Bell & Gossett 176R0649C User Manual

INSTRUCTION MANUAL

176R0649

REVISION C

INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.

Technologic® 502 Series
Pump Controller

WARNING

!

Eq u i p m E n t Ha z a r d !

WARNING

!

WARNING

!

dr i v E s a n d pa n E l s c o n t a i n d a n g E r o u s v o l t a g E s w H E n

c o n n E c t E d t o l i n E v o l t a g E . it i s s t r o n g l y r E c o m m E n d E d
t H a t a l l E l E c t r i c a l w o r k c o n f o r m t o t H E na t i o n a l

El E c t r i c a l co d E (nEc) a n d a l l n a t i o n a l a n d l o c a l

r E g u l a t i o n s . in s t a l l a t i o n , s t a r t -u p a n d m a i n t E n a n c E
s H o u l d b E p E r f o r m E d o n l y b y q u a l i f i E d p E r s o n n E l . fa i l u r E
t o f o l l o w t H E nEc o r l o c a l r E g u l a t i o n s c o u l d r E s u l t i n
d E a t H o r s E r i o u s i n j u r y .

Motor control equipment and electronic controls
are connected to hazardous line voltages. Extreme
care should be taken to protect against shock. The
user must be protected against supply voltage
and the motor must be protected against overload
in accordance with applicable national and local
regulations. Be sure equipment is properly grounded.
Wear safety glasses whenever working on electric
control or rotating equipment.

un i n t E n d E d st a r t !

wH E n d r i v E o r o p t i o n p a n E l i s c o n n E c t E d t o ac i n p u t

p o w E r , m o t o r m a y s t a r t a t a n y t i m E . tH E d r i v E , o p t i o n
p a n E l , m o t o r , a n d a n y d r i v E n E q u i p m E n t m u s t b E i n
o p E r a t i o n a l r E a d i n E s s . fa i l u r E t o b E in o p E r a t i o n a l
r E a d i n E s s w H E n p a n E l a n d d r i v E a r E c o n n E c t E d t o ac
i n p u t p o w E r c o u l d r E s u l t i n d E a t H , s E r i o u s i n j u r y , o r
E q u i p m E n t o r p r o p E r t y d a m a g E .

Warning Against Unintended Start

When the drive or option panel is connected to the AC
line, the motor may be started by means of an external
switch, a serial bus command, an input reference
signal, or a cleared fault condition. Use appropriate
cautions to guard against an unintended start.

gr o u n d i n g Ha z a r d !

fo r o p E r a t o r s a f E t y , i t i s i m p o r t a n t t o g r o u n d d r i v E ,

o p t i o n p a n E l , a n d m o t o r p r o p E r l y . fo l l o w t H E g r o u n d i n g
g u i d E l i n E s o f l o c a l a n d n a t i o n a l c o d E s . fa i l u r E t o
f o l l o w g r o u n d i n g g u i d E l i n E s c o u l d r E s u l t i n d E a t H o r
s E r i o u s i n j u r y .

Grounding

Proper protective grounding of the equipment must
be established in accordance with national and local
codes. Ground currents are higher than 3 mA. Use
high stranded wire whenever possible.

Safety Guidelines

1. The drive and option panel must be
disconnected from the AC line before any
service work is done.

2. DO NOT touch electrical parts of the
option panel or drive when the AC line is
connected. After the AC line is disconnected,
wait 30 minutes before touching any
electrical components.

3. The user must be protected against supply
voltage and the motor must be protected
against overload in accordance with
applicable national and local regulations.

4. While programming parameters, the motor
may start without warning. Activate the
STOP/OFF key on the control keypad when
changing parameters.

5. The STOP/OFF key on the local control
panel keypad of the drive does not isolate
the drive from the AC line voltage and is not
to be used as a safety switch.

2

Table of Contents

Safety Guidelines ............................................................................................................................................................................... 2

Warning Against Unintended Start ...................................................................................................................................................2

Section 1 Introduction ....................................................................................................................................................................... 5

Purpose of the Manual ....................................................................................................................................................................... 5

Overview.............................................................................................................................................................................................. 5

Typical Bypass Operation .................................................................................................................................................................. 7

Overload Protection. ........................................................................................................................................................................... 7

Disconnects ........................................................................................................................................................................................ 8

Power Fusing ...................................................................................................................................................................................... 8

Drive Option Panel Congurations ................................................................................................................................................... 9

Option Panel Voltage and Frame Ratings ........................................................................................................................................9

Section 2 Pre-installation................................................................................................................................................................ 10

Pre-installation Check ...................................................................................................................................................................... 10

Installation Site Check ..................................................................................................................................................................... 10

Harsh Environments ........................................................................................................................................................................ 11

Section 3 Installation....................................................................................................................................................................... 12

Common Backpanel Mounted Units ............................................................................................................................................... 12

Branch Circuit Protection ................................................................................................................................................................ 12

Drive Fuses ....................................................................................................................................................................................... 12

Internal Option Panel Fuses ............................................................................................................................................................ 12

Tools and Equipment Required ....................................................................................................................................................... 12

Mechanical Installation .................................................................................................................................................................... 13

Lifting ................................................................................................................................................................................................. 13

Cooling .............................................................................................................................................................................................. 13

Electrical Installation........................................................................................................................................................................ 14

Wire Type Rating .............................................................................................................................................................................. 15

Terminal Tightening Torques ........................................................................................................................................................... 15

Line Input (Mains) Connection ........................................................................................................................................................ 15

Motor Wiring ..................................................................................................................................................................................... 16

Grounding (Earthing) ....................................................................................................................................................................... 17

Control Wiring ................................................................................................................................................................................... 18

Drive Control Terminals ................................................................................................................................................................... 18

MCB-101 Master Control Board ...................................................................................................................................................... 19

Pressure and Feedback Wiring ....................................................................................................................................................... 20

Control Terminal Programming ...................................................................................................................................................... 20

Serial Communication Bus Connection ......................................................................................................................................... 20

Serial Communications Programming ........................................................................................................................................... 20

Installation of Backpanel Mounted Drives and Pumps ................................................................................................................. 24

Installation of 70X Series Drives and Pumps................................................................................................................................. 25

Section 4 Start Up............................................................................................................................................................................ 28

Pre-start Procedure .......................................................................................................................................................................... 28

Inspection Prior to Start Up ............................................................................................................................................................. 29

Start Up Procedure ........................................................................................................................................................................... 30

Drive Power Up ................................................................................................................................................................................. 30

Required Drive Programming.......................................................................................................................................................... 31

System Start Up ................................................................................................................................................................................ 32

Full Speed Operation and Checkout ............................................................................................................................................... 33

Section 5 User Interface.................................................................................................................................................................. 34

Operation and Programming Through the LCP ............................................................................................................................. 34

Navigation keys ................................................................................................................................................................................ 35

Section 6 Programming and Operation ......................................................................................................................................... 36

Basic Drive Programming ............................................................................................................................................................... 36

Entering Basic Motor Data ............................................................................................................................................................... 36

Designating Master or Follower Drives .......................................................................................................................................... 36

3

Section 7 Status Messages ............................................................................................................................................................ 48

Status Messages .............................................................................................................................................................................. 48

Section 8 Warnings and Alarms ..................................................................................................................................................... 52

System Monitoring ........................................................................................................................................................................... 52

Warning and Alarm Displays

Description and Remedy ................................................................................................................................................................. 52

Section 9 Start Up Troubleshooting

Appendix .......................................................................................................................................................................................... 62

Serial Communication Point Maps ................................................................................................................................................. 62

Protocols

Serial Communications Programming ........................................................................................................................................... 62

Metasys N2 Point Map...................................................................................................................................................................... 63

Metasys N2 Point Map (continued) ................................................................................................................................................. 64

Modbus RTU Point Map (by parameter)

Modbus RTU Point Map (by function) ............................................................................................................................................ 66

Modbus RTU Point Map (by function) ............................................................................................................................................ 67

Floor Level Network (FLN) Set-up ................................................................................................................................................... 68

Quick Start Check List

........................................................................................................................................................................................... 62

........................................................................................................................................................... 52

.............................................................................................................................................. 59

......................................................................................................................................... 65

..................................................................................................................................................................... 73

List of Figures

1-1. Technologic 502 Pump Controller .............................................................................................................................................5

1-2. Master Drive with Three Followers
1-3. Basic 3-contactor Bypass Functions

1-4. Disconnects ................................................................................................................................................................................. 8

1-5. Tier Denitions and Features

3-1. Drive Input Fuses ...................................................................................................................................................................... 12

3-2. Cooling Air Flow
3-3. Typical Unit Components
3-4. Power Connections

3-5. Input Power Panel with Line Disconnect ................................................................................................................................ 15

3-6. Wire Access Panels (bottom view)
3-7. Sample Motor Wiring

3-8. Control Terminal Access ..........................................................................................................................................................18

3-9. Drive Control Terminals
3-10. Master Board Control Terminals

3-11. Master Board Control Terminal Location .............................................................................................................................. 19

3-12. Customer Wiring Schematic Diagram, VFD with 1 Follower

3-13. Customer Wiring Schematic Diagram, VFD with 2 or 3 Followers ..................................................................................... 22

3-14. Backpanel Mounted Drives and Pumps (front and side views)

3-15. 70X Series Drive ...................................................................................................................................................................... 26

3-16. 70X Series Customer Connection Diagram .......................................................................................................................... 27

5-1. Local Control Panel................................................................................................................................................................... 34

5-2. LCP Display Area....................................................................................................................................................................... 34

7-1. Display Status Line ................................................................................................................................................................... 48

........................................................................................................................................................................ 13

......................................................................................................................................................... 13

................................................................................................................................................................... 14

................................................................................................................................................................ 16

............................................................................................................................................................ 18

............................................................................................................................................ 6

........................................................................................................................................ 7

..................................................................................................................................................... 9

.......................................................................................................................................... 16

............................................................................................................................................ 19

............................................................................................... 21

.......................................................................................... 24

List of Tables

1-3. Panel Voltage and Frame Ratings
3-1. Tools and Equipment Required
3-2. Connection Tightening Torques

3-3. Drive Control Terminal Functions ............................................................................................................................................ 19

4-1. Inspection Prior to Start Up
6-1. Quick Menu Layout

6-2. Parameter 39-** Group, Detailed Description ......................................................................................................................... 39

7-1. Status Message Denitions...................................................................................................................................................... 48

8-1. Warnings and Alarms ................................................................................................................................................................ 53

9-1. Fault Table .................................................................................................................................................................................. 59

................................................................................................................................................................... 37

4

.............................................................................................................................................. 9

............................................................................................................................................... 12

..............................................................................................................................................12

...................................................................................................................................................... 29

Section 1 Introduction

Purpose of the Manual

This manual is intended to provide detailed information
for the installation and operation of the option
panel used in conjunction with the Technologic

502 Pump Controller. To enable efcient handling

of the equipment, requirements are provided for
mechanical installation, power and control wiring,
proper grounding, and environmental considerations.
Pre-start and start up procedures are detailed.
Also included is a detailed overview of the option
panel bypass function. In addition, programming,

identication and operation of optional components,

and basic troubleshooting instructions are included
as well.

Overview

The Technologic 502 Pump Controller is a variable
frequency drive with embedded pump control software.

It is available in several different congurations.

Type B-3 Controller (2 Pumps/1 Drive)

The type B-3 controller consists of a Technologic 502
master with embedded pump controller software,
contact motor selection, and an electronically con­trolled bypass. Contact motor selection allows the
controller to alternate between two motors of equal
size, a duty pump and a standby. The duty pump is
controlled to maintain a set point. Selection between
motors is made automatically by the Technologic 502
or by manual selection through a selector switch. The
bypass enables either motor to be driven by 100%
line power while bypassing the controller circuitry.
The Technologic 502 and electronically controlled
bypass are factory wired and mounted to a common
backplate.

Type C-4 Controller (2 Pumps/2 Drives)

The type C-4 bypass consists of a Technologic 502
master and (1) follower drive each with embedded
pump controller software and an electronically con­trolled automatic bypass. The C-4 controller allows
for duty/standby operation where only one pump is
run at any time. Selection between drive mode or
automatic bypass is determined by the master. The
bypass can also be activated manually through each
drive’s keypad.

Figure 1-1. Technologic 502 Pump Controller

Drives on a common backpanel are factory-wired
between the master and follower drives and contain

a main disconnect. Congurations may include a

fused disconnect or bypass.

Type A-1 Controller (1 Pump/1 Drive)

The type A-1 consists of a stand-alone Technologic
502 master with embedded pump controller software
and an electronically controlled automatic bypass.
The bypass can also be activated manually through
the drive keypad.

Type D-4 Controller (2 Pumps/2 Drives)

The type D-4 bypass consists of a Technologic 502
master and (1) follower drive each with embedded
pump controller software and an electronically con­trolled automatic bypass. The D-4 controller allows
parallel operation between the master and follower
drive in response to a set point. Drive mode or au­tomatic bypass is determined by the master. The
bypass can also be activated manually through each

drive’s keypad.

5

Type S-1 Controller (with or without manual by-

Input power panel

Master drive

Follower 1

Follower 2

Input power raceway to VFDs

pass)

The type S-1 controller comes in two different con-

gurations. One consists of a Technologic 502 master

with embedded pump controller software with up to

three follower drives. The other S-1 conguration is

the same with the addition of a manual bypass for the
master and a manual bypass for each follower drive.
The controller allows parallel operation between the
master and follower drives in response to a set point.
All drives will run at the same synchronized speed.

A-0 (1 Technologic 502 Master 0nly)

A-M (1 Technologic 502 Master only with manual
bypass)

C-0 (1 Technologic 502 Master with (1) follower – No
Staging)

C-M (1 Technologic 502 Master with (1) follower each
with manual bypass – No Staging)

D-0 (1 Technologic 502 Master with (up to 3) follow­ers – Staging Allowed)

D-M (1 Technologic 502 Master with (up to 3) followers
each with manual bypass – Staging Allowed)

6

Figure 1-2. Master Drive with Two Followers

Typical Bypass Operation

Overload Protection.

With contactors M1 and M2 closed and contactor M3
open (see Figure 1-3), the pump is controlled by the
drive. Opening contactor M2 removes power to the
pump but allows the controller to remain powered.
This is the test mode and only available in the three-

contactor conguration shown. With contactors M1

and M2 open and contactor M3 closed, the pump
runs in bypass from the line input. For a two-contactor

conguration, M1 is absent. In this case, contactors

M2 and M3 control the options for running in drive or

bypass mode. The gure illustrates a drive disconnect

and fuses.

This thermally activated device provides mechanical
overload protection for the pump(s) while in bypass
operation. It measures motor current and is factory set
to the full load amps (FLA) of the pump. A 1.2 x FLA
service factor is built-in and maintained. Should the
motor current increase above that value, the overload
will calculate the level of increase to activate timing
for the trip function. The higher the current draw, the
quicker the trip response. The overload provides
Class 20 motor protection.

Figure 1-3. Basic 3-contactor Bypass Functions

7

Disconnects

DRIVE

DISCONNECT

DRIVE

OPTION PANEL

BACKPLATE

MAIN

MOUNTING PANEL

DISCONNECT

Power Fusing

Main disconnect. The main disconnect removes

line input power to the controller and bypass. A main
disconnect is available in two options. For safety, the
switch must be in the OFF position before the panel
door can be opened. (See Figure 1-4.)

•

Main disconnect with built-in

fuses. Two-position (ON/OFF) ro-

tary switch, with three built-in fuses,
one on each phase.

Main disconnect with separate

•

fuses. Two-position (ON/OFF)
rotary switch with a fuse block
mounted separately from the
disconnect. Three fuses, one on
each phase, are located on the fuse
block.

Drive disconnect. Two-position (ON/OFF) rotary
switch disconnects main AC line input power to the

drive only.

Motor Alternation Selector Switch

The B3 option includes contactor motor selection. It
provides motor alternation with one drive alternating
operation between two motors. The panel mounted
Motor 1/Auto/Motor 2 selector switch provides local
control of either motor along with an auto setting that
allows auto selection through the master drive.

Two types of fusing are available for the units—main
and drive fusing. For all power fuses, use the speci-

ed fuse or an equivalent replacement only. See the

fuse ratings label on the inside cover of the unit for
ratings.

Main fusing. Main fuses are located ahead of the
drive. Main fuses are designed to protect the circuitry
within the panel but are not adequate to protect the
drive. Main fuses are dual-element, time-delay type
and mount inside the bypass enclosure.

Drive fusing. Drive fuses are located ahead of the
drive and are a fast-acting type. Drive fuses are stan­dard in two-contactor and three-contactor bypasses.
A fuse/disconnect enclosure may be used if no op­tions other than a fuse block and disconnect switch
are required.

8

Figure 1-4. Disconnects

Drive Option Panel Congurations

contains the bypass as in Tier 2. Two option panels

are provided in Tier 3 with one containing the bypass
The Technologic 502 Drive Series has three tiers
of option panel enclosure types. The option panel

and the other the contactor motor selector. (See

Figure 1-5)

Tier 1 Tier 2 Tier 3

Drive with fuses

Drive with bypass Drive with bypass and contactor

and disconnect

Figure 1-5. Tier Denitions and Features

Option Panel Voltage and Frame Ratings

Table 1-1 denes the voltage and hp ratings of the

frames sizes for the drive and option panel. See the
mechanical drawing shipped with the unit for dimen­sions.

Frame A2 - A5

Volts VAC hp

208-230 2-5

460-480 3-10

575-600 3-10

Frame B1

Volts VAC hp

208-230 7.5-15

460-480 15-25

575-600 15-25

Frame B2

Volts VAC hp

208-230 15-20

460-480 30-40

575-600 30-40

motor selector (B3)

Frame C1

Volts VAC hp

208-230 25-30

460-480 50-75

575-600 50-75

Frame C2

Volts VAC hp

208-230 40-60

460-480 100-125

575-600 100-125

Frame D1

Volts VAC hp

460-480 150-200

575-600 150-200

Frame D2

Volts VAC hp

460-480 250-350

575-600 250-400

Table 1-1. Panel Voltage and Frame Ratings

9

Section 2 Pre-installation

Pre-installation Check Installation Site Check

1. Compare model number to what was

ordered.

2. Ensure each of the following are rated for

same voltage:

• Power line

• Drive

• Option panel

• Motor

3. Ensure that option panel output rating is

equal to or greater than motor total full
load current for full motor performance.

• Motor power size and option panel must

match for proper overload protection.

• If panel rating is less than motor, full motor

output cannot be achieved.

4. Check motor wiring:

• Any disconnect between drive and motor

should be interlocked to drive safety
interlock circuit to avoid unwanted drive
trips.

• Because the option panel relies on the

ambient air for cooling, it is important to
observe the limitations on ambient air
temperature. Derating starts above 40°C
(104°F) and 3300 feet (1000m) elevation
above sea level.

• It is important with backpanel mounted units

to check support strength. Make sure that
the proper mounting screws or bolts are
used.

• Keep the option panel interior free from dust

and similar dirt. In construction areas, if the
unit is not powered, provide a protective
covering. It is important to ensure that the
components stay as clean as possible. It
may be necessary to clean the interior once
construction is completed.

• Keep wiring diagrams, drawings and

manuals accessible for detailed installation
and operation instructions. It is important
that the manuals be available for equipment
operators.

• Do not connect power factor correction

capacitors between drive and motor.

• Two speed motors must be wired

permanently for full speed.

• Y-start, -run motors must be wired

permanently for run.

10

Harsh Environments

The mechanical and electrical components within
the option panel can be adversely affected due to
the environment. The effects of contaminants in the

air, either solid, liquid, or gas, are difcult to quantify

and control. Depending upon the severity of the
environment, optional NEMA 12, NEMA 3R or NEMA
4 enclosures may be used.

Airborne Liquids

Liquids in the air can condense in components. Water
vapor carried in the air is easily measured as relative

humidity, but other vapors are often more difcult

to measure or control. Steam, oil, and salt water
vapor (near sea locations) may cause corrosion of
components. In such environments, use NEMA 12
enclosures to limit the exchange of outside air into
the option enclosure. Extremely harsh environments
may require a higher level of protection.

Airborne Solids

Particles in the air may cause mechanical, electrical
or thermal failure in components. A NEMA 1 enclosure
provides a reasonable degree of protection against
falling particles, but it will not prevent the fan from
pulling dirty air into the enclosure. A typical indicator
of excessive levels of airborne particles is dust
around the fan. In dusty environments, use NEMA
12 enclosures.

Corrosive Chemicals

In environments with high temperatures and humidity,

corrosive gases such as sulfur, nitrogen and chlorine

compounds cause corrosion to occur in components.

Indications of corrosion are blackened copper or rust

on steel or oxidized aluminum. In such environments,

it is recommended that the equipment be mounted in

a cabinet with fresh air ventilation and that corrosive

compounds be kept away. A non-ventilated cabinet

tted with an air conditioner as a heat exchanger may

be used. Conformal coated circuit boards may be

specied to reduce the corrosive effects of a harsh

environment.

11

Section 3 Installation

WARNING

!

TOOLS
Spreader bar capable of lifting up to 1000 lbs.
Max diameter 0.875 in.
Forklift, crane, hoist or other lifting device
capable of handling up to 1000 lbs. (Qualified
device operator available for operating the
equipment.)
Metric socket set: 7 - 19mm
Socket extensions: 4 & 6 in
Torx driver set: T10 - T40
Torque wrench: 6 - 170 in-lbs

Common Backpanel Mounted Units

Branch Circuit Protection

br a n c H ci r c u i t pr o t E c t i o n rE q u i r E d !

pr o v i d E b r a n c H c i r c u i t pr o t E c t i o n i n a c c o r d a n c E w i t H

t H E na t i o n a l E l E c t r i c a l co d E . fa i l u r E t o p r o v i d E b r a n c H
c i r c u i t pr o t E c t i o n in a c c o r d a n c E w i t H t H E nEc m a y
r E s u l t i n E q u i p m E n t o r p r o p E r t y d a m a g E .

Drive Fuses

If specied as an option, drive input fuses will be

factory installed in the enclosure. If not factory sup­plied, they must be provided by the installer as part
of installation.

Internal Option Panel Fuses

Use the specied fuse or an equivalent replacement

only for internal option panel fuses. Fuse options
include the drive disconnect and contactor fuses.

Tools and Equipment Required

In addition to the standard tool kit, the tools and de­vices in Table 3-1 are recommended for installation
of the unit.

Table 3-1. Tools and Equipment Required

Figure 3-1. Drive Input Fuses

Table 3-2. Connection Tightening Torques

Power (hp) Torque (in-lbs)

Frame 200-240 V 380-480 V 525-600 V Line Motor DC Brake Ground Relay

A2 2 - 5 3 - 5 3 - 5 17 17 17 28 5

A3 5 10 5 - 10 17 17 17 28 5

A5 1.5 - 5 1.5 - 10 1.5 - 10 17 17 17 28 5

B1 7.5 - 15 15 - 25 -- 17 17 13 28 5

B2 20 30 - 40 -- 22, 40 22, 40 32 29 5

12

C1 25 - 40 50 - 75 -- 88 88 88 28 5

C2 50 - 60 100 - 125 -- 124, 212 124, 212 124 29 5

D1 -- 150-200 150-200 168 168 84 29 7

D2 -- 250-350 250-400 168 168 84 29 7

Mechanical Installation

4.0 in min.

CEILING

FLOOR

AIRFLOW

4.0 in min.

AIRFLOW

Input power panel

Master drive

Follower 1

Follower 2

Input power raceway to VFDs

Drive disconnect

Mains (line)
disconnect

Hoist ring

Lift unit by
hoist ring only

Lifting

Check the weight of unit to determine the safety of the
lifting method. (See the mechanical drawing supplied
with the equipment for unit weight.) Ensure that the
lifting device is suitable for the task. If necessary, plan
for a hoist, crane or forklift with appropriate rating to
move the units. For lifting, use hoist rings provided.

Cooling

• Mount the controller and panel vertically.

• Option panels rely on the ambient air

for cooling. It is important to observe the
limitations on ambient air temperature.
Derating start above 104oF (40oC) and 3300
feet elevation above sea level.

• Top and bottom clearance is required for

cooling (Figure 3-2). Generally, 4 to 10
inches (100 to 250 mm) minimum clearance
is required, depending upon the hp of the
unit. See the mechanical drawing shipped

with the unit for specic requirements.

Figure 3-2. Cooling Airow

Figure 3-3. Typical Unit Components

13

WARNING

!

WARNING

!

Electrical Installation

EquipmEnt Hazard!

rotating sHafts and ElEctrical EquipmEnt can bE

Hazardous. it is strongly rEcommEndEd tHat all
E l E c t r i c a l w o r k c o n f o r m t o a l l n a t i o n a l a n d l o c a l
r E g u l a t i o n s . in s t a l l a t i o n , s t a r t -u p , a n d m a i n t E n a n c E
s H o u l d b E p E r f o r m E d o n l y b y q u a l i f i E d p E r s o n n E l . fa i l u r E
t o f o l l o w l o c a l r E g u l a t i o n s c o u l d r E s u l t i n d E a t H o r
s E r i o u s i n j u r y .

• Motor control equipment and electronic

controls are connected to hazardous line
voltages. Extreme care should be taken to
protect against electrical hazard.

• Proper protective grounding of the

equipment must be established. Ground
currents are higher than 3 mA.

• A dedicated ground wire is required.

• Wear safety glasses whenever working on

electric control or rotating equipment.

notE

ma k E a l l p o w E r c o n n E c t i o n s w i t H m i n i m u m 75o c r a t E d

c o p p E r w i r i n g f o r i n s t a l l a t i o n s i n no r t H am E r i c a .

in d u c E d vo l t a g E !

ru n o u t p u t m o t o r c a b l E s f r o m m u l t i p l E d r i v E s s E p a r a t E l y .

in d u c E d v o l t a g E f r o m o u t p u t m o t o r c a b l E s r u n t o g E t H E r

c a n c H a r g E E q u i p m E n t c a p a c i t o r s E v E n w i t H t H E E q u i p m E n t
t u r n E d o f f a n d l o c k E d o u t . fa i l u r E t o r u n o u t p u t c a b l E s
s E p a r a t E l y c o u l d r E s u l t i n d E a t H o r s E r i o u s i n j u r y .

notE

ru n d r i v E i n p u t p o w E r , m o t o r w i r i n g , a n d c o n t r o l

w i r i n g i n t H r E E s E p a r a t E m E t a l l i c c o n d u i t s o r r a c E w a y s
f o r H i g H f r E q u E n c y n o i s E i s o l a t i o n . fa i l u r E t o i s o l a t E
p o w E r , m o t o r , a n d c o n t r o l w i r i n g c o u l d r E s u l t i n l E s s
t H a n o p t i m u m c o n t r o l l E r a n d a s s o c i a t E d E q u i p m E n t
p E r f o r m a n c E .

• Because the wiring from the option

enclosure to the motor carries high
frequency electrical pulses, it is important
that no other wires are run in this conduit. If
the incoming power wiring is run in the same
conduit as the motor wiring, these pulses
can couple electrical noise back onto the
building power grid.

At least three separate conduits must be connected
to the panel option. (See Figure 3-4.)

• Power wiring into the enclosure (and ground

back to the distribution panel)

14

• Power wiring from the enclosure to the

motor (and earth ground)

• Control wiring

Control wiring should always be isolated from the
high voltage power wiring.

Avoid getting metal chips into electronics.

Follow the connection procedures as illustrated in
the drawing provided with the unit.

For internal component identication, see Figure

3-5.

Figure 3-4. Power Connections

OT 45...100 M3

Ground lug

Line (mains)
disconnect

Ground bar

L1 L2

L3

Wire Type Rating

WARNING

!

• Use wiring corresponding to the wire
rating specication provided.

• The wire rating specication is located

on the wire rating label inside the cover
of the option panel.

Terminal Tightening Torques

• Tighten all connections to the torque
specication provided in Table 3-2.

Line Input (Mains) Connection

• Size wiring based upon the input current

of the drive. Recommended wire sizes are
provided on the connection drawing of the
unit.

• Local codes must be complied with for cable

sizes.

ru n i n p u t p o w E r , m o t o r w i r i n g a n d c o n t r o l w i r i n g in

t H r E E s E p a r a t E m E t a l l i c c o n d u i t s o r r a c E w a y s f o r H i g H
f r E q u E n c y n o i s E i s o l a t i o n . fa i l u r E t o i s o l a t E p o w E r ,
m o t o r a n d c o n t r o l w i r i n g c o u l d r E s u l t i n l E s s t H a n
o p t i m u m d r i v E a n d a s s o c i a t E d E q u i p m E n t p E r f o r m a n c E .

• Connect 3-phase AC input power wire

to terminals L1, L2, and L3 on the main
disconnect located in the input power panel
(see Figure 3-3).

• Depending on the conguration of the

equipment, input power may be connected
to a circuit breaker or input disconnect.

• Use with Isolated Input Source. Many
utility power systems are referenced to earth
ground. Although not as common, the input
power may be an isolated source. All drives
may be used with an isolated input source
as well as with ground reference power
lines.

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

Exterior

Interior

Figure 3-5. Input Power Panel with Line Disconnect

15

Motor Wiring

WARNING

!

WARNING

!

NOTE: CONNECT MOTOR LEADS
DIRECTLY TO VFD THROUGH ACCESS
PANEL. DO NOT ROUTE THROUGH
RACEWAY.

notE

sE E fi g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d

c o n t r o l w i r i n g d i a g r a m s .

in d u c E d vo l t a g E !

ru n o u t p u t m o t o r c a b l E s f r o m m u l t i p l E d r i v E s s E p a r a t E l y .
in d u c E d v o l t a g E f r o m o u t p u t m o t o r c a b l E s r u n t o g E t H E r

c a n c H a r g E E q u i p m E n t c a p a c i t o r s E v E n w i t H t H E E q u i p m E n t
t u r n E d o f f a n d l o c k E d o u t . fa i l u r E t o r u n o u t p u t m o t o r
c a b l E s s E p a r a t E l y c o u l d r E s u l t i n d E a t H o r s E r i o u s
i n j u r y .

wi r i n g is o l a t i o n !

ru n i n p u t p o w E r , m o t o r w i r i n g a n d c o n t r o l w i r i n g in

t H r E E s E p a r a t E m E t a l l i c c o n d u i t s o r r a c E w a y s f o r H i g H
f r E q u E n c y n o i s E i s o l a t i o n . fa i l u r E t o i s o l a t E p o w E r ,
m o t o r a n d c o n t r o l w i r i n g c o u l d r E s u l t i n l E s s t H a n
o p t i m u m d r i v E a n d a s s o c i a t E d E q u i p m E n t p E r f o r m a n c E .

• Motor wiring access panels are provided at

the base of the units as shown in Figure 3-6:

• Torque terminals in accordance with the

information provided in Table 3-2.

• Motor wiring should never exceed the

following maximum distances:

1000 ft (300m) for unshielded
500 ft (150m) for shielded

• Motor wiring should always be as short as

practical.

Motor terminals
T1, T2, T3

Ground

• Connect the 3-phase motor wiring to bypass

terminals T1 (U), T2 (V), and T3 (W). See
the connection drawing provided with unit.

• Depending on the conguration of the

equipment, motor wiring may be connected
to an electrical or mechanical overload, a
contactor, or terminal block (see Figure 3-7).

Figure 3-6. Wiring Access Panels (bottom view)

Motor wiring

Figure 3-7. Sample Motor Wiring

16

Grounding (Earthing)

WARNING

!

gr o u n d i n g Ha z a r d !

fo r o p E r a t o r s a f E t y , i t i s i m p o r t a n t t o g r o u n d d r i v E a n d

o p t i o n p a n E l p r o p E r l y . fa i l u r E t o g r o u n d d r i v E a n d o p t i o n
p a n E l p r o p E r l y c o u l d r E s u l t i n d E a t H o r s E r i o u s i n j u r y .

no t E

it i s t H E r E s p o n s i b i l i t y o f t H E u s E r o r c E r t i f i E d E l E c t r i c a l

i n s t a l l E r t o E n s u r E c o r r E c t g r o u n d i n g (E a r t H i n g ) o f
t H E E q u i p m E n t in a c c o r d a n c E w i t H n a t i o n a l a n d l o c a l
E l E c t r i c a l c o d E s a n d s t a n d a r d s .

• Follow all local and national codes for proper

electrical equipment grounding (earthing).

• Proper protective grounding of the

equipment must be established. Ground
currents are higher than 3 mA.

• A dedicated ground wire is required.

• Do not use conduit connected to the option

panel as a replacement for a ground wire.

• Do not ground one panel to another in a

“daisy chain” fashion. Each panel must have
a dedicated ground connection.

• A high strand count ground wire is preferred

for dissipating high frequency electrical
noise.

• Keep the ground wire connections as short

as possible.

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

• Connect the ground wire directly to a reliable

earth ground. Grounding studs are provided
on the back plate of the option panel for
grounding.

17

Control Wiring

WARNING

!

ru n i n p u t p o w E r , m o t o r w i r i n g a n d c o n t r o l w i r i n g i n

t H r E E s E p a r a t E m E t a l l i c c o n d u i t s o r r a c E w a y s f o r H i g H
f r E q u E n c y n o i s E i s o l a t i o n . fa i l u r E t o i s o l a t E p o w E r ,
m o t o r a n d c o n t r o l w i r i n g c o u l d r E s u l t i n l E s s t H a n
o p t i m u m d r i v E a n d a s s o c i a t E d E q u i p m E n t p E r f o r m a n c E .

• It is recommended that control wiring is

rated for 600 volts for 480 V and 600 V
drives and 300 volts for 200-240 V drives.

Drive Control Terminals

Denitions of the drive terminals are summarized in

Table 3-3. Figure 3-9 shows the removable controller
connectors and terminals.

• Connector 1 provides four programmable
digital inputs, two additional digital terminals
programmable as input or output, a 24 VDC
terminal supply voltage, and a common for
optional customer supplied 24 VDC voltage.

• Isolate control wiring from high power

components in the drive.

Control Wiring Access

• For units 5 hp or less (208 V) and 10 hp or

less (480 V), remove access cover plate with
screw driver. (See Figure 3-8.)

• For larger size units, remove front cover of

unit to access internally mounted control
terminals. (See Figure 3-8.)

• Connector 2 is for the serial
communications EIA-485 connector with
terminal 68 (+) and 69 (-).

• Connector 3 provides two analog inputs,
one analog output, 10 VDC supply voltage,
and commons for the inputs and output.

• Connector 4 is a USB port available for
use with the MCT-10 drive programming
software.

• Also provided are two Form C relay outputs

that are in various locations depending upon

the controller conguration and size.

Figure 3-8. Control Terminals Access

18

Figure 3-9. Drive Control Terminals

Table 3-3. Drive Control Terminals Functions

Terminal No.

Function

01, 02, 03
04, 05, 06

Form-C relay output. Useable for AC or DC voltage and
resistive or inductive loads. See drive support materials for
details on voltage and current ratings and relay location.

12, 13

24 VDC digital sup ply voltage. Useable f or digital inputs and
external transducers. T o use the 24 VDC for digital input
common, program param eter 5-00 for PNP operation.
Maximum output current is 200 mA total for all 24V loads.

18, 19, 32, 33

Digital inputs. Selectable for NPN or PNP function in
parameter 5-00. Default is PNP.

27, 29

Digital inputs or outputs. Programmable for either. Parameter
5-01 for terminal 27 and 5- 02 for 29 selects input/output
function. Default setting is input.

20

Common for digital inputs. To use for digital input common,
program parameter 5-00 for NPN operation.

39

Common for analog output.

42

Analog output. Programm able for various functions in
parameter 6-5x. The analog signal is 0 to 20 mA or 4 to 20 mA
at a maximum of 500 Ω.

50

10 VDC analog supply voltage. 15 mA maximum commonly
used for a potentiometer or thermistor.

53, 54

Analog input. Selectable for voltage (0-10 V) or current (0- or
4-20 mA). Closed is for current and open is for voltage.
Switches are located on the drive control card behind the
removable LCP. See drive support materials for details.

55

Common for analog inputs.

61

Common for serial communication. Do not use to terminate
shields. See drive support materials for proper shield
termination.

68 (+), 69 (-)

RS-485 interface. When the drive is connected to an RS-485
serial communication bus, a drive control card switch is
provided for termination resistance. ON for term ination and
OFF for no termination. See drive support materials for details.

MCB101
master board

Drive terminals

R1

249W

3 4 765 9 101

MCB-101 Master Board

11 12

X30A

13 14

D in

COM

D in 8 D in 9

(1)

GND3Dout4Dout

Out

+24V

(2)

GND

A in 3 A in 4 Out

+24V

Out

+24V

R2

249W

MCB-101 Master Control Board

The Master drive only contains the MCD-101 Master
Board which features additional programmable
connection terminals (see Figure 3-10). Typically,
differential pressure switches, remote system run and
system status, and an optional low suction pressure
switch are connected to these terminals. (See Figure
3-12, Control Wiring Schematic Diagram.)

Figure 3-10. Master Board Control Terminals

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

notE

sE E f i g u r E s 3-12 a n d 3-13 f o r p o w E r , m o t o r a n d c o n t r o l

w i r i n g d i a g r a m s .

Figure 3-11. Master Board Terminals Location

19

Pressure and Feedback Wiring

Serial Communications Programming

Connect differential pressure wiring and feedback
transmitter wiring to terminals as shown in Figure
3-9.

Control Terminal Programming

Control terminals must be programmed. Terminals
are multi-functional. Each terminal has a parameter
associated with it for setting the desired function. It is
essential for operation of the equipment that the con­trol terminals are programmed correctly. Installation
programming for units is factory set. See program­ming in this manual for more details.

See Figure 3-13 for the control terminals schematic
diagram.

Serial Communication Bus Connection

The bypass reports serial communication data to host
systems through the drive. Connection to the serial
communication network is made either through the
EIA-485 terminals on the controller (Figure 3-9) or, for
other protocols, terminals located on the communica­tion option card. For option card connection, see the
option card instructions provided with the unit.

• For bypass serial communication protocols

using the EIA-485 terminals, make connections
in the following manner.

Select the serial communication protocol type in Quick
Menu item Q8, Communications.

Press the OK key to access the parameter choices

and scroll to parameter 8-30, Protocol to select the
protocol in use.

notE

dE t a i l E d s E r i a l c o m m u n i c a t i o n i n s t r u c t i o n s a r E s H o w n in

t H E a p p E n d i x a t t H E E n d o f t H i s m a n u a l .

notE

it i s r E c o m m E n d E d t o u s E b r a i d E d -s H i E l d E d , t w i s t E d -p a i r

c a b l E s t o r E d u c E n o i s E b E t w E E n c o n d u c t o r s .

1. Connect signal wires to terminal (+) 68 and
terminal (-) 69 on control terminals of controller.

2. Terminate shield to grounded restraining clip
provided by stripping wire insulation at point of
contact.

3. If shielded cabling is used, do not connect end
of shield to terminal 61.

20

Figure 3-12. Customer Wiring Schematic Diagram, VFD with 1 Follower

21

M1

1T1

1T2

1T3

PUMP

MOTOR #1

60 Hz

3Ø

POWER

INPUT

L13

L11

L12

DISCONNECT

L1

L2

L3

GND

BAR

GND

(T1)

(T2)

(T3)

(L1)

(L2)

(L3)

WL3

GND

VL2

L1 U

MASTER

L13

L11

L12

MAIN

GND

GND

BLOCK

DISTRIBUTION

L13

L11

L12

GND

BAR

GND

CUSTOMER

SUPPLIED

BRANCH

CIRCUIT

PROTECTION

208V-600V

POWER TO

SLAVE VFD'S

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

RS485

DP3 DP4DP2DP1

VFD4-18

2J27

GENERAL

ALARM

240VAC, 2A

MAX.

(+)

(-)

CUSTOM FIELD

CONNECTION FOR

CONFIGURABLE

ANALOG OUTPUT

P

COM

N

DISCONNECT ENCLOSURE

COMMON PANEL

USB

TO VFD4-27

2J28

VFD2-27

2K08

TO VFD3-27

2J18

VFD4-27

2K28

VFD2-18

2K07

VFD3-18

2K17

VFD1-20

VFD1-5

1R21

VFD1-4

VFD1

20333219 27 29181312

2 3 4 76 9101

MCB-101 AUX. CONNECTOR

11 12

X30A

13

Din

COM

Din 7 Din 8 Din 9 3

Dout

4

Dout

Out

+24V

(2)

GND

Ain 3 Ain 4 Out

+24V

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

61 68 69 504239 53 54 55

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

OPT. LOW SUCTION

PRESSURE SWITCH

SYSTEM RUN

REMOTE

CUSTOMER

SUPPLIED (+24V)

RUN STATUS

(+24V)

1 2

ON

1 2

ON

ON=0-20mA

OFF=0-10V

S201 S202

DS1

FU1

(LOCATED ON VFD)

DISCONNECT

V/S PUMP

R1

249W

R2

249W

2K08

VFD2-33

2L08

VFD2-20

1K18

VFD1-12

2B02 2C02 2C02

14

Out

+24V

VFD3-27

2K18

FEEDBACK Ain1

4-20mA

FEEDBACK Ain2

4-20mA

FEEDBACK Ain3

4-20mA

FEEDBACK Ain4

4-20mA

(-) (+) (-) (+) (-) (+)(-) (+)

22

Figure 3-13.1. Customer Wiring Schematic Diagram, VFD with 2 or 3 Followers (1 of 2)

M2

2T1

2T2

2T3

PUMP

MOTOR #2

DIST. BLK

FROM

POWER

INPUT

L13

L11

L12

W

GND

V

U

FOLLOWER 1

L13

L11

L12

GND

GND

GND

BAR

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

COMMON PANEL

LOCATED IN

ENCLOSURE

DISCONNECT

X30A-6

1N19

X30A-2

1N17

VFD1-29

1K24

VFD1-20

1L24

M4

4T1

4T2

4T3L13

L11

L12

W

GND

V

U

FOLLOWER 3 (OPT.)

GND

GND

GND

BAR

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

USB

VFD1-5

1R24

TO DP4

1I30

PUMP

MOTOR #4

M3

3T1

3T2

3T3

PUMP

MOTOR #3

W

GND

V

U

FOLLOWER 2 (OPT.)

L13

L11

L12

GND

GND

GND

BAR

4 5 6

RELAY 2

1 2 3

RELAY 1

C NO NCC NO NC

VARIABLE

FREQUENCY

DRIVE

X30A-7

1N20

TO DP3

1I29

VFD1-29

VFD1-20

VFD1-29

VFD1-20

VFD2 VFD4VFD3

61 68 69 504239 53 54 55

20

333219 27 29181312

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

USB

61 68 69 504239 53 54 55

20

333219 27 29181312

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

USB

61 68 69 504239 53 54 55

20

333219 27 29181312

Out

+24V

Din Din

D I/O D I/O

Din Din Din

COM

Out

+24V

COM P N A Out

COM

A Out Out

+10V

Ain Ain Ain

COM

L3

L2

L1

DS2

FU2

(LOCATED ON VFD)

DISCONNECT

V/S PUMP

L3

L2

L1

DS3

FU3

(LOCATED ON VFD)

DISCONNECT

V/S PUMP

L3

L2

L1

DS4

FU4

(LOCATED ON VFD)

DISCONNECT

V/S PUMP

1B09

1B09

1B10

X30A-4

1N18

X30A-3

1N18

Figure 3-13.2. Customer Wiring Schematic Diagram, VFD with 2 or 3 Followers (2 of 2)

23