Belshaw MD-2 Installation Manual
Installation, Operation and Maintenance Manual
IM 959
Group: Aftermarket Products
Enclosed Variable Frequency Drive
Installation and Operation Manual
Part Number: IM 959
Date: September 2008
Supersedes: New
For McQuay enclosed variable frequency drive products
incorporating MD-2 variable frequency drives
460-480 Volt, 1-100 HP
200-240 Volt, 1-40 HP
Table of Contents
Introduction................................................................................................................................................................................. 4
Safety Symbols, Words and Labels........................................................................................................................................ 4
Hazardous Identification Information................................................................................................................................ 4
Before You Begin................................................................................................................................................................... 5
Specifications .............................................................................................................................................................................. 6
Receiving and Preliminary Inspection ........................................................................................................................................ 9
Storing and Shipping.............................................................................................................................................................. 9
Lifting and Handling ............................................................................................................................................................ 10
Dimensions and Weights........................................................................................................................................................... 11
Accessories and Options ........................................................................................................................................................... 12
NEMA Enclosure Type ................................................................................................................................................... 13
Disconnect Type.............................................................................................................................................................. 13
Phase Failure Monitoring ................................................................................................................................................ 13
Panel Door Security......................................................................................................................................................... 14
Wiring to Terminal Blocks .............................................................................................................................................. 14
Electrical Bypass ............................................................................................................................................................. 14
Auxiliary Contacts........................................................................................................................................................... 14
Hand/Off/Automatic Selector Switch.............................................................................................................................. 14
Local/ Remote Selector Switch........................................................................................................................................ 14
Communication Protocol................................................................................................................................................. 14
Forced Air Ventilation..................................................................................................................................................... 15
Interior Heater.................................................................................................................................................................. 15
Pressure Transmitter........................................................................................................................................................ 15
Remote Keypad ............................................................................................................................................................... 15
Spare Filters..................................................................................................................................................................... 15
Spare Fuses...................................................................................................................................................................... 15
Transient Arrestor............................................................................................................................................................ 16
Mounting the Drive Controller.................................................................................................................................................. 17
Clearances ............................................................................................................................................................................ 17
Mounting Methods ............................................................................................................................................................... 18
Bus Voltage Measurement Procedure .................................................................................................................................. 19
Wiring ....................................................................................................................................................................................... 20
Wiring Recommendations.................................................................................................................................................... 20
Branch Circuit Protection ................................................................................................................................................ 20
Grounding........................................................................................................................................................................ 21
Power Wiring................................................................................................................................................................... 22
Power Terminals.............................................................................................................................................................. 25
Control Terminals............................................................................................................................................................ 26
Integrated Display Terminal...................................................................................................................................................... 30
Programming the Drive Controller....................................................................................................................................... 31
Mode Access.................................................................................................................................................................... 31
Parameter Groups ............................................................................................................................................................ 32
Access to Menus and Parameters ......................................................................................................................................... 33
AUF Quick Menu................................................................................................................................................................. 35
Complete List of Parameters and Definitions ........................................................................................................................... 37
Logic Input Functions .......................................................................................................................................................... 42
Relay Output Functions........................................................................................................................................................ 46
Analog Inputs ....................................................................................................................................................................... 49
Analog Outputs..................................................................................................................................................................... 50
PID Control .......................................................................................................................................................................... 52
PID Setpoint .................................................................................................................................................................... 53
PID Tuning ...................................................................................................................................................................... 54
Floating Point Control ..................................................................................................................................................... 56
Wiring Diagram ........................................................................................................................................................................ 57
Troubleshooting ........................................................................................................................................................................ 58
Drive Controller Fault Conditions........................................................................................................................................ 58
2 IM 959
Pre-alarm Displays ............................................................................................................................................................... 63
Drive Controller Alarm Conditions...................................................................................................................................... 64
Resetting the Drive Controller after a Fault Condition is Detected...................................................................................... 66
Parts........................................................................................................................................................................................... 67
Parts List............................................................................................................................................................................... 67
Product Support......................................................................................................................................................................... 70
IM 959 3
Introduction
McQuay enclosed variable frequency drives (VFDs) can be added to most motor and pump applications to reduce energy
costs during low demand periods of a heating, ventilating, and air conditioning (HVAC) system. McQuay VFDs are
designed and tested for use with a variety of HVAC system components including:
• Rooftop units
• Air handling units
• Chilled water pumps
• Heating water pumps
• Cooling tower fans
• Condenser water pumps
This manual contains information regarding the installation and startup of a McQuay enclosed variable frequency drive
product. The information in this manual pertains to the following enclosed drive products.
• 1-100 horsepower, 400-480 volt Enclosed Variable Frequency Drives
• 1-40 horsepower, 200-240 volt Enclosed Variable Frequency Drives
Safety Symbols, Words and Labels
The following symbols and labels are used throughout this manual to indicate immediate or potential hazards. It is the owner
and installer’s responsibility to read and comply with all safety information and instructions accompanying these symbols.
Failure to heed safety information increases the risk of property damage and/or product damage, serious personal injury or
death. Improper installation, operation and maintenance can void the warranty.
Hazardous Identification Information
!
DANGER
Dangers indicate a hazardous situation which will
result in death or serious injury if not avoided.
!
WARNING
Warnings indicate potentially hazardous situations
which can result in property damage, severe
personal injury, or death if not avoided.
!
CAUTION
Cautions indicate potentially hazardous situations,
which can result in personal injury or equipment
damage if not avoided.
4 IM 959
Before You Begin
Read and understand these instructions before performing any procedure on this drive controller.
!
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
• Read and understand this manual before installing or operating the McQuay Enclosed Variable
Frequency Drive controller. Installation, adjustment, repair and maintenance must be performed by
qualified personnel.
• The user is responsible for compliance with all international and national electrical code requirements
with respect to grounding of all equipment.
• Many parts of this drive controller, including the printed circuit boards, operate at line voltage. DO
NOT TOUCH. Use only electrically insulated tools.
• DO NO TOUCH unshielded components or terminal strip screw connections with voltage present.
• DO NOT short across terminals PA/+ and PC/- or across the DC bus capacitors.
• Before servicing the drive controller:
− Disconnect all power, including external power control that may be present.
− Place a “Do Not Turn On” label on all power disconnects.
− Lock all power disconnects in the open position.
− WAIT 15 MINUTES to allow the DC bus capacitors to discharge. Then follow the DC bus voltage
measurement procedure on page
LED is not an indicator of the absence of DC bus voltage.
• Install and close all covers before applying power or starting and stopping the drive controller.
Failure to follow these instructions will result in death or serious injury.
19 to verify that the DC voltage is less than 45 volts. The drive
IM 959 5
Specifications
®
Table 1: McQuay Enclosed Drive Specifications
Input voltage
Displacement power factor
Input frequency
Output voltage
Galvanic isolation
frequency range of the power converter
Current limit
switching frequency
Speed reference
Frequency resolution in analog reference
Speed accuracy
20-100% of motor rated torque
Efficiency
Reference sample time
Acceleration and decelerations ramps
Motor protection
Keypad display
Storage temperature
Operating temperature
Humidity
Altitude
Enclosure
Codes and standards
208 Vac +/- 10%, 230 Vac +/- 10%, 460 Vac +/- 10%
Approximately 0.96
50/60 Hz +/- 5%
Three-phase output, maximum voltage equal to input voltage
Galvanic isolation between power and control (inputs, outputs, and power supplies)
0.5 to 200 Hz (factory setting of 60 Hz maximum)
110% of nominal drive full load amperage (FLA) for 60 seconds
Selectable from 6 to 16 kHz
factory setting: 6 kHz
1
VIA
: 4 to 20 mA, Impedance = 242 ohm or
0 to 10 Vdc, Impedance = 30 kohm
0 to 20 mA (reassignable, X-Y range with keypad display)
VIB: 0 to +10 Vdc, Impedance = 30 kohm
030048 Hz (11bits)
+/- 10% of nominal slip without speed feedback
Typically greater than 95%
2 ms
0.1 to 3,200 seconds (adjustable in 0.1 sec. increments)
Class 10 overload protection when any bypass option is installed and internal
electronic thermal protection on drive controller
Self-diagnostics with fault messages
-13 to +158 oF (-25 to + 70 oC) with vent cover on the VFD removed and without
derating
NEMA 1, non-ventilated, no direct sunlight: +14
NEMA 1, ventilated, no direct sunlight: +14
NEMA 12: +14
NEMA 3R: +14
o
to +122oF (-10o to +50oC)
o
to +122oF (-10oto +50oC), 0oF (-17.8oC) with heater option
o
to +104oF (-10o to +40oC)
o
to +122oF (-10o to +50oC)
95% with no condensation or dripping water, conforming to IEC 60068-2-3
3,300 ft. (1000 m) maximum without derating; derate the current by 1% for each
additional 330 ft. (100 m) up to 10,000 ft. (3000 m)
UL Type 1, UL Type 12, or UL Type 3R
UL Listed per UL508A. Conforms to applicable NEMA ICS, NFPA, and IEC
standards.
1
Not available with the following communication card options: BACnet®, LonWorks
Metasys® N2, ApogeeTM P1
Factory set for voltage control.
6 IM 959
Table 2 and Table 3 list specifications of each enclosed drive controller according to voltage, horsepower, and ampere rating.
(A)
(kg)
-
)
(
)
(
)
(
)
-
-
)
(
)
(
)
(
)
-
)
(
)
(
)
(
)
-
-
)
(
)
(
)
(
)
(
)
(
)
(
)
(
)
(
)
(
)
(
)
(
)
(
(
)
(
)
(
)
Mounting dimensions and maximum weight dimensions are illustrated in Table 4 on page
11.
Table 2: 200-240V Enclosed Drive Controller Specifications
Nominal Dimensions in. (mm)
Nominal
Voltage
230
Horsepower
(kW)
1 (0.75) 4.6
2 (1.5) 7.5
3 (2.2) 10.6
5 (4) 17.5
7.5 (5.5) 24.2
10 (7.5) 32
15 (11) 46.2
20 (15) 61
25 (18.5) 74.8
30 (22) 88
40 (30) 117
Maximum
Continuous
Current
Average
Weight
lbs.
70-80 (32
36
70-80 (32
36)
70-80 (32
36
70-80 (32
36
70-80 (32
36)
70-80 (32
36
115-135
52-61
115-135
(52-61)
115-135
52-61
250-280
(113-
250-280
113-
Frame
Size
1
1
1
1
1
1
2
2
2
4
4
Width Height Depth
11.40
289.56
11.40
(289.56)
11.40
289.56
11.40
289.56
11.40
(289.56)
11.40
289.56
13.25
336.35
13.25
(336.35)
13.25
336.35
16.50
(368.30)
16.50
368.30
43.50
1104.9
43.50
(1104.9)
43.50
1104.9
43.50
1104.9
43.50
(1104.9)
43.50
1104.9
50.00
1270.00
50.00
(1270.00)
50.00
1270.00
71.00
(1803.40)
71.00
1803.40
10.25
260.35
10.25
(260.35)
10.25
260.35
10.25
260.35
10.25
(260.35)
10.25
260.35
12.10
307.34
12.10
(307.34)
12.10
307.34
15.35
(389.89)
15.35
389.89
* Exact weight of each drive controller varies and depends on the options selected at time of purchase.
IM 959 7
Table 3: 400-480 Enclosed Drive Controller Specifications
-
-
-
-
-
-
-
Nominal Dimensions in. (mm)
Nominal
Voltage
480
Horsepower
(kW)
1 (0.75) 2.2
2 (1.5) 3.7
3 (2.2) 5.1
5 (4) 9.1
7.5 (5.5) 12
10 (7.5) 16
15 (11) 22.5
20 (15) 30.5
25 (18.5) 37
30 (22) 43.5
40 (30) 58.5
50 (37) 79
60 (45) 94
75 (55) 116
100 (74.6) 160
Maximum
Continuous
Current (A)
Average
Weight
lbs. (kg)
70-80 (32
36)
70-80 (32
36)
70-80 (32
36)
70-80 (32
36)
70-80 (32
36)
70-80 (32
36)
70-80 (32
36)
115-135
(52-61)
115-135
(52-61)
180-200
(82-91)
180-200
(82-91)
180-200
(82-91)
180-200
(82-91)
250-280
(113-
127)
250-280
(113-
127)
Frame
Size
1
1
1
1
1
1
1
2
2
3
3
3
3
4
4
Width Height Depth
11.40
(289.56)
11.40
(289.56)
11.40
(289.56)
11.40
(289.56)
11.40
(289.56)
11.40
(289.56)
11.40
(289.56)
13.25
(336.35)
13.25
(336.35)
13.25
(336.55)
13.25
(336.55)
13.25
(336.55)
13.25
(336.55)
16.50
(368.30)
16.50
(368.30)
43.50
(1104.90)
43.50
(1104.90)
43.50
(1104.90)
43.50
(1104.90)
43.50
(1104.90)
43.50
(1104.90)
43.50
(1104.90)
50.00
(1270.00)
50.00
(1270.00)
61.50
(1562.10)
61.50
(1562.10)
61.50
(1562.10)
61.50
(1562.10)
71.00
(1803.40)
71.00
(1803.40)
10.25
(260.35)
10.25
(260.35)
10.25
(260.35)
10.25
(260.35)
10.25
(260.35)
10.25
(260.35)
10.25
(260.35)
12.10
(307.34)
12.10
(307.34)
12.10
(307.34)
12.10
(307.34)
12.10
(307.34)
12.10
(307.34)
15.35
(389.89)
15.35
(389.89)
* Exact weights of each drive controller vary and depend on the options selected at time of purchase.
8 IM 959
Receiving and Preliminary Inspection
!
WARNING
DAMAGED PACKAGING
If the packaged appears damaged, it can be dangerous to open it or handle it. Handle with care.
Failure to follow this instruction can result in death, serious injury, or equipment damage.
!
WARNING
DAMAGED EQUIPMENT
Do not operator or install any drive controller that appears damaged.
Failure to follow this instruction can result in death, serious injury, or equipment damage.
Before installing the McQuay enclosed VFD controller, read this manual and follow all precautions.
Before removing the drive controller from its packaging, verify that the carton was not damaged in shipping. Carton damage
usually indicates improper handling and the potential for device damage. If any damage is found, notify the carrier and your
McQuay Parts Distributor.
Storing and Shipping
If the drive controller is not being immediately installed, store it in a clean, dry area where the ambient temperature is
between -13 and +158
shipping carton and packing material to protect it.
o
F (-25 and +70 oC). If the drive controller must be shipped to another location, use the original
IM 959 9
Lifting and Handling
!
WARNING
HANDLING AND LIFTING HAZARD
Keep the area below any equipment being lifted clear of all personnel and property. Use the lifting method illustrated
in Figure 1 on page
Failure to follow this instruction can result in death, serious injury, or equipment damage.
RISK OF TOPPLING
• Keep the drive controller on the pallet until ready to install.
• Never place the drive controller in an upright position without proper support, such as a hoist, braces, or other
mounting support.
Failure to follow this instruction can result in death, serious injury, or equipment damage.
• A hoist must be used for handling and lifting all McQuay drive controllers.
• After removing the drive controller from its packaging, inspect it for damage. If any damage is found, notify the
carrier and your McQuay Parts Distributor.
• Verify that the drive controller nameplate and label conform to the packing slip and corresponding purchase order.
10.
!
WARNING
Figure 1: Lifting and Hoisting the Drive Controller
10 IM 959
Dimensions and Weights
Figure 2: Enclosed Drive Dimensions
Table 4: Enclosed Drive Dimensions and Weights Frame size is determined by voltage and horsepower and is
shown in Tables 2 and 3, of pages 7 and 8 respectively.
FRAME
SIZE
1
2
3
4
DIMENSIONS, in. (mm)
A B C D E G H
11.40
(289.56)
13.25
(336.35)
13.25
(336.55)
16.50
(368.30)
12.64
(321.05)
14.49
(368.05)
14.49
(368.05)
17.74
(450.60)
10.25
(260.35)
12.10
(307.34)
12.10
(307.34)
15.35
(389.89)
0.39
(9.91)
0.39
(9.91)
0.39
(9.91)
0.39
(9.91)
13.58
(344.93)
15.43
(391.92)
15.43
(391.92)
18.68
(474.47)
41.28
(1048.51)
47.78
(1213.61)
59.28
(1505.71)
68.78
(1747.01)
43.50
(1104.90)
50.00
(1270.00)
61.50
(1562.10)
71.00
(1803.40)
AVERAGE
WEIGHT
lbs. (kg)
70-80
(32-36)
115-135
(52-61)
180-200
(82-91)
250-280
(113-127)
IM 959 11
MAXIMUM
WEIGHT,
lbs. (kg)
100 (45)
150 (68)
220 (100)
300 (136)
Accessories and Options
This section defines all available options that can be selected with a McQuay enclosed VFD. Figure 3 illustrates a twodimensional layout of the entire VFD enclosure and shows individual component locations. Refer to Figure 22 on page
for a typical wiring schematic for each or all of the components shown on the two-dimensional layout.
Figure 3: Enclosed Drive Controller Dimensional Layout and Internal Components
57
12 IM 959
NEMA Enclosure Type
The National Electrical Manufacturing Association (NEMA) sets electrical manufacturing standards for the United States.
NEMA establishes specific design criteria for which industrial electrical panels and enclosures should be designed and built.
NEMA establishes ratings and definitions for each type of industrial panel. The following definitions are referenced in
accordance with NEMA Standard 250-2003 (NEMA Enclosures section, November 2005). These NEMA types apply to the
McQuay Enclosed Variable Frequency Drive product.
• NEMA Type 1 - Enclosures are intended for indoor use, primarily to provide a degree of protection against the
contact with the enclosed equipment. The McQuay enclosed drive controller temperature limit for this NEMA type
without forced air ventilation is +14
installed is +14
o
to +122oF (-17.8o to +50oC).
• NEMA Type 12 - Enclosures are intended for indoor use, primarily to provide a degree of protection against
circulating dust, falling dirt, and non-corrosive liquids. The McQuay enclosed drive controller temperature limit for
this NEMA type is +14
o
to +122oF (-10o to +50oC).
• NEMA Type 3R (non-filtered) - Enclosures are intended for outdoor use, primarily to provide a degree of protection
against rain, sleet, and damage from external ice formation. The McQuay enclosed drive controller temperature
limit for this NEMA type is +14
when the heater option is present.
o
to +104oF (-10o to +40oC). The temperature range with forced air ventilation
o
to +122oF (-10o to +50oC). The drive controller is rated down to 0°F (-17.8°C)
• NEMA Type 3R (filtered) -
Enclosures are intended for outdoor use, primarily to provide a degree of protection
against rain, sleet, and damage from external ice formation, as well as a degree of protection against circulating dust,
falling dirt, and non-corrosive liquids.. The McQuay enclosed drive controller temperature limit for this NEMA type
o
to +122oF (-10o to +50oC). The controller is rated down to 0°F (-10°C) when the heater option is installed.
is +14
Disconnect Type
The National Electric Code (NEC) requires a unit disconnect on electrical motor circuits. A unit disconnect is a selectable
option on McQuay enclosed drive products. A disconnect allows power to be isolated from the enclosed drive controller for
serviceability and safety. Refer to DS1 of Figure 3 on page
12 for the disconnect location inside the enclosure. The
following types of disconnects are selectable with McQuay enclosed drive controllers.
• None – If a disconnect is located upstream of the motor power circuit, then a unit disconnect may not have been
installed inside the drive controller enclosure. Power may have to be shut down upstream within the power circuit
before installation and startup of the drive controller can be carried out in this situation.
• Non-Fusible Disconnect – This type of disconnect is manually operated and allows incoming power to be isolated
from the drive controller. This type of disconnect adds no circuit protection to the unit.
• Fusible Disconnect – This type of disconnect is manually operated and allows incoming power to be isolated from
the drive controller. This type of disconnect adds a certain level of circuit protection by incorporating a J type fuse.
• Circuit Breaker Disconnect – This type of disconnect is manually operated and allows incoming power to be isolated
from the drive controller. This type of disconnect adds a certain level of circuit protection by incorporating a circuit
breaker that can be manually reset.
Phase Failure Monitoring
A phase failure monitor is a selectable option on McQuay enclosed drive controllers. Refer to PVM1 of Figure 3 on page 12
for the location of the phase failure monitor inside the enclosure. The phase failure monitor is a device that protects the
motor from the following system failures:
• Single phasing (loss of any phase)
• Low voltage
• High voltage
• Voltage imbalance
• Phase reversal
• Rapid cycling
IM 959 13
Panel Door Security
Panel door security is a selectable option on McQuay enclosed drive controllers that allows the enclosure to be locked by way
of a paddle lockable device. This keeps unauthorized personnel from entering the enclosure or tampering with the drive
controller and internal components.
Wiring to Terminal Blocks
This option terminates all enclosed drive control wiring (I/O) to a common terminal block. Refer to Figure 10 on page 28 for
terminal designations. Figure 3 on page
12 shows the location of the terminal block (TB2) inside the enclosure.
Electrical Bypass
Electrical bypass is an available option on enclosed drive controllers. A bypass allows the variable frequency drive to be
eliminated from the power circuit. When the drive controller is put in the bypass mode, an independent circuit is enabled that
does not include (bypasses) the VFD. The unit operates at full speed with an across-the-line start when bypass mode is
selected. Variable speed control by way of the VFD is lost when the controller is in the bypass mode.
There are two types of electrical bypass options on McQuay enclosed drive controllers. A two-contactor bypass does not
isolate the VFD from main line voltage power. If the VFD fails and the bypass mode is enabled, the drive controller cannot
be serviced until the unit is completely shut down. A three-contactor bypass isolates the bypass circuit from the inverter
circuit. This means that the VFD can be serviced while running in the three-contactor bypass mode. M10B of Figure 3 on
12 represents the two contactor bypass option. M10C is the three contactor bypass and shown as a selectable option
page
within Figure 3.
Auxiliary Contacts
Each contactor on the enclosed drive controller is equipped with one normally open and one normally closed contact. If this
option is selected, an additional normally open and normally closed contact is added to each contactor within the McQuay
enclosed drive controller. When this option is selected with a two-contactor bypass, then four normally open and four
normally closed contacts are equipped on the unit. If a three-contactor bypass is present within the unit, and the auxiliary
contacts option is selected, then six (6) normally open and six (6) normally closed contacts will be present within the
enclosed drive controller.
Hand/Off/Automatic Selector Switch
S1 shown within Figure 3 on page 12 represents the Hand/Off/Automatic (HOA) switch. This option is a three-position
selector switch located on the outside of the enclosure. When this option is selected, the drive controller can be switched
between three different modes: Hand, Off, or Auto mode. The Hand mode allows the drive speed to be controlled via the
display keypad. The Off mode stops power to the VFD. The Automatic mode allows the system to control motor speed.
Local/ Remote Selector Switch
S2 represents the local/remote selector switch within Figure 3 on page 12. This option is a two-position selector switch
located on the outside of the enclosure. This option allows the drive controller to be selected between two modes - Local or
Remote mode. Local mode allows the drive speed to be controlled via the display keypad or system controls. Remote mode
allows the drive to be controlled by the building automation system (BAS) controls.
Communication Protocol
Modbus® is the standard communication protocol within the McQuay enclosed drive controller. Other communication
options are available. Separate installation and operation instructions are included with the enclosed drive controller when a
communication option other than Modbus is selected. The following communication protocols are available for the McQuay
enclosed drive controller:
• Modbus (Standard)
• Metasys® N2
• BACnet®
ONWORKS®
• L
14 IM 959
• Apogee P2™
Forced Air Ventilation
McQuay enclosed drive controllers may have thermostatically controlled forced air ventilation installed as an option. When
this option is selected, the ventilation fan (located at the top of the enclosure as shown in Figure 3 on page 12) will cycle on
o
F (29.4oC), and will shut off at 67oF (19.4oC). This option comes standard on NEMA 12 and 3R enclosures.
at 85
Thermostatically controlled forced air ventilation is a selectable option on NEMA 1 enclosure types. The upper temperature
limits for this selectable option are listed below.
• NEMA 1, non-ventilated: +104
• NEMA 1, ventilated: +122
• NEMA 12: +122
• NEMA 3R: +122
o
F (+50oC)
o
F (+50oC)
o
F (+40oC)
o
F (+50oC)
Interior Heater
McQuay enclosed drive controllers are selectable with an enclosed heater where weather conditions require it. The heater
will cycle on at 40
is positioned on the inside of the enclosure, along the side of the VFD (see Figure 3 on page 12 for details). When this option
is selected on Frame 4 enclosed drive controllers, two heaters are installed inside the enclosure. All other frame sizes ship
with one heater installed. The temperature limits with or without a heater installed are listed below.
• Enclosures with a heater installed: 0
• Enclosures without a heater installed: +14
o
F (4.4oC), and shut off at 50oF (10oC) when this option is installed inside the drive enclosure. The heater
o
F (-17.8oC)
o
F (-10oC)
Pressure Transmitter
This option is selectable when the drive controller will be installed in a fan application, where VFD speed will be controlled
by a pressure transmitter. The pressure transmitter can either be selected to mount on the inside of the enclosure (NEMA 1)
or outside of the enclosure (NEMA 4X). The pressure transducer is represented as SPS1 on the two dimensional layout of
Figure 3 on page
12.
The transducer is powered by 24 VDC via the P24 terminal of the MD-2 VFD. It transmits a 4-20 mA signal to the VIB
analog input terminal at the MD-2 VFD. The 4-20 mA signal is converted to a 2-10 VDC signal via a 499 ohm resistor
installed between the VIB and CC terminals of the VFD (refer to SPS1 of Figure 22 on page
57 for details).
Remote Keypad
The remote keypad is an available option on McQuay enclosed drive controllers. The remote keypad comes with a 9.8-foot
(3 m) cable that allows the user display and keypad to be accessed from a remote location. The remote keypad option is
available in a NEMA 1 or NEMA 3R rating. The NEMA 1 option is shipped loose, inside the enclosure for field mounting in
an indoor application. The NEMA 3R option is shipped loose, inside the VFD enclosure for field mounting in an outdoor
application.
Spare Filters
When this option is selected, the enclosed drive controller will ship with extra filters on NEMA 12 and NEMA 3R (filtered)
enclosure types. In these types of enclosure types, one filter is mounted inside the bottom of the enclosure at the outside air
intake louver. A second filter is mounted inside the top of the enclosure at the exhaust air louver. When spare filters are
ordered, an additional five (5) filters are shipped with the unit.
Spare Fuses
When this option is selected, the enclosed drive controller will ship with extra fuses when a fused disconnect or control
power transformer is installed in the unit. There are three large, fast acting, J type fuses when a fused disconnect is selected.
There are also three fuses installed on the control power transformer (CPT) when 115 VAC power is installed inside the drive
controller enclosure. When spare fuses are ordered, an additional quantity of three fuses for a fused disconnect, and three
fuses for the CPT are shipped with the unit.
IM 959 15
Transient Arrestor
The transient arrestor is a selectable option on McQuay enclosed drive controllers. This option adds a certain level of circuit
protection to the drive controller. The transient arrestor acts like a filter to stop sudden over-voltage transient conditions that
may exist in the power circuit. The large transients can be caused internally by the distribution network, or externally from
events such as lightning or motor arcing. The transient arrestor is shown as TA1 on the two-dimensional layout of Figure 3
on page 12.
16 IM 959
Mounting the Drive Controller
Clearances
When mounting a McQuay drive controller:
• Install the drive controller vertically, +/- 10
• Do not place the drive controller close to heat sources.
• Leave sufficient free space around the drive controller to ensure that air can circulate from the bottom to the top of
the unit.
• Leave enough free space in front of the drive controller enclosure door so that it opens at least 90
• Clearances must be in accordance with local AHJ requirements.
The enclosed drive controller has certain clearance requirements. Refer to Figure 4
mounting. The top of the enclosure should have a clearance of no less than six (6) inches (not including the shroud on
NEMA 3R enclosures). The bottom of the enclosure should also have a clearance minimum of six inches. There is no side
minimum clearance limit for mounting the drive controller. However, the drive controller should be mounted in a way that
still allows adequate clearance room for the enclosure door to open.
Figure 4: Minimum Clearance Requirements for Mounting the Enclosures
o
.
6 inch minimum
o
.
below for necessary clearances when
No
Limit
6 inch minimum
No
Limit
IM 959 17
Mounting Methods
• Mount the drive in an upright position.
• Mount the drive controller against a back panel or mounting support capable of supporting the maximum controller
weights shown in Table 5.
• Use mounting hardware capable of supporting the drive controller weight. Again, refer to Table 5 for maximum
weight requirements.
Table 5: Maximum Weights for Enclosed Drives.
VOLTAGE HORSEPOWER
1–10 1 100 (45)
208-230
460
Install the drive controller using the mounting feet provided on the outside of the enclosure. Refer to dimensional references
B and G of Table 4 on page
question.
15-25 2 150 (68)
30-40 4 300 (136)
1 - 15 1 100 (45)
20 - 25 2 150 (68)
30 - 60 3 220 (100)
75 - 100 4 300 (136)
11 for the mounting dimensions between each mounting foot depending on the frame size in
FRAME
SIZE
MAXIMUM WEIGHT,
lbs (kg)
18 IM 959
Bus Voltage Measurement Procedure
Before working on the drive controller, remove all power and wait 15 minutes to allow the DC bus to discharge. Then
measure the DC bus voltage between the PA/+ and PC/- terminals.
!
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH. DISCONNECT ALL POWER.
Read and understand the precautions in the “Before You Begin” section on page
Failure to follow this instruction can result in death or serious injury.
The DC bus voltage can exceed 1,000 VDC. Use a properly rated voltage-sensing device when performing this procedure.
To measure the DC bus voltage:
1. Disconnect all power.
2. Wait 15 minutes to allow the DC bus to discharge.
3. Measure the voltage of the DC bus between the PA/+ and PC/- terminals to ensure that the voltage is less than 45
VDC.
4. If the DC bus capacitors do not discharge completely, contact your local McQuay Parts Distributor. Do not repair or
operate the drive controller.
4 before performing this procedure.
Figure 5: Capacitor Charging LED
IM 959 19
Wiring
Wiring Recommendations
Good wiring practice requires the separation of control wiring from all power (line) wiring. In addition, power wiring to the
motor must have the maximum possible separation from all other power wiring, whether from the same drive controller or
other drive controllers. Do not run power and control wiring, or multiple power wiring, in the same conduit. This
separation reduces the possibility of coupling electrical transients from power circuits into control circuits or from motor
power wiring into other power circuits.
!
DANGER
IMPROPER WIRING PRACTICES
• Follow the wiring practices described in this document in addition to those already required by the
National Electrical Code and local electrical codes.
• Do not apply input line voltage to the output terminals (U/T1, V/T2, W/T3).
• Check the power connections before energizing the drive controller.
• If replacing another drive controller, verify that all wiring connections to the McQuay enclosed drive
controller comply with all wiring instructions in this manual.
Failure to follow these instructions will result in death, serious injury, or equipment damage.
Follow the practices listed below when wiring McQuay drive controllers:
• Verify that the voltage and frequency of the input supply line and the voltage, frequency, and current of the motor
match the rating on the drive controller nameplate.
• Use metallic conduit for all drive controller wiring. Do not run control and power wiring in the same conduit.
• Separate the metallic conduits carrying power wiring or low-level control wiring by at least 3 in. (76 mm).
• Separate the non-metallic conduits or cable trays carrying power wiring form the metallic conduit carrying control
wiring by at least 12 inches (305 mm).
• Whenever power and control wiring cross, the metallic conduits and non-metallic conduits or trays must cross at
right angles.
• Equip all inductive circuits near the drive controller (such as relays, contactors, and solenoid valves) with noise
suppressors.
• Cable lengths greater than 100 feet (30.5 m) can affect the drive controller and motor performance. For cables
longer than 100 feet, an output filter may be necessary.
Branch Circuit Protection
Refer to NEC Article 430 for sizing of branch circuit conductors. Ensure that all branch circuit components and equipment
(such as transformers, feeder cables, disconnect devices and protective devices) are rated for the input current of the drive
controller, or for the rated output current, whichever value is larger. Rated input and output current values are shown on the
drive controller nameplate.
NOTE: Ensure that the branch circuit feeder protection rating is not less than the rated output current of the drive controller.
20 IM 959
!
DANGER
INADEQUATE OVERCURRENT PROTECTION
• Over current protective devices must be properly coordinated.
• The National Electrical Code and the Canadian Electricity Code require branch circuit protection. Use
the fuses recommended on the drive controller nameplate to achieve published fault-withstand current
ratings.
• Do not connect the drive controller to a power feeder whose short circuit capacity exceeds the drive
controller short circuit current rating listed on the drive controller nameplate.
Failure to follow these instructions will result in death, serious injury, or equipment damage.
Grounding
Grounding of the drive controller should be done using the ground lug located at the bottom, on the inside of the enclosure.
The ground lug has a tag designation and is labeled GLG1
.
Figure 6: Ground Lug Location on McQuay Enclosed Drive Controllers
Ground Lug
(GLG1)
!
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Ground the equipment using the provided ground connecting point as shown in Figure 8 on page
22. The drive controller panel must be properly grounded before power is applied.
Failure to follow these instructions will result in death, serious injury, or equipment damage.
IM 959 21
Ground multiple drive controllers as shown in Figure 7 below. Do not loop the ground cables or connect them in series.
Figure 7: Grounding Multiple Controllers
Power Wiring
The drive controller enclosure does not come equipped with standard knockouts installed. Field-drilled power and control
wiring openings will have to be cut into the enclosure. Power and control wiring can be brought into the drive controller
through the bottom, the right side, or the left side of the enclosure. It is up to the installer to size, place, and cut the power
and control wiring holes correctly for their specific application, and according to the necessary conductor sizes shown in
Table 6 or Table 7 depending on power termination locations. Wire size must be selected in accordance with NEC table
310.16 for copper conductors at a temperature rating of 165
o
F (75oC) and/or local codes.
Figure 8: Typical Knockout Locations for Control and Power Wiring of the Drive Controller
Typical knockout locations
22 IM 959
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