6 R4 x x 14831

75 077A-6 R6 x 15635

100 099A-6 R6 x 15636

125 125A-6 R6 x 15637

150 144A-6 R6 x 15638

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Revision Table: Rev. Revision Date Responsible

A Initial Version 03/25/2008 PDO

B Added RLIM reference 05/16/2008 PDO

C General Revision 05/30/2008 PDO

Documents

Changing E-Clipse Bypass Control Unit (RBCU) Replacement Instructions1.pdf · ABB Drive Services Status Revision C Page 1/14 Changing E-Clipse Bypass Control Unit (RBCU) WARNING!