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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
1/14
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).
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
2/14
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
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
3/14
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
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
4/14
8. Push in the lower tabs and pull out from the bottom of the Bypass
Control Unit (RBCU).
9. Push in the upper tabs and pull out from the top of the Bypass
Control Unit (RBCU).
Digital
Input Terminals
Digital Output Terminals
Communication Terminals
Communication Module Port
Communication Module Standoff
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
5/14
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
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
6/14
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
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
7/14
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
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
8/14
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.
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
9/14
Parameter Grouping 112
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
10/14
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
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
11/14
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
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
12/14
400 Volt Rating Table
HP Current Frame Ver
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
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
13/14
600 Volt Rating Table
HP Current Frame Ver
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
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
14/14
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
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