Installation and
Commissioning Guide
HMI Bypass
Controller
HVAC Drive H300
Part Number: PSD-H300HMIBP-ICG
Issue: 2.0
Contents
Section 1 - Introduction ........................................................................................5
Section 2 - Installation Instructions .....................................................................6
2.1 Receiving ......................................................................................................6
2.2 Nameplate Information ................................................................................6
2.2.1 Labels ...................................................................................................6
2.2.1.1 HMI Bypass Package Label ............................................................6
2.2.1.2 Typical Standard VFD Rating Label ...............................................7
2.3 Part Number Identication ............................................................................8
2.4 Mounting & Clearances .................................................................................9
2.5 Wiring and Precautions ..............................................................................10
2.5.1 General ..............................................................................................10
2.5.2 Input Wiring .......................................................................................10
2.5.3 Output Wiring ....................................................................................11
2.5.4 Control Circuit Wiring .........................................................................12
2.5.4.1 Analog Input ..............................................................................12
2.5.4.2 Digital Inputs .............................................................................12
2.5.4.3 Relay Outputs ............................................................................12
2.5.4.4 Digital Output ............................................................................13
2.5.4.5 Additional HVAC H300 VFD Connections ....................................13
2.5.4.6 Additional SI-I/O Connections ....................................................13
2.5.5 Grounding .........................................................................................14
2.5.6 Customer Connection Terminals .........................................................14
2.5.6.1 Emergency Bypass Operation .....................................................14
2.5.7 Customer Connection Diagram ..........................................................15
2.5.8 HVAC Drive H300 HMI Bypass Schematic ............................................16
2.6 Inspection ..................................................................................................18
Section 3 – Overview of the HMI bypass ..........................................................18
3.1 HMI Bypass Touchscreen Functions .............................................................18
3.1.1 Splash Screen ......................................................................................18
3.1.2 Main Control Screen ...........................................................................19
3.1.3 Drive Status and System Diagnostics...................................................20
3.1.3.1 General Status ............................................................................20
3.1.3.2 Additional Drive Status ....................................................................21
3.1.3.3 Trip Log ............................................................................................21
3.1.3.4 Graphical Trend Viewer ..............................................................22
3.1.3.5 I/O Status ...................................................................................23
3.2 System Settings...........................................................................................23
3.2.1 Motor Map ..........................................................................................24
3.2.3 Advanced VFD Settings .......................................................................26
3.2.4 Skip Frequencies .................................................................................27
3.2.5 Motor Ramp/Limits .............................................................................27
3.2.6 I/O Settings .........................................................................................28
2 HMI Bypass Controller Installation and Commissioning Guide
3.2.7 Auto-Reset Setup ................................................................................28
3.2.8 Remote Control ..................................................................................29
3.2.10 Modbus RTU Conguration ...............................................................30
3.2.10.1 Serial Data Format ....................................................................31
3.2.11 Alarm Response ................................................................................31
3.2.12 Alarm Response - Fireman’s Override ................................................32
3.2.13 Advanced I/O Settings ......................................................................32
3.2.14 PID Setup ..........................................................................................33
3.2.14.1 PID Setup - Sleep/Wake Function ..............................................33
3.2.15 Miscellaneous ...................................................................................34
3.3 Touchscreen HMI Settings ...........................................................................34
3.3.1 Setting the Date and Time ..................................................................35
3.4 Touchscreen LCD HMI Software Update Procedure ......................................36
Section 4 – Startup ...............................................................................................37
4.1 Setup Wizard Process ..................................................................................38
4.2 Setup Wizard - Step-by-Step Instructions ....................................................38
4.3 Checking Motor Rotation ............................................................................42
4.3.1 Check #1: Rotation on VFD power .....................................................42
4.3.2 Check #2: Rotation on Bypass power ..................................................42
4.4 Normal Operation .......................................................................................43
4.4.1 Current System Status ........................................................................43
4.4.2 Starting Operation .............................................................................44
4.4.3 Ending Operation ...............................................................................44
Section 5 - Troubleshooting ................................................................................45
Section 6 - Additional Information ....................................................................47
6.1 Specications - HVAC Drive H300 HMI Bypass .............................................47
6.1.1 Approvals ...........................................................................................47
6.1.2 Design ................................................................................................47
6.1.3 Operating Conditions .........................................................................47
6.1.4 Options ..............................................................................................48
6.2 Maintenance & Inspection ...........................................................................48
6.3 VFD Parameter Access .................................................................................49
6.4 VFD Replacement ........................................................................................49
6.5 HVAC Drive H300 HMI Bypass Parameter Defaults .......................................50
HMI Bypass Controller Installation and Commissioning Guide 3
Safety and Precautions
WARNING
1. Read this manual in its entirety before installing or operating the HMI
bypass package. This manual applies to HMI bypass packages with the
Nidec Control Techniques HVAC Drive H300 variable frequency drive.
2. Do not connect or disconnect wiring, or perform signal checks while the
power supply is turned ON.
3. The internal capacitor of the installed drive may be charged even after the
power supply has been turned OFF. To prevent electrical shock, disconnect
all power before servicing the HMI bypass. Wait at least 10 minutes
after the power supply has been disconnected and all LEDs have been
extinguished.
4. Do not perform a voltage withstand test on the HMI bypass or the
installed drive. This electronic equipment uses semiconductors and is
vulnerable to high voltage. Severe damage to the equipment may occur.
5. The HMI bypass is suitable for use on a circuit capable of delivering not
more than 100,000 RMS symmetrical Amperes, 240 volts maximum (230
Volt class units), 480 Volts maximum (460 Volt Class units), 600 Volts
maximum (575 Volt Class units).
6. Static sensitive printed circuit boards are installed in the HMI bypass
package. Damage may occur due to Electrostatic Discharge (ESD). DO NOT
handle any components without following proper ESD precautions.
Failure to observe these and other precautions highlighted in this manual
will expose the user to high voltages, resulting in equipment damage, serious
injury or death.
The information contained within this document is proprietary to Nidec
Control Techniques and may not be copied, reproduced or transmitted
to other parties without the expressed written consent of Nidec Control
Techniques.
No patent liability is assumed with respect to the use of information
contained herein. Moreover, because Nidec Control Techniques is constantly
improving its high quality products, the information contained in the manual
is subject to change without notice. Every precaution has been taken in
the preparation of the manual. Nevertheless, the manufacturer assumes no
responsibility for errors or omissions. Neither is liability assumed for damages
resulting from the use of the information contained in this publication.
4 HMI Bypass Controller Installation and Commissioning Guide
Section 1 - Introduction
Thank you for purchasing your Nidec Control Techniques HMI bypass
package. This manual provides information concerning the installation,
wiring and general startup procedures for the HVAC Drive H300 line of HMI
bypass packages. The HMI bypass is a complete integrated HVAC control
system which employs the latest Variable Frequency Drive (VFD) technology
and incorporates a dedicated micro-processor based controller for HVAC
applications. The HMI bypass package uses a dedicated LCD touchscreen
Human Machine Interface (HMI) that clearly shows the system operating
status. The HMI bypass is designed for ease of installation and startup.
Please follow this instruction manual’s guidelines for proper installation and
programming of your HMI bypass package.
HVAC Drive H300
LCD touchscreen HMI bypass
Lower enclosure
Disconnect handle
(padlockable)
HMI Bypass Controller Installation and Commissioning Guide 5
Section 2 - Installation Instructions
2.1 Receiving
After unpacking the HMI bypass package:
3 Verify that the part numbers on the package match the numbers on your
purchase order, packing slip or tagging information.
3 Check the unit for physical damage which may have occurred during
shipping. If any part of the package is missing or damaged, notify the
carrier and your Nidec Control Techniques representative immediately.
3 Verify that all internal hardware (i.e. components, screws, etc.) is properly
seated and fastened securely.
2.2 Nameplate Information
The HMI bypass package has two nameplates for identification. The main
label is located on the inside of the enclosure. This nameplate provides
information on the entire package. The second nameplate is located on
the VFD. This nameplate contains information related to the VFD only. The
nameplate information should be recorded and kept in a safe location. This
information is required for any service or repair.
2.2.1 Labels
2.2.1.1 HMI Bypass Package Label
6 HMI Bypass Controller Installation and Commissioning Guide
2.2.1.2 Typical Standard VFD Rating Label
* This label is only applicable to VFD size 7 and above.
Refer to the following page Section 2.3 Part Number Identification for further
information relating to the labels.
HMI Bypass Controller Installation and Commissioning Guide 7
2.3 Part Number Identification
Order Code Configurator
HVAC/R Packaged Drives
Packaged HVAC/R Drives from 1 to 600 hp
BASE ORDER CODE POWER & DOOR OPERATOR OPTIONS CONTROL OPTIONS
[Order Code
digit number]
P X XXXX N X X X - X 0 X X X X X 0 - X X X X 0 X X X X X
1 2 3 - 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
[1] Package Types
G = Pre-Engineered, New Generation
P = Pre-Engineered
S = Seismic*
C = Custom*
*Contact Factory
[2] Voltage Ratings
8 = 208 Vac
2 = 230 Vac
4 = 460 Vac
5 = 575 Vac
[3] - [6] Horsepower Ratings
0001 = 1 HP 0060 = 60 HP
01P5 = 1.5 HP 0075 = 75 HP
0002 = 2 HP 0100 = 100 HP
0003 = 3 HP 0125 = 125 HP
0005 = 5 HP 0150 = 150 HP
0007 = 7.5 HP 0200 = 200 HP
0010 = 10 HP 0250 = 250 HP
0015 = 15 HP 0300 = 300 HP
0020 = 20 HP 0350 = 350 HP
0025 = 25 HP 0400 = 400 HP
0030 = 30 HP 0450 = 450 HP
0040 = 40 HP 0500 = 500 HP
0050 = 50 HP 0600 = 600 HP
[7] Duty Ratings
N = Normal Duty
[8] Enclosure Styles
1 = NEMA 1
2 = NEMA 12
3 = NEMA 3R
4 = NEMA 4X
B = NEMA 1 (Bypass Only)
F = NEMA 1 (Disconnect with Fusing)
[9] Input Power Connections
1 = Circuit Breaker (25 kAIC)
2 = Disconnect Switch with Fusing
3 = Circuit Breaker (65 kAIC)
4 = Circuit Breaker (100 kAIC)
5 = Fused Disconnect (100 kAIC)
Input fuses for drives are included as
standard for all input power options
[10] Products
A = Afnity Active Front End
B = Afnity Drive
2 = Unidrive M200
3 = HVAC Drive H300
X = HVAC Drive H300 AFE
[12] Bypass Options
0 = No Bypass
1 = Electronic 3-Contactor Bypass
2 = Manual Bypass
3 = HMI 2-Contactor Bypass
with VFD Service Swtich
4 = HMI 2-Contactor Bypass
6 = Soft Starter 3-Contactor Bypass
[14] Door-Mounted Keypad/HMI
0 = None
C = LCD Keypad
E = LED Keypad
H = Door-mounted Touchscreen HMI
E = LED Keypad
Unidrive M200 includes LED keypad as standard.
Afnity BA includes LCD keypad as standard.
[15] Input Filtering
0 = None
1 = Input Reactor 3%
2 = Input Reactor 5%
3 = RFI Filter
4 = Input Reactor 3% + RFI Filter
5 = Input Reactor 5% + RFI Filter
6 = Matrix AP Filter
Enclosure size considerations. Addition of one or
multiple ltering options may change the size
and/or style of the enclosure.
Matrix lter - consult factory.
[16] Output Filtering
0 = None
1 = Output Reactor 3%
2 = dV/dt Filter
3 = Sine Filter
4 = Output Reactor 1.5%
[17] Multiple Motors
0 = None Drive Protected
2 = Two Manual Motor Protectors (MMP)
3 = Three Manual Motor Protectors
4 = Four Manual Motor Protectors
5 = Five Manual Motor Protectors
6 = Six Manual Motor Protectors
Cumulative amp ratings of motors must not
exceed the drive rating. Each motor must have its
own overload protection. Multiple Manual Motor
Protectors are of equal size.
[18] Space Heater**
0 = None
2 = 200 W
4 = 400 W
Larger heaters can be chosen for extremely cold
ambient temperatures.
[21] - [23] Option Modules
0 = None
A = SM-APPS-LITE-V2
C = SM-BIPOLAR
D = SM-CANOPEN
E = SM-DEVICENET
H = SM-ETHERCAT
I = SM-ETHERNET
K = SM-I/O-120V
L = SM-I/O-24V
M = SM-I/O-32
N = SM-I/O-LITE
P = SM-I/O-PLUS
Q = SM-I/O-TIMER
R = SM-INTERBUS
S = SM-LON
T = SM-PROFIBUS-DP
V = SM-REGISTER
W = SI-I/O*
Y = AI-485-ADAPTOR*
Z = KI-485-ADAPTOR*
1 = SI-PROFIBUS*
2 = SI-ETHERNET*
3 = SI-DEVICENET*
4 = SI-CANOPEN*
5 = SI-PROFINET-V2*
6 = SI-ETHERCAT*
Unidrive M200 has 1 option
module slot only, Afnity has 2
option module slots, HVAC Drive
H300 has 3 option slots
[24] Phase Loss Monitor
0 = None
1 = Yes
[26] Temperature Controller***
0 = None
1 = Thermocouple
2 = RTD
*SI options used with Unidrive M200 & HVAC Drive H300
**Available with NEMA 3R enclosure only
***Selection of options 26-29 require a cooling tower NEMA 3R enclosure.
NOTE:
For options not included in the Order Code Congurator, please consult
factory for a custom quote.
[27] Basin Heater**
0 = None
1 = 1 kW
2 = 2 kW
3 = 3 kW
4 = 4 kW
5 = 5 kW
6 = 6 kW
7 = 7 kW
8 = 8 kW
9 = 9 kW
A = 10 kW
B = 11 kW
C = 12 kW
D = 13 kW
E = 14 kW
F = 15 kW
G = 16 kW
H = 17 kW
I = 18 kW
J = 19 kW
K = 20 kW
[28] Spray Pump***
0 = None
1 = 1 HP
2 = 2 HP
3 = 3 HP
5 = 5 HP
7 = 7 HP
A = 10 HP
B = 15 HP
[29] De-icer / Sun Shield***
0 = None
1 = De-icer
2 = Sun Shield
3 = De-icer & Sun Shield
[30] Siemens FLN
0 = None
1 = Yes
8 HMI Bypass Controller Installation and Commissioning Guide
2.4 Mounting & Clearances
TOP SIDE-TO-SIDE
Install the HMI bypass package on a vertical surface and allow the following
minimum clearances for normal heat dissipation.
12 in
6 in 12 in 6 in
WARNING
WARNING
Potentially hazardous voltage
can exist within this device. Only fully trained, qualied personnel should
service this equipment.
Pressing the stop button will not remove power from this equipment.
Never service this equipment without rst being sure all power is safely
removed. Hazardous voltage levels may exist for up to 5 minutes after
power is disconnected!
WARNING
WARNING
Potentially hazardous voltage
can exist within this device. Only fully trained, qualied personnel should
service this equipment.
Pressing the stop button will not remove power from this equipment.
Never service this equipment without rst being sure all power is safely
removed. Hazardous voltage levels may exist for up to 5 minutes after
power is disconnected!
Air Flow
Notes:
• Ambient operating temperature; 32 °F to 104 °F (0 °C to 40 °C)
• Install the unit in a dry environment free from oil mist and dust
• Install the unit in a location free from radioactive materials, combustible
materials, harmful gases or liquids
• Do not install the unit in a location susceptible to excessive vibrations
• Do not install in direct sunlight
• During installation, protect the unit from foreign particles such as metal
shavings produced by drilling
• Failure to follow these notes could void the warranty
HMI Bypass Controller Installation and Commissioning Guide 9
2.5 Wiring and Precautions
2.5.1 General
1. DO NOT connect or disconnect wiring or perform signal checks while the
power supply is turned ON.
2. Connect the power supply wiring to the HMI bypass input terminals L1, L2
and L3 on the main circuit disconnect device.
3. Connect the motor wiring to the bypass output terminals T1, T2 and T3 at
the Class 20 Motor O/L or the output reactor if installed.
4. Never touch the output circuit directly or place the output line in contact
with the package enclosure.
5. DO NOT connect power factor correction capacitors on the output circuit.
6. Power supply wiring and motor wiring must be in separate conduits with
separate ground conductors. (DO NOT use conduits as ground).
7. Control wiring must be in conduit separate from both power supply and
motor wiring.
8. Tighten the screws on the main circuit disconnect (if provided) and control
circuit terminals.
9. Observe national and local codes when wiring electrical devices.
Failure to observe these precautions may result in equipment damage or
improper operation and may not be covered under warranty.
2.5.2 Input Wiring
The HMI bypass package may be supplied with several different input device
options. These input options include protective devices as well as non–
protective devices. It is the responsibility of the installing parties to ensure
that requirements for branch circuit protection of the appropriate size and
location are observed. All incoming power is connected to terminals L1, L2,
and L3. The following input options are available.
» Fused disconnect
» Circuit breaker
» Input line reactor
» Input RFI filter
10 HMI Bypass Controller Installation and Commissioning Guide
Connect the main power supply, motor and control wiring using the following
control wiring
Recommended
y
recommended conduit locations. The input phase sequence does not affect
the output phase sequence of the VFD. It will affect bypass sequence and
motor rotation direction.
conduit entrances
WARNING
WARNING
Potentially hazardous voltage
can exist within this device. Only fully trained, qualied personnel should
service this equipment.
Pressing the stop button will not remove power from this equipment.
Never service this equipment without rst being sure all power is safely
removed. Hazardous voltage levels may exist for up to 5 minutes after
power is disconnected!
incoming suppl
motor connection
2.5.3 Output Wiring
The HMI bypass package is always supplied with a Class 20 motor O/L on its
output. However, the unit may be supplied with several different output
options. The following output options are available.
• Single motor O/L (Terminals T1, T2, and T3)
• Dual motor O/L (Terminals (Motor 1 – T1, T2, and T3)
(Motor 2 – T4, T5, and T6))
• Output reactor
Note: All contactors and relays supplied in the HMI bypass package are
suppressed with R/C snubbers. If adding additional inductive loads (i.e.
magnetic contactors, magnetic relays, magnetic valves, solenoids, magnetic
brakes, etc.) in or near the HMI bypass package, use an appropriate surge
suppressor across the coils to limit the transients on the supply lines.
HMI Bypass Controller Installation and Commissioning Guide 11
2.5.4 Control Circuit Wiring
2.5.4.1 Analog Input
A 4 to 20 mA analog input signal is available by connecting to the customer
terminals 5 (+) and 4 (-).
Terminal No. Description
4 0V Common Analog
5 Speed/Frequency Reference
2.5.4.2 Digital Inputs
The HMI bypass combines digital inputs from the HVAC H300 VFD and SI-I/O
option module. As per the following table, the HMI bypass control provides
ten (10) digital inputs.
There are ten (10) digital inputs. (24 Vdc).
Terminal No. Description
1 (3 positions) 0V Common
22 Fireman’s Override
23 Damper Feedback
24 Fire Alarm
25 Customer Reset
27 Auto Run
29 Enable
203 Safety
204 Relay Output Select (223)
207 Remote Bypass Select
208 Remote VFD Select
Terminal 204 is used as an input signal to control terminal 223 relay output
when terminal 223 is set to “T204 24V Input”. All digital inputs are dry
contacts (voltage free).
2.5.4.3 Relay Outputs
There are two (2) form A relay outputs.
Terminal No. Description
221 System Fault
222 0V Common for dry contacts 221 & 223
223 System On or 204 24V Input
When Relay Output Select is set up for “204 24V Input” terminal 223 will be
controlled by the input on terminal 204.
12 HMI Bypass Controller Installation and Commissioning Guide
There is one (1) form C relay output.
Terminal No. Description
71 0V Damper Control Contact Common
74 Damper Control Contact (NO)
2.5.4.4 Digital Output
There is one (1) digital output. (24 Vdc).
Terminal No. Description
202 Auto Mode Selected
2.5.4.5 Additional HVAC H300 VFD Connections
Additional analog inputs and outputs are available by making connections
directly to the HVAC H300 VFD. The following connections are located on the
VFD and not the customer connection terminal block.
VFD Terminal No. Description
4 0V Common Analog Input
6 Analog PID Feedback
VFD Terminal No. Description
7 Speed/Frequency Output
8 Analog Torque Output
9 0V Common Analog Output
For further information see HVAC Drive H300 User Guide.
2.5.4.6 Additional SI-I/O Connections
Additional Analog I/O and Digital I/O can be made by making connections
directly to the SI-I/O module mounted in slot 3 of the HVAC Drive H300. The
following connections are not found on the customer connection terminal
block.
SI-I/O Terminal No. Description
205 Digital Input/Output 4
206 0V Common SI-I/O
209 Analog Input 3/Digital Input 7
210 0V Common SI-I/O
211 Analog Output 1/Digital Input 8
HMI Bypass Controller Installation and Commissioning Guide 13
2.5.5 Grounding
(a) Acceptable (b) Acceptable (c) Not Acceptable
Never ground the HMI bypass package in common with welding machines,
motors or other high current electrical equipment. Run all ground wires in a
separate conduit.
When using several electronic bypass packages side by side, ground as shown
below.
√ √
x
2.5.6 Customer Connection Terminals
All control circuit connections are made through the Customer Connection
terminal block. There are connections between the Customer Terminal block,
the HVAC Drive H300, and the SI-I/O module. These connections are made at
the factory and are for reference only. DO NOT change this wiring as it will
cause the HMI bypass to operate improperly or not at all.
See following page for Customer Connection Terminal diagram.
2.5.6.1 Emergency Bypass Operation
In situations requiring Emergency Bypass operation (i.e. drive removal or +24
Vdc supply failure) bypass contactor can be engaged to run the motor across
the line by moving Jumper (41-100) to (44-EB). Note the thermal overload
protection is protecting the motor.
14 HMI Bypass Controller Installation and Commissioning Guide
2.5.7 Customer Connection Diagram
NOTE: For Emergency Bypass
Operation (i.e. drive removal
or +24 Vdc supply failure) bypass
contactor can be engaged to run
the motor across the line by
moving Jumper (41-100) to (44EB). Note the thermal overload
protection is protecting the motor.
HMI Bypass Controller Installation and Commissioning Guide 15
2.5.8 HVAC Drive H300 HMI Bypass Schematic
16 HMI Bypass Controller Installation and Commissioning Guide
HMI Bypass Controller Installation and Commissioning Guide 17
2.6 Inspection
Once all wiring is complete, verify that:
1. All wiring is installed.
2. Excess screws, metal filings and wire clippings are removed from inside the
unit(s).
3. Screws and fasteners are securely tightened.
4. Exposed wiring has no contact with other wiring or terminals.
Section 3 – Overview of the HMI bypass
All start/stop, safety, fire alarm inputs and VFD analog output are routed to the
inputs of the VFD and IO module via customer terminal connections.
The analog input is factory set to accept a 4–20 mA speed reference signal.
All control wiring must be run in a separate conduit from ANY high voltage or
power wiring. The wiring should also be properly grounded and shielded when
necessary to ensure proper operation.
3.1 HMI Bypass Touchscreen Functions
3.1.1 Splash Screen
Upon initial power-up or any power cycle the LCD touchscreen HMI will
reset to the splash screen. If the HMI Bypass has been setup, operation will
continue in the same state as it was before shutdown/power loss.
4.1.1 Splash Screen
CONTINUE: Navigate to the main control screen.
SETUP WIZARD: Begins the bypass configuration process. Users must enter the
security pin number before changing system settings. See section 4.1 for HMI
bypass commissioning using the setup wizard.
18 HMI Bypass Controller Installation and Commissioning Guide
3.1.2 Main Control Screen
From the main screen, users can control the state of the bypass system and
navigate to system configuration (settings) and status menus.
HAND: Pressing this icon will put the bypass system in Hand Mode. In VFD and
Hand Mode, the system will run at a manually selected frequency and the
bypass contactor will automatically close if BYP (Bypass Mode) is selected and
the VFD output is off.
AUTO: Pressing this icon puts the bypass system in Auto Mode. In Auto Mode,
the system will require the “Auto Run Input” on terminal 27 to be active in
order to run the motor. If VFD Mode is also selected, the system will follow
the analog speed reference on terminal 5 (4-20 mA). If BYP is selected, the
system will run at line frequency, but still requires the “Auto Run Input”
(terminal 27).
STOP: This button will stop the motor and also acts as a reset.
Note: If a Remote Bypass, Remote VFD, or Fireman’s Override command is
present on the digital inputs, the STOP icon will not stop the motor.
VFD: Puts the system in VFD Mode. The output contactor is closed and the
motor is powered by the VFD.
BYP: Puts the system in Bypass Mode. The bypass contactor will close and the
motor will rotate at line frequency.
Note: If you are in Hand|Auto “VFD” Mode and want to switch To Bypass
“BYP” Mode, serlect Bypass Mode “BYP” and then reselect HAND or AUTO.
HMI Bypass Controller Installation and Commissioning Guide 19
3.1.3 Drive Status and System Diagnostics
3.1.3.1 General Status
The drive status screen displays basic VFD information.
Motor RPM: Displays the estimated speed of the motor.
Current Magnitude: The instantaneous drive output current scaled so that it
represents the r.m.s. phase current in Amps under steady-state conditions.
Output Power: Displays the current power output of the VFD.
Output Frequency: Displays the frequency applied to the motor.
Drive Thermal Accumulator: Displays the percentage of the thermal trip level
of the drive.
Motor Thermal Accumulator: Displays the level of the motor overload
accumulator.
Software Version: Displays the current software version of the LCD
touchscreen HMI program.
More: Navigates to an additional Drive Status page.
Trip Log: Navigates to the system fault log.
View Trends: Displays the Graphical Trend Viewer for Motor RPM, Motor Load
%, and Motor Thermal Overload %.
I/O Status: Shows the current status of all digital inputs, outputs and relays.
20 HMI Bypass Controller Installation and Commissioning Guide
3.1.3.2 Additional Drive Status
This screen displays the estimated total running cost of the HMI bypass system
and filter change reminders.
Power Consumption: Displays the current power consumption of the VFD.
Power Cost per kWhr: Defines the cost of energy per kWh in cents.
Total Power Consumption: Displays the accumulated VFD power consumption.
Total Running Cost: Uses the Total Power Consumption and Power Cost per
kWhr to calculate Total Running Cost.
3.1.3.3 Trip Log
The previous 5 system faults are recorded and displayed. For accurate
timestamps, the time must be manually set in the HMI settings menu.
Clear Log: Pressing this button will clear the recorded fault list.
• Motor Overload/PL: Motor thermal overload relay (resettable) or phase
loss monitor (if fitted) is tripped connecting 24V to terminal 26 or VFD
parameter 18.035 is set to 1 via serial communications.
Recommended actions:
» Check Motor
» Check Insulation, phase to phase, and phase to ground
» Check Bearings
» Check Load/transmission
» Check for Phase loss or phase loss monitor (if fitted)
» Reduce Starts per hour
» Check Motor winding configuration (delta or wye)
HMI Bypass Controller Installation and Commissioning Guide 21
If all above checks are good, attempt to reset the overload relay using the
overload reset button.
• Fire Alarm: A 24V input signal on Fire Alarm input (24) is present.
Recommended action:
» If an external fire alarm is not present, verify customer terminal block
wiring.
• Damper Timeout: A 24V input signal on Damper Feedback (23) is present,
Damper Fault Response is “ENABLED,” and Damper Timeout has expired.
Recommended action:
» Check operation of the customer damper and verify customer terminal
block wiring.
• Safety Input: A 24V input signal on Safety input (203) is present
Recommended action:
» If an external Safety input is not present, verify customer terminal block
wiring.
• Watchdog: External VFD trip due to loss of communication between VFD
and HMI.
Recommended action:
» Verify physical Ethernet connection between VFD and LCD touchscreen
HMI. Verify IP address of LCD touchscreen HMI and VFD are on the
same network.
Notes: If the fault cannot be cleared from the LCD touch screen HMI with a
reset it may be required to access the HVAC Drive H300 VFD directly with a
keypad or through Connect VFD configuration software.
For a full explanation of VFD faults, refer to the HVAC Drive H300 VFD User
Guide.
3.1.3.4 Graphical Trend Viewer
Historical view of Motor RPM, Motor Load (0-100%), and Motor Thermal
Overload (0-100%) going back 8 minutes. Use the left and right arrows to
navigate between the graphs.
22 HMI Bypass Controller Installation and Commissioning Guide
3.1.3.5 I/O Status
Displays the status of inputs, outputs, and relays in the system, terminals 22
through 74.
MORE: Navigates to the second I/O status page. The second I/O status page
displays the SI-I/O expansion module I/O, terminals 202 through 223 and
analog input terminals 5 and 6.
3.2 System Settings
From this screen, users can access the configuration menus for the bypass
system.
Default Settings: After confirmation, all system settings will revert to default
values.
Setup Wizard: Begins the commissioning process starting with motor data.
HMI Bypass Controller Installation and Commissioning Guide 23
3.2.1 Motor Map
The HMI Bypass motor data can be found or entered in the Motor Data
screen. The Motor Data screen also allows access to the autotune feature and
Advanced VFD settings. Motor data can usually be found on the nameplate of
the motor.
Rated Frequency: Set to the rated frequency of the motor (nameplate value).
Current: Set to the rated current of the motor (nameplate value).
Speed: Set to the rated speed of the motor (nameplate value).
Voltage: Set to the rated voltage of the motor (nameplate value).
Motor Poles: Set to the number of poles of the motor. If motor poles are set
to “0”, the number of motor poles will be calculated automatically.
Power Factor: Set to the motor power factor (nameplate value). If the power
factor is not known, it can be automatically calculated by performing a
rotating autotune.
Note: If the power factor is calculated using the autotune function the user
will not be able to manually change the value.
Autotune: Navigates to the autotune feature page. autotune is not necessary
to run the motor, but doing so will result in improved performance and
efficiency.
Advanced: Navigates to the advanced motor settings.
24 HMI Bypass Controller Installation and Commissioning Guide
3.2.2 Autotune
WARNING
The VFD is able to perform either a stationary or a rotating autotune. The
motor must be at a standstill before an autotune is enabled. A rotating
autotune should be used whenever possible, so the measured value of power
factor of the motor is used by the drive.
Autotune: is an algorithm that the VFD uses to detect physical characteristics
of the motor in order to improve control and efficiency.
To perform an autotune, first select either STATIONARY or ROTATING
(recommended) and then hit the AUTOTUNE button. The motor must be at a
standstill before an autotune is enabled.
Note: The drive will not perform an autotune if there is an existing fault or if
the STO input is not closed.
Note: A rotating autotune should only be used if the motor is uncoupled. To
clear incorrect values calculated from a coupled rotating autotune perform a
stationary autotune. Performing a stationary autotune will clear the incorrect
values and reset motor rated power factor to factory default (0.85).
A rotating autotune will cause the motor to accelerate up to 40 Hz in the
direction selected regardless of the reference provided. Once complete the
motor will coast to a stop.
HMI Bypass Controller Installation and Commissioning Guide 25
3.2.3 Advanced VFD Settings
The Advanced VFD Settings menu allows access to advanced settings of the
VFD.
Voltage Boost: Defines the level of voltage boost at 0Hz when using a fixed V
to F relationship.
Current Limit: Limits the current when the motor is being accelerated or
decelerated.
Open-Loop Control Mode: Defines the VFD output mode. The default setting
for Open-Loop Control Mode is “Fixed” or V/Hz.
• Ur S: Resistance compensation, stator resistance measured at each start.
• Ur: Resistance compensation with no stator resistance measurement.
• Fixed: (Default) Fixed boost with a linear characteristic. Also known as V/
Hz Boost mode.
• UR Auto: Resistance compensation, stator resistance measured on the first
start.
• Ur I: Resistance compensation, stator resistance measured at power-up.
Also known as Open-Loop Vector mode.
• Square: Fixed boost with square characteristic. Also known as Quadratic
Motor V/Hz mode.
• Current 1P: Single phase current output.
Note: For further information on Open-Loop control modes refer to the HVAC
H300 User Guide.
Reverse Motor Direction: If Reverse Motor Direction is on, the output phase
sequence is reversed so that the phase sequence in W-V-U for positive
frequencies and U-V-W for negative frequencies.
Dynamic V to F: Dynamic V to F is intended for applications where power
loss should be kept to a minimum under low load conditions, but dynamic
performance is not important. The setting is enabled by default.
26 HMI Bypass Controller Installation and Commissioning Guide
3.2.4 Skip Frequencies
The skip reference functions are available to prevent continuous operation
within a specified speed range (i.e., where mechanical resonance may occur).
The HMI Bypass allows up to three (3) speed/frequencies to be skipped.
Skip Reference: Sets the center point of the speed/frequency reference the
VFD should skip.
Band Width: Defines the range which speed/frequency references are
rejected in either direction. The actual reference band is, therefore, twice that
defined in the Band Width, with Skip Reference as the center of the band.
3.2.5 Motor Ramp/Limits
The Motor Ramps/Limits screen allows configuration of speed/frequency limits
as well as acceleration and deceleration values the VFD will use during motor
start and stop.
Max Switching Freq: Defines the maximum switching frequency used by the drive.
If drive will operate at this frequency unless the inverter becomes too hot. Under
these conditions the drive will reduce switching frequency to avoid tripping.
Minimum Frequency: Defines the minimum value for the reference.
Maximum Frequency: Defines the maximum value for the reference.
Generally set to 60 Hz or less.
Accel Time: Defines the rate of acceleration. This is the time to accelerate
from minimum frequency to maximum frequency.
Decel Time: Defines the rate of deceleration. This is the time to decelerate
from maximum frequency to minimum frequency.
HMI Bypass Controller Installation and Commissioning Guide 27
3.2.6 I/O Settings
The I/O Setting screen allows the setup of the system I/O.
Analog Speed Reference Mode: Defines the input mode for analog input
speed/frequency reference (5). The following list provides a brief explanation
of the available settings. For further information see HVAC H300 User Guide.
• 0-20 mA: 0-20 mA
• 20-0 mA: 20-0 mA
• 4-20 mA Trip: 4-20mA trip on current loss
• 20-4 mA Trip: 20-4mA trip on current loss
• 4-20 mA (default): 4-20mA no action on loss
• 20-4 mA: 20-4mA no action on loss
• 0-10 Vdc: 0-10Vdc no action on loss
Scaling: The analog input will be multiplied by a factor between 0.000 to
10.000.
Relay Output Select (T223): Select between “System On” and “T204 24V
Input” The HMI Bypass default is “System ON.”
System ON: Configures relay terminal 223 to close when the HMI Bypass has
power
T204 24V Input: Configures relay terminal 223 to close dependent on the
signal input to terminal 204.
3.2.7 Auto-Reset Setup
This screen defines the VFD behavior when tripped/faulted.
28 HMI Bypass Controller Installation and Commissioning Guide
Auto-Reset Delay: The time interval between reset attempts. The HMI Bypass
default is 5 seconds.
Hold Drive Healthy: If set to “ON,” the fault alarm relay will not close until all
reset attempts have been exhausted.
Note: If Hold Drive Healthy is set to “ON” and if Number of Auto-Reset
Attempts is set to “6” (infinite) the Drive Healthy status will always remain
“Healthy.”
3.2.8 Remote Control
The Remote Control screen defines whether the HMI Bypass is controlled by
the customer terminal block inputs or serial fieldbus communications.
This screen allows you to select either “Local” or “Remote” (Serial/Ethernet
communications) control for each individual input. If Remote is selected, the
bypass system will be controlled by the corresponding bit in the VFD rather
than the digital input. Parameter’s referenced below can only be accessed
directly from the HVAC Drive H300 with a keypad or with Connect VFD
configuration software. For further information on Remote setup see the
HVAC Drive H300 User Guide.
Remote Local
Input Parameter Terminal
Fireman Override* 18.031 22
Damper Feedback 18.032 23
Fire Alarm 18.033 24
Reset 18.034 25
Forward/Reverse** 18.037 -
Motor Overload 18.035 26
Auto Run 18.036 27
*Remote Fireman’s Override is only available if Fireman’s Override VFD mode
is off. Remote control will then initiate a bypass run.
**Foreword/Reverse is a remote parameter only used to reverse a running
motor using configured ramps.
SERIAL COMMS: Navigates to the serial communication configuration screens.
HMI Bypass Controller Installation and Commissioning Guide 29
3.2.9 Serial Communications
This screen allows for the configuration of settings needed for serial
communication.
BAN (Building Automation Network) Protocol: Selects the network protocol.
0 = Modbus RTU
1 = BACnet
2 = Metasys N2 Open
MS/TP Max Master Mac Address: (BACnet use only) this is the highest address
that the bypass system will use when looking for the next master on the
network with which token passing can be achieved. Range 0-127
Communications Timeout Period: The period in seconds that the system will
wait to see a valid communications frame on the network.
NOTE: See HVAC Drive H300 User Guide for further serial communications
setup details.
3.2.10 Modbus RTU Configuration
This screen allows for the configuration of settings needed for serial
communication.
Serial Address: Defines the node address for the serial communications
interface range from 1 to 247.
Note: It is necessary to perform a reset by hitting the “RESET” button on the
previous page for this setting to take effect.
Baud Rate: Defines the baud rate used by the serial communications interface.
30 HMI Bypass Controller Installation and Commissioning Guide
3.2.10.1 Serial Data Format
Defines how the serial data packets are formatted. Stop bits, parity, and
standard/modified address schemes.
3.2.11 Alarm Response
The Alarm Response screen allows for the configuration of the Automatic
Bypass and Damper Fault Response features.
Automatic Bypass: When enabled, the system will automatically go
into Bypass Mode after a fault is detected and after “Auto-Bypass Time”
has elapsed.
Auto-Bypass Time: This is the delay between the VFD fault detection
and closing the bypass contactor.
Damper Fault Response: When enabled, a damper feedback signal will
be required to run the motor. If no signal is detected after the “Damper
Timeout” window has elapsed, a Damper Timeout fault will be triggered.
Damper Timeout: The window of time during which the bypass system will
wait for a damper feedback signal. If this time has elapsed and no damper
feedback is detected, a damper timeout fault is triggered.
Damper Motor On Delay: The time delay between when a motor run signal
is received (VFD or Bypass) and when the motor starts. This time is typically
adjusted to allow for damper operation.
HMI Bypass Controller Installation and Commissioning Guide 31
3.2.12 Alarm Response - Fireman’s Override
This Alarm Response screen allows for the configuration of the Fireman’s
Override feature.
Fireman’s Override: When enabled, a fireman override command will ignore
“Motor Overload” and “Damper Timeout” faults. The system will still wait for
a damper feedback, but if no feedback is detected and a timeout is triggered,
the system will bypass anyway. The system will run to destruction as long as
the override command and safety input (terminal 203) are present.
Note: When disabled, “Motor Overload” and “Damper Timeout” will stop the
motor.
Firemans’s Override (VFD mode): If ON, a Fireman’s Override command will
initiate VFD operatin rater than turning the bypass contactor on.
VFD Override Setpoint: Determines the frequency reference used by the VFD
when in override mode.
Fireman’s Override PID Control: Allows PID control loop to regulate frequency
reference in override mode (ignores VFD Setpoint frequency).
Note: Fireman’s Override (VFD mode) must be ON for Fireman’s Override PID
Control to function (requires analog input to terminal 6 of VFD).
3.2.13 Advanced I/O Settings
The Advanced, I/O Settings screen, allows the setup of the I/O settings needed
for the onboard PID feature
Analog PID Feedback Mode: Defines the input mode for analog input 2 (PID
feedback input) VFD terminal 6.
Sensor Range: Defines the operating range of the feedback sensor. This
information can be found in the documentation provided with your sensor.
32 HMI Bypass Controller Installation and Commissioning Guide
3.2.14 PID Setup
The PID setup screen allows for the configuration of the onboard PID feature.
Control Action: Direct control means that as the PID error increases, the speed
reference also increases. A common application for direct control is a cooling/
heating fan. Reverse control will decrease the speed reference as the PID
error increases. A common application for reverse PID control is a pump with
pressure feedback.
Display Units: Determines the display units for PID setpoint and feedback.
Does not affect PID operation. An example would be “F” or “psi.”Gains:
Determines the gains for the internal PID controller.
3.2.14.1 PID Setup - Sleep/Wake Function
This screen allows the setup of the Sleep/Wake Threshold feature.
The Sleep/Wake function is used to stop the motor if the frequency or
speed reference falls below a specified level so that the system does not run
inefficiently at low speeds.
If the reference is greater than the Sleep/Wake Threshold for longer than
the Wake Delay, then the motor is enabled. If the reference falls below the
(Sleep/Wake Threshold - Sleep Offset) for longer than the Sleep Delay, then
the motor is disabled.
Sleep/Wake Threshold: This is the threshold that the speed reference is
compared against. A value of zero will disable the Sleep/Wake function.
HMI Bypass Controller Installation and Commissioning Guide 33
Wake Delay: Defines the elapsed time before the system restarts the motor if
the wake function is active.
Sleep Delay: Defines the elapsed time before the system stops the motor if
the sleep function is active.
Max Sleep Offset time: Defines the maximum amount of time that the Sleep
Offset function can be active.
3.2.15 Miscellaneous
The miscellaneous screen is used to setup the security pin feature and read/
write HVAC H300 VFD parameters.
Security Pin Protection: Determines whether the security pin is enabled or
disabled. If it is disabled, users will no longer be prompted to enter security
pin when entering system settings. By default, the HMI Bypass will ship with
Security Pin Protection Enabled with a Security Pin of “1111”.
Set Security Pin: Set the security pin to any 4-digit number.
Smartcard Parameter Cloning: With a Control Techniques’ Smartcard in the
VFD Smartcard slot, users can read and write parameter files to the Smartcard
to easily duplicate or backup settings.
3.3 Touchscreen HMI Settings
Select the HMI SETTINGS button to navigate to the Internal HMI menu screen
where you can set/update Date/Time from the default (Central Standard Time
“CT”). HMI Backlight and Ethernet settings can also be accessed from this
screen.
34 HMI Bypass Controller Installation and Commissioning Guide
Note: It is recommended that the HMI SETTINGS menu be accessed for Date/
Time setting and Backlight setting only. Changing any other HMI settings
may prevent the HMI Bypass from operating satisfactorily.
In order to navigate to the HMI Settings menu, click YES.
3.3.1 Setting the Date and Time
LCD Touchscreen HMI XP-Runtime Menu
Press the “Settings” icon to navigate to the HMI Settings menu.
Select DateTime Setting.
HMI Bypass Controller Installation and Commissioning Guide 35
A window will appear with date and time. Set values to current date and
time. Press “OK” when complete.
To return to the HMI Bypass menus press the “Start” icon from the
XP-Runtime menu.
To navigate back to the HMI Bypass menus press the “Start” icon from the
XP-Runtime menu
3.4 Touchscreen LCD HMI Software Update Procedure
To update the LCD touchscreen HMI program from a portable USB drive:
1. Start with a USB drive that has the correctly formatted file and file
directory.
• Drive:\XP_Project\[name]
• The program should be saved as a compiled .xpdz file using the
XP-Builder software.
2. Ensure that USB flash drive has been fitted into the USB host port on the
back of the eXP20 HMI.
3. To access the XP-Runtime menu, hit the “HMI Settings” button in the
system menu and press yes to confirm.
4. Select “Storage Function”
5. Select “Project Download”
36 HMI Bypass Controller Installation and Commissioning Guide
6. Choose the correct file name from the list and hit “OK”
7. Wait while the HMI extracts and installs the new project file.
Section 4 – Startup
This section provides guidance on how to setup an HVAC Drive H300 HMI
Bypass. It is recommended that before the initial HMI Bypass setup process
begins that the HVAC H300 HMI Bypass Installation and Commissioning Guide
is read in its entirety and the steps in Section 2.1 through 2.6 are completed.
It is recommended that initial setup of the HMI Bypass is completed using the
Setup Wizard. The Setup Wizard can be accessed from the Splash Screen upon
system power up or from the System Settings menu.
The Setup Wizard will step you through the basic HMI Bypass setup screens.
HMI Bypass Controller Installation and Commissioning Guide 37
4.1 Setup Wizard Process
The Setup Wizard will step you through the Motor Data, Motor Ramps/Limits,
I/O Settings, Auto-Reset Setup, Remote Control, Alarm Response – Automatic
Bypass, and Alarm Response – Fireman’s Override setup screens. If the PID
Controller is to be used, upon selection, it will step you through the Advanced
I/O Settings, PID Setup, and PID Setup – Sleep/Wake screens.
4.2 Setup Wizard - Step-by-Step Instructions
The following steps provide a basic step-by-step guides for initial setup of the
HMI Bypass.
Step 1 – Start Setup Wizard: Press the Setup Wizard Icon on the Splash Screen
or System Settings screen.
38 HMI Bypass Controller Installation and Commissioning Guide
Step 2 – Motor Data: Enter motor nameplate information in the following
settings.
• Rated Frequency: Motor nameplate value
• Current: Motor nameplate value
• Speed: Motor nameplate value
• Voltage: Motor nameplate value
• Power Factor: Motor nameplate value
Once complete press the “NEXT” icon.
Step 3 – Motor Ramps/Limits: Enter the necessary settings for the application.
Once complete press the “NEXT” icon.
Step 4 – I/O Settings: Verify the Analog Speed Reference mode matches the
HMI Bypass system analog speed/frequency reference type.
Once complete press the “NEXT” icon.
HMI Bypass Controller Installation and Commissioning Guide 39
Step 5 - Auto-Reset Setup:
If Auto-Reset feature is desired, set the number auto-reset attempts and the
delay between attempts when the VFD trips. Setting Hold Drive Healthy to
“ON” will hold the VFD drive health status to “Healthy” until the Auto-Reset
attempts are complete.
Once complete press the “NEXT” icon.
Step 6 – Remote Control:
Select whether the HMI Bypass function is to be controlled by Remote serial
communications or Local customer terminals. By default the HMI Bypass will be
set for Local control via the customer terminals.
Once complete press the “NEXT” icon.
Step 7 – Alarm Response – Automatic Bypass:
If the application requires the HMI Bypass to automatically transfer to Bypass
mode upon VFD trip set Automatic Bypass to “ENABLE”. The HMI Bypass will
transfer to Bypass Mode after the Auto-Bypass time has elapsed.
40 HMI Bypass Controller Installation and Commissioning Guide
If the application requires the HMI Bypass to disable in the case of loss of
Damper Feedback input (terminal 23) and enable the Damper Timeout trip,
then the Damper Fault Response should be set to “ENABLED.” If enabled,
set Damper Timeout for the time between loss of Damper Feedback input
(terminal 23) and when the HMI Bypass initiates a Damper Timeout trip.
Once complete press the “MORE” icon.
Step 8 - Alarm Response - Fireman’s Override:
Set Fireman’s Override (VFD mode) to “ON” if you require the VFD to run at
a fixed frequency when the Fireman’s Override is ENABLED. The fixed speed
setting is adjusted in the SETPOINT window. Setting to “OFF” will result in the
system running in Bypass Mode when the Fireman’s Override is ENABLED
Note: To adjust the setpoint Fireman’s Override (VFD mode) must be “ON.”
Once set, return Fireman’s Override (VFD mode) to “OFF” for normal HMI
Bypass operation.
Set Fireman’s Override PID Control to “ON” if you require the VFD to run
from PID control frequency reference.
Note: This feature requires the PID controller to be setup and ignores VFD
Setpoint frequency.
Once complete press the “NEXT” icon.
Step 9 - PID Controller: The Setup Wizard will prompt the question, “Are you
using the onboard PID controller?”
HMI Bypass Controller Installation and Commissioning Guide 41
If “NO” then setup the HMI Bypass basic setup is complete and the Setup
WARNING
Wizard will return to the System Settings screen.
If “YES” the Setup Wizard will continue to the optional PID setup screen.
Optional Step - Onboard PID Controller: If the Onboard PID Controller will be
used, the Setup Wizard will continue to the Advanced I/O Settings, PID Setup,
and PID Setup – Sleep/Wake screens. For further information regarding the
setup of these screens refer to section 4.2.14.
4.3 Checking Motor Rotation
Before attempting a trial operation of the HMI bypass package, ensure that
the enclosure door is securely closed. Also, ensure all personnel are clear of
the connected load as this operation will energize and rotate the motor.
After applying 3 phase power to the HMI bypass package, ensure that
the HMI is illuminated. If any alarms are present, refer to the trip log and
troubleshooting sections.
There is no standard for the rotational direction of an induction motor based
on the motor lead markings. This, plus the uncertainty of the phase rotation
of the utility power being applied to the HMI bypass package terminals,
requires that the motor rotation direction be checked and be correct in both
VFD and Bypass Modes. Failure to confirm rotation may cause severe damage
to the HMI bypass package, motor or the driven equipment.
4.3.1 Check #1: Rotation on VFD power
Place the VFD package in Hand (local) Mode control by pressing the VFD
and HAND icons on the HMI bypass touchscreen. The VFD icon will turn
blue indicating that the bypass is in VFD Mode and the HAND icon will be
highlighted indicating that the bypass is in local control. Use the up arrow on
the touchscreen HMI to increase the speed reference of the VFD or the down
arrow on to decrease the speed reference of the VFD.
Note the direction of rotation as the motor shaft begins to rotate as
compared to the required rotation direction.
To stop the VFD/Motor, press the STOP icon on the HMI touchscreen.
4.3.2 Check #2: Rotation on Bypass power
NOTE: This operation will start the motor across the line. Place the HMI
bypass in the Bypass Mode by pressing the BYP icon on the HMI bypass LCD
touchscreen. The BYP icon will be highlighted green indicating the HMI
bypass is in Bypass Mode.
42 HMI Bypass Controller Installation and Commissioning Guide
Press the HAND icon on the HMI bypass touchscreen. The HAND icon will
be highlighted indicating the HMI bypass is in local control. This will start
the motor across the line. Check motor rotation.
To stop the motor press STOP on the HMI touchscreen.
Note the direction of rotation as the motor shaft begins to rotate as
compared to the required rotation direction.
Motor Rotation Correction
VFD Correct Correct Incorrect Incorrect
Bypass Correct Incorrect Correct Incorrect
Action No Action Change any
two power
leads at input
disconnect
Change any two leads
at input disconnect, and
change any two leads at
the output of the motor
overload
Change any
two leads
at output of
motor overload
4.4 Normal Operation
There are two (2) buttons used to select the modes of operation available:
1. VFD (VFD Mode) – Energizes the VFD output contactor
2. BYP (Bypass Mode) – Allows bypass operation
Stop (reset) Button
The STOP button section will stop motor operation in either the VFD or
Bypass modes. This button will also reset any faults indicated by the system.
4.4.1 Current System Status
The One-line diagram on the main screen will indicate if the motor is being
run by the VFD or across the line (bypass) by highlighting the active control
in green. The VFD or the BYP icon will highlighted green and the One-line
diagram will indicate the motor status.
HMI Bypass Controller Installation and Commissioning Guide 43
4.4.2 Starting Operation
There are two (2) basic steps required to begin operation.
Step 1 – Select the operation mode by pressing the VFD or BYP (bypass) icon.
You must select one of these modes. For VFD operation, press the VFD icon.
For bypass operation press the BYP (bypass) icon. Upon selection the selected
icon will be highlighted in green.
Step 2 – Select the start mode by pressing either the HAND or AUTO icon.
Upon selection the selected icon will be highlighted. Selecting HAND allows
an immediate start in VFD or Bypass Mode; whichever was selected in step 1.
RUN will not occur until the customer-supplied run contact closes between
terminals 27 and 1 (AUTO RUN INPUT and 24 Vdc). The RUN status indication
will illuminate when the contact closes.
4.4.3 Ending Operation
Press STOP/(reset) icon once – Cancels the start mode of operation.
44 HMI Bypass Controller Installation and Commissioning Guide
Section 5 - Troubleshooting
The HMI will annunciate VFD and system alarms and trips when supply and
control power is applied.
The chart below is intended to assist with troubleshooting a system when the
HMI is not illuminated or no fault is indicated.
Symptom Indications Corrective Actions
Power disconnect is
ON, the HMI display
does not illuminate
when the screen is
tapped
Motor does not
rotate when VFD
mode is selected and
HAND is pressed or
AUTO is pressed and
the Auto-Run input
is ON
HMI is OFF - Check power lights on 24 Vdc power supply
- If power lights on, check 24 Vdc connections
to HMI
- If no power lights, check the 24 Vdc power
supply and control transformer fusing and
connections
HMI Bypass
status
displays
"VFD FAULT
DETECTED"
VFD and
BYP are
not visible
and/or HMI
displayed
"Timeout"
VFD and BYP
are green
and status
displays
"RUN"
- Check Trip log in HMI (see Section 3.1.3.3 for
instructions)
- If no fault is indicated on the HMI connect to
the drive using a plug in keypad or Connect
software and record the trip code. Refer to
the drive manual for further assistance or
download the diagnostic APP from www.
controltechniques.us
- Check that the optional VFD service switch
is ON
- Check the VFD input fusing
- Check Ethernet cable connection between
HMI and VFD SI-ETHERNET module
- Check HMI IP address is 192.168.0.2 (see
Section 3.3 for instructions)
- Check VFD SI-ETHERNET module connection
status lights (see Section 6.4 for instructions)
- Check mechanical motor to load couplings
are intact
- Ensure that motor connections are made
and no VFD to motor disconnects are open
- If VFD contactor is not closed check control
transformer and contactor coil
- Check I/O status screen Terminal 29 STO
status is “ON”
- If Terminal 29 STO status is “OFF,” check OC
[1-C11] auxiliary contactor and connections
HMI Bypass Controller Installation and Commissioning Guide 45
Symptom Indications Corrective Actions
Motor does not
rotate when Bypass
mode is selected and
HAND is pressed or
AUTO is pressed and
the Auto-Run input
is ON
Fuses blow on
power up
Input circuit breaker
trips on power up
Input circuit breaker
trips when a Bypass
run is initiated
- Check mechanical motor to load couplings
are intact
- Ensure that motor connections are made
and no bypass to motor disconnects are open
- Check that the mechanical load is not
binding
- If Bypass contactor is not closed check
control transformer and contactor coil
- Check VFD input wiring
- Replace VFD (see Section 6.4 for instructions)
- Check control transformer
- If fuses are blown see “Fuses blow” on
power up
- Check motor cables
- Check motor direction
- Check motor
46 HMI Bypass Controller Installation and Commissioning Guide
Section 6 - Additional Information
6.1 Specifications - HVAC Drive H300 HMI Bypass
The HMI bypass package features a user-friendly application-specific full-color
live-graphics LCD touch screen HMI (Human Machine Interface) to simplify
operation and provide status indication.
6.1.1 Approvals
• VFD Section – UL508C
» UL Plenum rated
• Bypass Section – UL508A
6.1.2 Design
• 2 contactor bypass with optional VFD service switch
• NEMA 1, NEMA 12, NEMA 3R, and NEMA 4X enclosure options
• LCD Color touch screen HMI
• 32-bit microprocessor
• MODBUS RTU, BACnet, and Metasys N2 communications
• EtherNet/IP and Modbus TCP/IP
• HAND/OFF/AUTO selection icons
• VFD/BYPASS selection icons
• Auto transfer to bypass on VFD fault (selectable)
• Damper Mode (programmable)
• Damper actuator control (5 A @ 125 Vac relay contact)
• Fire Alarm – programmable to:
» Fireman’s Override
» Fireman’s Override VFD Control
• PID controller
• Class 20 motor overload relay
• One (1) analog output:
» 0-10 Vdc, scalable
• Two (2) analog inputs – programmable for:
» 4-20 mA, scalable (default auto speed input)
» 0-10 Vdc, scalable (default onboard PID controller input)
• Speed search function
• 3 skip frequencies
• Digital manual speed control
• Bypass setup wizard
6.1.3 Operating Conditions
• Altitude: to 3,300 ft, higher with derating
HMI Bypass Controller Installation and Commissioning Guide 47
• Ambient operating temp: +32 to +104 °F (0 to +40 ˚C)
WARNING
• Storage temp: -40 to +140 ˚F (-40 to +60 ˚C)
• 95% relative humidity, non-condensing
• Input voltage: +10%, -10%; 208, 230, 460 and 575 Vac
• Protected from exposure to direct sunlight
6.1.4 Options
• Input fused disconnect
• Input circuit breaker
• Input or output reactors
• Multiple motor overloads
• Input RFI filter
6.2 Maintenance & Inspection
This section describes the basic periodic maintenance and inspection
procedures for the electronic bypass.
CAUTION! To prevent electrical shock and damage, disconnect all power
before servicing the electronic bypass package. Then wait at least ten (10)
minutes after the power supply is disconnected and all LEDs are extinguished.
The bypass system will function longer if kept clean, cool and dry, and if all
precautions highlighted in this manual are observed. Periodically inspect
the electronic bypass package as described in the table below to prevent
accidents and to ensure high performance with high reliability.
Component Check Corrective Action
External terminals,
connectors, mounting
screws, etc.
Heat sink Build-up of
Printed Circuit Board
(PCB)
Cooling fan For abnormal
Power components Accumulation
Loose screws
or connectors
dust and dirt
Accumulation
of conductive
dust or oil
noise and
vibration
of dust and
dirt
Secure / tighten
Blow with dry compressed air
(4 to 6kg-cm2 pressure)
Blow with dry compressed air (4 to 6kgcm2 pressure). If dust cannot be removed,
replace the board.
Replace the cooling fan
Blow with dry compressed air
(4 to 6kg-cm2 pressure)
48 HMI Bypass Controller Installation and Commissioning Guide
6.3 VFD Parameter Access
WARNING
The HVAC Drive H300 VFD parameters settings required
for operation in a bypass system are set at the factory.
Adjustments can be made to VFD parameters via the HMI
for all standard applications. If there is a need to access
advanced parameters not accessible via the HMI there are
2 methods available:
1. Remove the HVAC Drive H300 keypad cover and plug in
a keypad, order code HOA-KEYPAD-RTC. For a complete list of parameters go
to www.controltechniques.com
2. Connect a PC to the SI-ETHERNET module
in the drive and use “Connect” software to
access parameters. This software is available
as a no charge download from www.
controltechniques.com
In order to successfully connect to the drive
via the SI-ETHERNET module the PC
Ethernet IP address needs to be set to
192.168.0.xxx where xxx is not = 010 and
the subnet mask needs to be 255.255.255.0.
CAUTION: Changes made to VFD parameters may result in unintended motor
operation and damage to equipment.
6.4 VFD Replacement
If the VFD has to be replaced, it is
recommended that the SI-ETHERNET module
in the existing drive is re-used and fitted to
the replacement drive. If a new SI-ETHERNET
MODULE is needed, order code HMI-BYP-SI-
ETHERNET is pre-configured at the factory
for HVAC Drive H300 HMI Bypass settings. If
a new SI-ETHERNET module is fitted it is necessary to set the IP address of
the module to 192.168.0.010 and the subnet mask to 255.255.255.0. A VFD
keypad or Connect software is required to set the address.
HMI Bypass Controller Installation and Commissioning Guide 49
To configure a drive to HVAC Drive H300 HMI Bypass factory defaults
(examples: replacement VFD or existing VFD that is reset to HVAC Drive H300
defaults), from the System Settings screen select the Default Settings icon.
Select “YES” to restore the HVAC Drive H300 HMI Bypass to system defaults.
Select “NO” to return to the SYSTEM SETTINGS Screen.
Warning: Selecting “YES” will reset the HVAC Drive HMI Bypass to factory
default settings and the Setup Wizard must be completed again.
6.5 HVAC Drive H300 HMI Bypass Parameter Defaults
The following table represents the parameter differences of an HVAC Drive
H300 HMI Bypass and a standalone HVAC Drive H300 parameter defaults.
These do not include user settable HMI Bypass settings.
VFD
Paremeter
01.014 Reference Selector A2 Preset A1 A2
01.021 Preset Reference 1 15.0 Hz 0.0 Hz
01.023 Preset Reference 3 20.0 Hz 0.0 Hz
01.052 Hand/Off/Auto Operating Mode 0 1
01.053 Fire Mode Reference 40.0 Hz 0.0 Hz
02.004 Ramp Mode Std boost Standard
02.008 Standard Ramp Voltage Drive rating Drive rating
02.011 Acceleration Rate 1 20.0 s 10.0 s
02.021 Deceleration Rate 1 20.0 s 10.0 s
04.015 Motor Thermal Time Constant 1 120.0 s 89.0 s
04.016 Thermal Protection Mode 0x0 0x1
04.037 Motor Thermal Time Constant 2 50.0 s 89.0 s
05.007 Rated Current Drive rating Drive rating
05.008 Rated Speed Drive rating Drive rating
Parameter
Description
HMI
Bypass Value
HVAC Drive
H300 Default
50 HMI Bypass Controller Installation and Commissioning Guide
VFD
Paremeter
05.009 Rated Voltage Drive rating Drive rating
05.018 Maximum Switching Frequency 3 kHz 3 kHz
05.027 Enable Slip Compensation Off On
06.015 Drive Enable Off On
06.019 Date/Time Selector Acc Powered Local Keypad
06.043 Control Word Enable On Off
06.048 Supply Loss Detection Level Drive rating Drive rating
06.065 Standard Under Voltage Threshold Drive rating Drive rating
06.066 Low Under Voltage Threshold Drive rating Drive rating
07.010 Analog Input 1 Destination 1.037 1.036
07.014 Analog Input 2 Destination 18.018 1.037
07.022 Analog Output 2 Source 10.001 4.002
07.040 Analog Input 1 Minimum 0.05 % 0.00 %
07.041 Analog Input 2 Minimum 0.05 % 0.00 %
08.021 Digital I/O 01 Source/Destination 1.054 10.002
08.022 Digital I/O 02 Source/Destination 0.000 10.033
08.023 Digital I/O 03 Source/Destination 0.000 6.030
08.024 Digital Input 04 Destination 10.033 1.054
08.025 Digital Input 05 Destination 0.000 1.041
08.027 Relay Output Source 0.000 10.001
08.031 Digital I/O 01 Output Select Off On
08.071 Digital I/O Output Enable Register 1 0xFF7F 0x0000
09.004 Logic Function 1 Source 1 19.031 0.000
09.005 Logic Function 1 Source 1 Invert On Off
09.006 Logic Function 1 Source 2 9.002 0.000
09.007 Logic Function 1 Source 2 Invert On Off
09.008 Logic Function 1 Output Invert On Off
09.009 Logic Function 1 Delay 8.0 s 0.0 s
09.010 Logic Function 1 Destination 10.032 0.000
09.014 Logic Function 2 Source 1 19.031 0.000
09.015 Logic Function 2 Source 1 Invert On Off
09.016 Logic Function 2 Source 2 19.041 0.000
09.017 Logic Function 2 Source 2 Invert On Off
10.030 Braking Resistor Rated Power 0.000 kW 0.050 kW
10.031 Braking Resistor Thermal Time Constant 0.000 s 3.300 s
10.034 Number of Auto reset Attempts None 5
10.035 Auto reset Delay 10.0 s 5.0 s
10.061 Braking Resistor Resistance 22.00 5.0 s
Parameter
Description
HMI
Bypass Value
HVAC Drive
H300 Default
HMI Bypass Controller Installation and Commissioning Guide 51
VFD
Paremeter
10.034 Number Of Auto-reset Attempts None 5
10.035 Auto-reset Delay 10.0 s 5.0 s
10.061 Braking Resistor Resistance 00.00 Ω 75.00 Ω
11.024 Serial Mode 7 1 NP 8 2 NP
11.044 User Security Status All Menus
12.010 Variable Selector 1 Mode Subtract Input 1
12.028 Variable Selector 2 Source 1 18.021 0.000
12.031 Variable Selector 2 Destination 1.053 0.000
14.003 PID1 Reference Source 18.017 0.000
14.004 PID1 Feedback Source 18.018 0.000
14.014 PID1 Output Lower Limit 0.01 % -100.00 %
18.013 Application Menu 1 Read-write Integer 13 2 0
18.017 Application Menu 1 Read-write Integer 17 750 0
18.019 Application Menu 1 Read-write Integer 19 1111 0
18.020 Application Menu 1 Read-write Integer 20 32727 0
18.021 Application Menu 1 Read-write Integer 21 24545 0
18.031 Application Menu 1 Read-write bit 31 On Off
20.001 Application Menu 3 Read-write Integer 1 20839 0
29.010 User Selectable Parameter 1 18.029 0.000
29.011 User Selectable Parameter 2 18.030 0.000
29.012 User Selectable Parameter 3 1.021 0.000
2.02.005 DHCP Enable Off On
2.02.006 IP Address 192.168.0.10 192.168.1.100
2.02.007 Subnet Mask 255.255.0.0 255.255.255.0
2.02.008 Default Gateway 0.0.0.0 192.168.1.254
3.01.011 T2 Digital I/O 1 Mode Digital Output Digital Input
3.01.015 T7 Digital Input 5, Analog Input 1 Mode Digital Input Volt In
3.01.016 T8 Digital Input 6, Analog Input 2 Mode Digital Input Volt In
3.01.017 T9 Digital Input 7, Analog Input 3 Mode Digital Input Volt In
3.01.019 Collective Digital I/O Mode CDIO Mappings CDIO Disabled
3.02.031 Collective Digital Input Destination 0.18.013 0.00.000
3.02.032 Collective Digital Output Source 0.18.022 0.00.000
Parameter
Description
HMI
Bypass Value
HVAC Drive
H300 Default
The HMI IP address can be accessed through the HMI Settings icon and should
not be changed from the default IP address (192.168.0.2) or the HMI Bypass
will not function.
52 HMI Bypass Controller Installation and Commissioning Guide
Notes:
HMI Bypass Controller Installation and Commissioning Guide 53
Notes:
54 HMI Bypass Controller Installation and Commissioning Guide
Notes:
HMI Bypass Controller Installation and Commissioning Guide 55
www.hvacr-drives.com
©2019 Control Techniques a division of Nidec Motor Corporation. The information contained in this manual is for guidance only and does not form
part of any contract. The accuracy cannot be guaranteed as Nidec Control Techniques have an ongoing process of development and reserve the right
to change the specification of their products without notice.
Control Techniques. Registered Office: 7078 Shady Oak Road Eden Prairie, MN 55344-3505 USA.
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