Danfoss Vertical Bypass Operating guide

MAKING MODERN LIVING POSSIBLE

Instruction Manual

Vertical Bypass/Non Bypass Panel

Safety	Vertical Bypass/Non Bypass Panel

Safety

WARNING

EQUIPMENT HAZARD!

The vertical bypass/non bypass panel contains dangerous voltages when connected to mains voltage. It is strongly recommended that all electrical work conform to the National Electrical Code (NEC) and all national and local regulations. Installation, start-up and maintenance should be performed only by qualified personnel. Failure to follow the NEC or local regulations could result in death or serious injury.

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

WARNING

UNINTENDED START!

When the vertical bypass/non bypass panel is connected to AC input power, the motor may start at any time. The drive, panel, motor, and any driven equipment must be in operational readiness. Failure to be in operational readiness when panel and drive are connected to AC input power could result in death, serious injury, or equipment or property damage.

Warning against unintended start

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

WARNING

GROUNDING HAZARD!

For operator safety, it is important to ground drive, vertical bypass panel, and motor properly. Follow the grounding guidelines of local and national codes. Failure to follow grounding guidelines could result in death or serious injury.

Grounding

Correct protective grounding of the equipment must be established in accordance with national and local codes. Ground currents are higher than 3mA.

Safety Guidelines

1.Disconnect the drive and vertical bypass/non bypass panel from mains before commencing service work

2.DO NOT touch electrical parts of the vertical bypass/non bypass panel or drive when mains is connected. After mains has been disconnected, wait 15 minutes before touching any electrical components or read the label on vertical bypass/non bypass panel.

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

4.While programming parameters, the motor may start without warning. Activate the [Off] key on the LCP when changing parameters.

5.The [Off] key on the LCP does not isolate the drive from mains voltage and is not to be used as a safety switch.

MG.13.A1.22 - VLT® is a registered Danfoss trademark

Safety	Vertical Bypass/Non Bypass Panel

MG.13.A1.22 - VLT® is a registered Danfoss trademark

Contents	Vertical Bypass/Non Bypass Panel

Contents

1 Introduction	2-1
1.1.1 Purpose of the Manual	2-1
1.1.2 Overview	2-1
1.1.3 Typical Bypass Operation	2-1
1.2 Bypass Circuits	2-1
1.2.1 Three-contactor Bypass	2-1
1.3 Bypass Options	2-2
1.3.1 Common Run/Stop with Bypass	2-2
1.3.2 Automatic Bypass	2-2
1.3.3 Run Permissive in Bypass	2-2
1.3.4 Basic Fire Mode in Bypass	2-2
1.3.5 Advanced Fire Mode in Bypass	2-2
1.3.6 Overload Protection	2-2
1.4 Bypass Platform Configurations	2-3
1.5 Switch Mode Power Supply	2-3
1.5.1 Control Transformer	2-3
1.6 Disconnects	2-3
1.6.1 Main Disconnect	2-3
1.6.2 Mode Selector Switch	2-4
1.6.3 Panel Configurations	2-5
1.6.4 Panel Voltage and Frame Ratings	2-6
1.7 Power Component Functions	2-6
1.7.1 Power Fusing	2-6
2 Pre-installation	3-1
2.1.1 Receiving Inspection	3-1
2.1.2 Pre-installation Check	3-1
2.1.3 Installation Site Check	3-1
2.2 Harsh Environments	3-2
2.2.1 Airborne Liquids	3-2
2.2.2 Airborne Solids	3-2
2.2.3 Corrosive Chemicals	3-2
3 Installation	4-1
3.1.1 Tools Required	4-1
3.1.2 Drive Fuses	4-1
3.1.3 Internal Main Panel Fuses	4-5
3.2 Mechanical Installation	4-5

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Contents	Vertical Bypass/Non Bypass Panel

3.2.1 Lifting	4-5
3.2.2 Hoist or Overhead Lift	4-5
3.2.3 Forklift	4-5
3.2.4 Shipping Weights	4-5
3.3 Cooling	4-6
3.4 Electrical Installation	4-7
3.4.1 Component Identification & Customer Connection	4-8
3.4.2 Wire and Cable Access	4-16
3.4.3 Wire Size	4-19
3.4.4 Wire Type Rating	4-21
3.4.5 Terminal Tightening Torques	4-21
3.4.6 Input Line Connection	4-25
3.4.7 Motor Wiring	4-25
3.4.8 Grounding (Earthing)	4-26
3.4.9 Control Wiring	4-26
3.4.10 Serial Communication Bus Connection	4-26
3.4.11 Drive Control Terminals	4-27

4 Start Up	5-1
4.1.1 Inspection Prior to Start Up	5-2
4.1.2 Start Up Procedure	5-2
5 Electromechanical Bypass (EMB2) Operation	6-1
5.1.1 Typical Control Connections for Common HVAC Applications	6-1
5.1.2 EMB2 Auto Bypass	6-3
5.1.3 EMB2 Common Run/Stop	6-3
5.1.4 EMB2 Run Permissive	6-4
5.1.5 EMB2 Overload	6-4
5.1.6 EMB2 Safety Interlock	6-5
5.1.7 EMB2 Fire Mode	6-5
5.1.8 EMB2 Fault Reporting	6-5
5.1.9 EMB2 Switches	6-6
6 Electronically Controlled Bypass (ECB) Operation	7-1
6.1 Electronically Controlled Bypass (ECB) Operation	7-1
6.1.1 Overview	7-1
6.1.2 ECB Control Card	7-2
6.1.3 ECB Drive or Bypass Selection	7-5
6.1.4 ECB Programming	7-7

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Contents	Vertical Bypass/Non Bypass Panel

6.1.5 ECB Hand/OFF/Auto	7-8
6.1.6 ECB Mode of Operation	7-8
6.1.7 Bypass Status Word Bit Examples	7-10
6.1.8 ECB Auto Bypass	7-10
6.1.9 ECB Run Permissive	7-11
6.1.10 ECB Overload	7-11
6.1.11 ECB Safety Interlock	7-12
6.1.12 ECB Common Run/Stop	7-12
6.1.13 ECB Advanced Fire Mode	7-13
6.1.14 ECB Fault Reporting	7-13

7 Start Up Troubleshooting	8-1
7.1.1 Option Panel Alarm and Warnings	8-1
8 Appendix	9-1
8.1.1 Dimensions	9-1
8.1.2 Mechanical Diagrams	9-2
8.1.3 Typical Wiring Diagrams	9-6

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Contents	Vertical Bypass/Non Bypass Panel

Contents | Figure

Figure 1.1: Basic Non Bypass Circuit	1-2
Figure 1.2: Basic Bypass Circuit	1-3
Figure 2.1: Sample Panel Label	2-1
Figure 3.1: Proper Lifting Method	3-5
Figure 3.2: Side Cooling Clearance	3-6
Figure 3.3: Cooling Airflow	3-6
Figure 3.4: Power Connections	3-7
Figure 3.5: P2 Bypass Mechanical Layout Diagram	3-8
Figure 3.6: P2 Non Bypass Mechanical Layout Diagram.	3-9
Figure 3.7: P3 Bypass Mechanical Layout Diagram.	3-10
Figure 3.8: P3 Non Bypass Mechanical Layout Diagram.	3-11
Figure 3.9: P4 Bypass Mechanical Layout Diagram.	3-12
Figure 3.10: P4 Non Bypass Mechanical Layout Diagram.	3-13
Figure 3.11: P5 Bypass Mechanical Layout Diagram.	3-14
Figure 3.12: P5 Non Bypass Mechanical Layout Diagram.	3-15
Figure 3.13: Bypass Panel Conduit Entry Diagram	3-16
Figure 3.14: Non Bypass Panel Conduit Entry Diagram	3-16
Figure 3.15: P2 Panel	3-17
Figure 3.16: P3 Panel	3-17
Figure 3.17: P4 Panel	3-18
Figure 3.18: P5 Panel	3-19
Figure 3.19: Control Terminals Location	3-26
Figure 3.20: Removable Drive Connectors and Terminals	3-27
Figure 5.1: Customer Side EMB2 Control Card Terminal Connections	5-2
Figure 5.2: Sample Overload Device	5-5
Figure 6.1: Local Control Panel (LCP)	6-1
Figure 6.2: ECB Control Card Terminal Connections	6-3
Figure 6.3: Bypass Trip Time Delay	6-10
Figure 6.4: Drive Display with Bypass Start Time Delay Active	6-11
Figure 6.5: Sample Overload Device	6-12
Figure 8.1: P2 Bypass	8-2
Figure 8.2: P2 Non-bypass	8-3
Figure 8.3: P3 P4 P5 Bypass	8-4
Figure 8.4: P3 P4 P5 Non-bypass	8-5
Figure 8.5: EMB2 with Control Relay, Part 1	8-6
Figure 8.6: EMB2 with Control Relay, Part 2	8-7
Figure 8.7: EMB2, Part 1	8-8

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Contents	Vertical Bypass/Non Bypass Panel

Figure 8.8: EMB2, Part 2	8-9
Figure 8.9: ECB, Part 1	8-10
Figure 8.10: ECB, Part 2	8-11
Figure 8.11: ECB with Control Relays, Part 1	8-12
Figure 8.12: ECB with Control Relays, Part 2	8-13
Figure 8.13: Non-bypass	8-14

MG.13.A1.22 - VLT® is a registered Danfoss trademark

Contents	Vertical Bypass/Non Bypass Panel

Contents | Table

Table 1.1: Contactor Operation	1-2
Table 1.2: Bypass Configurations	1-3
Table 1.3: Tier Definitions and Features	1-5
Table 1.4: Panel Voltage and Frame Ratings	1-6
Table 3.1: Tools Required	3-1
Table 3.2: Drive Fuses 208 V	3-1
Table 3.3: Drive Fuses 230 V	3-2
Table 3.4: Drive Fuses 460 V	3-3
Table 3.5: Drive Fuses 600 V	3-4
Table 3.6: Sample Fuse Rating Label	3-5
Table 3.7: Approximate Shipping Weights	3-5
Table 3.8: Reference Designator Definitions	3-8
Table 3.9: Wire Size Chart, 208 and 230 V	3-20
Table 3.10: Wire Size Chart 460 and 600 V	3-21
Table 3.11: Tightening Torques, 208 and 230 V	3-22
Table 3.12: Tightening Torques, 460 V	3-23
Table 3.13: Tightening Torques, 600 V	3-24
Table 3.14: Sample Tightening Torque and Wire Rating Label	3-25
Table 3.15: Drive Control Terminals Functions	3-27
Table 4.1: Inspection prior to Startup	4-2
Table 5.1: EMB2 Default Parameter Settings for Common HVAC Applications	5-1
Table 5.2: Common Functions for Controlling Motor using Bypass and Typical Terminal Connections.	5-1
Table 6.1: Parameter Group 5-** Factory Default Settings	6-2
Table 6.2: ECB Card Terminals	6-4
Table 6.3: LCP Control Keys Programming	6-8
Table 6.4: Bypass Parameter Functions	6-9
Table 6.5: Parameter 31-10 Bypass Status Word Bit Definitions	6-9
Table 7.1: Panel Alarms and Warnings (ECB only)	7-1
Table 7.2: Panel Status Display (ECB only)	7-1
Table 7.3: Fault Table	7-2

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Introduction	Vertical Bypass/Non Bypass Panel

1 Introduction

1.1.1 Purpose of the Manual

This manual is intended to provide detailed information for the installation and operation of the vertical panel used in conjunction with a Danfoss variable frequency drive (VFD). To enable efficient handling of the equipment, requirements are provided for installation of mechanical, electrical, control wiring, proper grounding, and environmental considerations. Pre-start and start up procedures are detailed. Also included is a detailed overview of the panel bypass function. In addition, identification of other optional components and their operation and start up troubleshooting instructions are included. For the electronically controlled bypass, additional programming and operation information is provided.

1.1.2 Overview

A variable frequency drive regulates the speed and operation of an electric motor. The drive is programmable and offers many features and savings compared to operating a motor from unregulated line voltage. The panel is a protective enclosure in which the drive and various optional components are assembled and mounted. The vertical non bypass panel is always configured with a disconnect switch and fuses to protect the drive. The vertical bypass panel allows switching between running the motor from the drive (variable speed) or across the line input power (constant speed).

The vertical bypass panel comes with one of two control options:

•The electromechanical bypass (EMB2)

•Electronically controlled bypass (ECB)

The EMB2 is operated by a selector switch on the front of the panel. The EMB2 controls a motor by switching between drive control, operation in bypass, or off. In addition, a test selection is available, which disengages the motor from the drive but keeps the drive operational while the motor runs in bypass. The switching function activates contactors to provide power to the motor through the drive or bypass circuitry, as required.

The ECB also uses contactors to provide power to the motor through the drive or bypass circuitry. However, the ECB contains a local processor that interacts with the drive’s control logic for programmable options, remote

1 1

inputs, and status reporting. The VFD’s logic circuitry is backed up by an independent panel-mounted power supply so that, even if the drive loses power, control and communication functions are maintained. Programming and display are provided by the LCP. An important feature of the ECB is the ability to accept commands from a building automation system (BAS) and to report operational status in return.

See more detailed descriptions of the EMB2 in 5 Electromechanical Bypass (EMB2) Operation and ECB in 6 Electronically Controlled Bypass (ECB) Operation of this manual.

1.1.3 Typical Bypass Operation

With contactors M1 and M2 closed and contactor M3 open, the motor is running in drive control. Opening contactor M2 removes power to the motor but allows the drive to remain under power. This is referred to as test mode. With contactors M1 and M2 open and contactor M3 closed, the motor is running in bypass from the line input power.

1.2 Bypass Circuits

1.2.1 Three-contactor Bypass

The bypass circuit consists of a bypass contactor (M3) interlocked with a drive output contactor (M2), a drive input contactor (M1), and an overload relay. For the EMB2, a door mounted Drive/OFF/Bypass/Test Selector switch is used to electrically select whether the motor is powered by the drive, connected to the full speed bypass, or disconnected from both. The test position applies power to the motor through the bypass (M3 closed) contactor but removes power from the drive (M2 open) while keeping the drive powered (M1 closed). A Pilot light indicates when in bypass. For the ECB, control selection is made through the drive keypad by pressing the DRIVE BYPASS key and selecting from the available options shown. Display data indicates when in bypass. The circuitry may be supplied with either an input disconnect switch or an input circuit breaker.

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1-1

Introduction	Vertical Bypass/Non Bypass Panel

1		1		Contactor	Drive Mode	OFF	Bypass	Test Mode
							Mode
				M1	Closed	Open	Open	Closed
				M2	Closed	Open	Open	Open
				M3	Open	Open	Closed	Closed

Table 1.1 Contactor Operation

			DRIVE						CUSTOMER SUPPLIED
			DISCONNECT						AC MOTOR.
		L1	1L1	Fuse	2L1	L1/91	VFD	U/96	T1
	INPUT	L2	1L2		2L2		TYPE 1 ENCLOSURE	V/97
				Fuse		L2/92			T2
	POWER	L3	1L3		2L3			W/98	T3
				Fuse		L3/93
			DS1
								EARTH
								GROUND

Figure 1.1 Basic Non Bypass Circuit

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1.3 Bypass Options

1.3.1 Common Run/Stop with Bypass

Allows a remote signal to initiate operation in either drive control or bypass depending upon the position of the bypass selector switch.

1.3.2 Automatic Bypass

This feature automatically transfers the motor from drive to bypass without operator intervention when a fault condition trips the drive, after a programmable time-out period. The VFD’s internal fault circuitry controls this action. The time delay permits all automatically resettable faults to clear prior to transfer to bypass. Run permissive or safety circuit signals override the auto bypass function and may prevent or delay bypass operation.

1.3.3 Run Permissive in Bypass

With run permissive active, the drive sends a run request and waits for a remote response before commanding the motor to start. The response indicates the system is safe to operate.

1.3.4 Basic Fire Mode in Bypass

This option switches the panel to bypass whenever a remote fire mode signal is given to the VFD through the input terminals. In either drive or bypass, fire mode is intended to ignore common safety and overload inputs for emergency situations. The motor will continue to run in bypass until fire mode is removed or the drive, panel, or motor fails. External safety signals and motor overload are ignored when in fire mode.

1.3.5 Advanced Fire Mode in Bypass

The advanced fire mode allows for a variety of programmable responses to an external fire mode command signal. Bypass options are programmed through the drive’s fire mode parameters. See 6.1.13 ECB Advanced Fire Mode.

1.3.6 Overload Protection

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

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Introduction	Vertical Bypass/Non Bypass Panel

1.4 Bypass Platform Configurations

The two bypass platform configurations are ECB and EMB2. The features available as options with each platform are listed in Table 1.2. The ECB, also listed below, has all option features available. See 5 Electromechanical Bypass (EMB2) Operation for additional details on the EMB2 and

6 Electronically Controlled Bypass (ECB) Operation for the ECB.

	Control Features	EMB2	ECB		1		1
	Safety Interlock	X	X
	Common Start / Stop	X	X
	Automatic Bypass	X	X
	Run Permissive	X	X
	Basic Fire Mode	X	X
	Advanced Fire Mode		X
	Serial Communication		X

Table 1.2 Bypass Configurations

MAIN DISCONNECT							EARTH
							GROUND
	L1		1L1	M1
INPUT		Fuse		2L1	Fuse	3L1	L1/91
	L2		1L2	2L2		3L2
POWER	L3	Fuse	1L3	2L3	Fuse	3L3	L2/92
		Fuse			Fuse		L3/93
		DS1

VFD

Type 1 Enclosure

				CUSTOMER
		M2	OL1	SUPPLIED
				AC MOTOR
	U/96	2T1	1T1
		2T2	1T2	T1
	V/97
		2T3	1T3	T2
	W/98			T3
	EARTH	M3
	GROUND

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	MK903	MK902		MK904	CONTROL
					TRANSFORMER
	24 V DC SMPS
	MK901
	1	2	3	4
	5 -	6	7	+ 8

Figure 1.2 Basic Bypass Circuit

1.5 Switch Mode Power Supply

The VFD’s logic circuitry is backed up by an independent panel-mounted switch mode power supply so if the drive loses power, control and communication functions are maintained. The SMPS converts three-phase AC input power to 24 V DC control power. Since the SMPS draws power from all three phases, it offers immunity protection from most phase-loss and brown-out conditions. The SMPS is internally protected from short circuit on its output and three board-mounted fuses provide additional protection. The SMPS is not designed for external use and may take up to 5 sec. to initialize at power-up. The SMPS will maintain a 24 V DC output with a low input line voltage. The 200 Volt SMPS will maintain the 24 V DC output with a line voltage as low as 150 V AC and the 600 V SMPS to 335 V AC. Refer to Figure 1.2.

1.5.1 Control Transformer

A control transformer is included on larger horsepower units where the contactor coils are AC. The control transformer steps down the line input voltage to 120V AC. The coils of AC contactors are isolated from the Switch Mode Power Supply via relays.

1.6 Disconnects

1.6.1 Main Disconnect

The main disconnect removes line input power to the drive and bypass. A main disconnect is available in four options.

•Fused disconnect. Two-position (ON/OFF) rotary switch, padlock compatible, with three fuses, one on each phase, built into the switch. For safety, the switch must be in the OFF position before

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1-3

Introduction	Vertical Bypass/Non Bypass Panel

1 1

•

•

•

the option panel door can be opened. (Bypass panel only.)

Disconnect without fuses. For user-supplied fuses option. (Bypass panel only.)

Main circuit breaker. A thermal/ magnetic current interrupt device using an ON/TRIP/OFF/RESET switch. When in the ON position, a trip fault removes power from the drive/bypass circuit and the switch moves to the TRIP setting. The switch must be moved to the RESET position momentarily after the fault has been cleared to reset the circuit breaker. (Bypass panel only.)

Main Disconnect with drive fuses. Non-bypass panel two-position (ON/OFF) rotary switch that disconnects the main AC line power to the drive only.

1.6.2 Mode Selector Switch

The mode selector switch is used for 3-contactor bypass on EMB2 units. The selector switch allows the operator to select from four modes of operation.

Drive mode: When drive mode is selected, the M1 and M2 contactors are closed allowing power to flow in and out of the drive to the motor.

Off mode: This mode opens all contactors removing any power to the motor.

Bypass mode:When bypass mode is selected, the M3 contactor closes and allows the motor to run directly from the input line power.

Test mode:Test mode closes the M1 and M3 contactors and allows the motor to be powered by the input line power. This also allows the drive to power up without being connected to the motor. Refer to Figure 1.2.

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Introduction Vertical Bypass/Non Bypass Panel

	1.6.3 Panel Configurations			1	1
	The VLT FC Drive Series comes in two panel enclosure types. One is the non bypass and the other is the bypass. See
	Table 1.3 for descriptions and available options.
	Non bypass		Bypass
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Drive plus both of the following:		Drive with bypass:
1.	Fuses	1. Fuses
2.	Disconnect	2.	Disconnect/Circuit Breaker
		3.	Contactors
		4.	Power Supply
		5.	Control Module

Table 1.3 Tier Definitions and Features

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1-5

Introduction Vertical Bypass/Non Bypass Panel

1		1		1.6.4 Panel Voltage and Frame Ratings
				Table 1.4Table 1.5 defines the voltage and hp ratings of the frames sizes for the panel. See 8 Appendix for overall and
				mounting dimensions.
				Panel P2			Bypass			Non Bypass
				(B3 - Drive)		FC102/202/322		FC102/202/322			FC302
				Volts VAC					HP (KW)
				208	& 230	7.5	(5.5) - 15 (11)	7.5	(5.5) - 15 (11)		7.5 (5.5) - 10 (7.5)
				460	& 600	15 (11) - 25 (18.5)		15 (11) -25 (18.5)			15 (11) - 20 (15)
				Panel P3			Bypass			Non Bypass
				(B4 - Drive)
						FC102/202/322		FC102/202/322			FC302
				Volts VAC					HP (KW)
				208			20(15)	20 (15) - 25 (18.5)			15 (11) - 20 (15)
				230		20 (15) - 25 (18.5)
				460	& 600	30	(22) - 50 (37)	30	(22) - 50 (37)		25 (18.5) - 40 (30)
				Panel P4			Bypass			Non Bypass
				(C3 - Drive)
						FC102/202/322		FC102/202/322			FC302
				Volts VAC					HP (KW)
				208		25 (18.5) - 40 (30)		30	(22) - 40 (30)		25 (18.5) - 30 (22)
				230		30	(22) - 40 (30)
				460	& 600	60	(45) - 75 (55)	60	(45) - 75 (55)		50 (37) - 60 (45)
				Panel P5)			Bypass			Non Bypass
				(C4 - Drive)
						FC102/202/322		FC102/202/322			FC302
				Volts VAC					HP (KW)
				208	& 230	50	(37) - 60 (45)	50	(37) - 60 (45)		40 (30) - 50 (37)
				460	& 600	100	(75) - 125 (90)	100	(75) - 125 (90)		75 (55) - 100 (75)

Table 1.4 Panel Voltage and Frame Ratings

1.7 Power Component Functions

1.7.1 Power Fusing

For main panel power fuses, only use the specified fuse or an equivalent replacement. For drive fuses only use the specified fuse. See the fuse ratings label on the inside cover of the unit or Table 3.2Table 3.3, Table 3.3Table 3.4, Table 3.4Table 3.5 and Table 3.5Table 3.6.

Main fusing

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

Drive fusing

Drive fuses are located ahead of the drive and are a fastacting type. Drive fuses are standard in all bypass and nonbypass panels.

5,000 or 100,000 amp SCCR

The bypass panel supplied with a non fusible Main Disconnect Switch is 5,000 amps short-circuit current rating (SCCR). The bypass panel supplied with a Fusible disconnect or circuit breaker is 100,000 amp SCCR. The non bypass panel supplied with a non-fusible Main Disconnect is 100,000 amp SCCR. See the panel label for SCCR rating.

NOTE!

The 600 V circuit breaker option is 5,000 amp (SCCR).

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Pre-installation	Vertical Bypass/Non Bypass Panel

2 Pre-installation

2.1.1 Receiving Inspection

Inspect the packaging and equipment closely when received. Any indication of careless handling by the carrier should be noted on the delivery receipt, especially if the equipment will not be immediately uncrated. Obtain the delivery person’s signed agreement to any noted damages for any future insurance claims. Ensure that the model number and power match the order and intended use for the drive.

IMPORTANT!

LOST OR DAMAGED GOODS

INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL

If goods are received short or in damaged condition, insist on a notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the transportation company. If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an inspection and can grant a concealed damage notation. If you give the transportation company a clear receipt for equipment that has been damaged or lost in transit, you do so at your own risk and expense.

Danfoss is willing to assist you to collect claims for loss or damage, but willingness on our part does not make us responsible for collection of claims or replacement of material. The actual filing and processing of the claim is your responsibility.

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Figure 2.1 Sample Panel Label

Ensure that the model number and power match the order and intended use for the drive.

2.1.2 Pre-installation Check	2	2

1.Compare panel model number to what was ordered.

2.Ensure each of the following are rated for the same voltage:

•Drive

•Panel

•Power line

•Motor

3.Ensure that the panel output rating is equal to or greater than motor total full load current for full motor performance.

•Motor power size and panel must match for proper overload protection.

•If panel rating is less than motor; full motor output cannot be achieved.

4.Check motor wiring:

•Any disconnect between drive and motor should be interlocked to drive safety interlock circuit to avoid unwanted drive trips.

•Do not connect power factor correction capacitors between the drive and motor.

•Two speed motors must be wired permanently for full speed.

•	Y-start, -run motors must be wired
	permanently for run.

2.1.3 Installation Site Check

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

•It is important with multiple panels to check wall strength. Make sure that the proper mounting screws or bolts are used.

•Ensure that the wall or floor area for installation will support the weight of the unit.

•If construction work continues after the equipment is mounted, it is important to keep the interior free from concrete dust and similar

MG.13.A1.22 - VLT® is a registered Danfoss trademark

2-1

		Pre-installation	Vertical Bypass/Non Bypass Panel
		dirt. If the unit does not have power applied to it,
		supply a protective covering. It is important to
		ensure that the components stay as clean as
2	2	possible. It may be necessary to clean the interior
		once construction is completed.

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

2.2Harsh Environments

The mechanical and electrical components within the panel can be adversely affected by the environment. The effects of contaminants in the air, either solid, liquid, or gas, are difficult to quantify and control.

2.2.1 Airborne Liquids

Liquids in the air can condense in components. Water carried in the air is easily measured as relative humidity, but other vapors are often more difficult to measure or control. Steam, oil and salt water vapor may cause corrosion of components. In such environments, use TYPE 12 enclosures to limit the exchange of outside air into the option enclosure. Extremely harsh environments may require a higher level of protection.

2.2.2 Airborne Solids

Particles in the air may cause mechanical, electrical or thermal failure in components. A TYPE 1 enclosure provides a reasonable degree of protection against falling particles, but it will not prevent the fan from pulling dirty air into the enclosure.

2.2.3 Corrosive Chemicals

In environments with high temperatures and humidity, corrosive gases such as sulfur, nitrogen and chlorine compounds cause corrosion to occur in components. Indications of corrosion are blackened copper or rust on steel or oxidized aluminum. In such environments, it is recommended that the equipment be mounted in a cabinet with fresh air ventilation and that corrosive compounds be kept away. A non-ventilated cabinet fitted with an air conditioner as a heat exchanger may be used. Conformal coated circuit boards may be specified to reduce the corrosive effects of a harsh environment.

2-2	MG.13.A1.22 - VLT® is a registered Danfoss trademark

Installation	Vertical Bypass/Non Bypass Panel

3 Installation

3.1.1 Tools Required

In addition to the standard tool kit, the tools in Table 3.1 are recommended for installation of the panel.

3.1.2 Drive Fuses

TOOLS
Spreader bar capable of lifting up to 750 lbs.
Max diameter 0.5 in.
		3		3
Forklift, crane, hoist or other lifting device capable of handling
up to 750 lbs. (Qualified device operator available for operating
the equipment.)
Metric Socket Set: 7 - 19mm
Socket Extensions: 4, 6, and 12 inch
Torx driver set: T10 - T40
Torque wrench: 6 - 375 lbs-in
Allen Wrenches:1/8, 3/16, 1/4, & 5/16 inches
Metric or English wrenches: 7 - 19mm
Table 3.1 Tools Required

To maintain UL, the drive fuses should be replaced only with the fuses specified in , , , and . If an alternate drive fuse is desired please consult the factory. See the specifications label inside the cover of the unit for acceptable replacement drive fuses. A sample of this data can be seen in Table 3.6

208 V AC

			Panel	Main Fuse	Drive Fuse	Transformer Fuse	Panel	Drive Fuse
		UL Motor	(FC102/202/322)				(FC302)
	HP (KW)			(FC102/202/322)	(FC102/202/322)	(FC102/202/322)		(FC302) Danfoss
		Current	Non Bypass &				Non
				Danfoss (Bussman)	Danfoss (Bussman)	Danfoss (Bussman)		(Bussman)
			Bypass				Bypass
	7.5 (5.5)	24.2		34035600 (LPJ-40-	176F8953 (JJN-50)			176F8953
				SP)				(JJN-50)
							P2
	10 (7.5)	30.8	P2	34035700 (LPJ-50-	176F8953 (JJN-50)			176F8955
				SP)				(JJN-60)
	15 (11)	46.2		34042800 (LPJ-70-	176F8955 (JJN-60)			176F8957
				SP)				(JJN-80)
							P3
	20 (15)	59.4	P3	34042900 (LPJ-90-	176F8957 (JJN-80)			176F8960
				SP)				(JJN-125)
	25 (18.5)	74.8	P3 - Non Bypass P4	34043100 (LPJ-125-	176F8960 (JJN-125)			176F8960
			- Bypass	SP)			P4	(JJN-125)
	30 (22)	88		34043200 (LPJ-150-	176F8960 (JJN-125)			174N6538
			P4	SP)				(JJN-150)
	40 (30)	114		34043300 (LPJ-175-	174N6538 (JJN-150)			174N6839
				SP)			P5	(JJN-200)
	50 (37)	143		34042300 (LPJ-250-	174N6839 (JJN-200)	34046200 (FNQ-		174N6840
				SP)		R-1.25)		(JJN-250)
			P5	34042300 (LPJ-250-		34046200 (FNQ-
	60 (45)	169			174N6840 (JJN-250)
				SP)		R-1.25)

Table 3.2 Drive Fuses 208 V

MG.13.A1.22 - VLT® is a registered Danfoss trademark

3-1

Installation

Vertical Bypass/Non Bypass Panel

230 V AC

Panel

Main Fuse

Drive Fuse

Transformer Fuse

Panel

Drive Fuse

UL Motor

(FC102/202/322)

(FC302)

HP (KW)

(FC102/202/322)

(FC102/202/322)

(FC102/202/322)

(FC302) Danfoss

Current

Non Bypass &

Non

Danfoss (Bussman)

Danfoss (Bussman)

Danfoss (Bussman)

(Bussman)

Bypass

Bypass

7.5 (5.5)

22

34042600 (LPJ-35-

176F8953 (JJN-50)

176F8953

3

3

SP)

P2

(JJN-50)

10 (7.5)

28

P2

34042700 LPJ-45-

176F8953 (JJN-50)

176F8955

SP

(JJN-60)

15 (11)

42

34042800 (LPJ-70-

176F8955 (JJN-60)

176F8957 JJN-80

SP)

P3

20 (15)

54

34042900 (LPJ-90-

176F8957 (JJN-80)

176F8960

SP)

(JJN-125)

P3

25 (18.5)

68

34043000 (LPJ-100-

176F8960 (JJN-125)

176F8960

SP)

P4

(JJN-125)

30 (22)

80

34043100 (LPJ-125-

176F8960 (JJN-125)

174N6538

P4

SP)

(JJN-150)

40 (30)

104

34043200 (LPJ-150-

174N6538

174N6839

SP)

(JJN-150)

(JJN-200)

P5

50 (37)

130

34043400 (LPJ-200-

174N6839

34046200 (FNQ-

174N6840

SP)

(JJN-200)

R-1.25)

(JJN-250)

P5

60 (45)

154

34042300 (LPJ-250-

174N6840

34046200 (FNQ-

SP)

(JJN-250)

R-1.25)

Table 3.3 Drive Fuses 230 V

3-2	MG.13.A1.22 - VLT® is a registered Danfoss trademark

Installation

Vertical Bypass/Non Bypass Panel

460 V AC

Panel

Transformer

Main Fuse

Drive Fuse

Fuse

Panel

Drive Fuse

UL Motor

(FC102/202/322)

HP (KW)

(FC102/202/322)

(FC102/202/322)

(FC102/202/322

(FC302) Non

(FC302) Danfoss

Current

Non Bypass &

Danfoss (Bussman)

Danfoss (Bussman)

) Danfoss

Bypass

(Bussman)

Bypass

(Bussman)

15 (11)

21

34042600 (LPJ-35-

176F8952 (JJS-40)

P2

176F8952

3

3

SP)

(JJS-40)

20 (15)

27

P2

34035600 (LPJ-40-

176F8952 (JJS-40)

176F8954

SP)

(JJS-50)

25 (18.5)

34

34035700 (LPJ-50-

176F8954 (JJS-50)

176F8956

SP)

(JJS-60)

30 (22)

40

34035800 (LPJ-60-

176F8956 (JJS-60)

P3

176F8958

SP)

(JJS-80)

40 (30)

52

P3

176U5037 (LPJ-80-

176F8958 (JJS-80)

176F8959

SP)

(JJS-100)

50 (37)

65

34043000 (LPJ-100-

176F8959 (JJS-100)

176F8961

SP)

(JJS-125)

P4

60 (45)

77

34043100 (LPJ-125-

176F8961 (JJS-125)

176F9078

SP)

(JJS-150)

P4

75 (55)

96

34043200 (LPJ-150-

176F9078 (JJS-150)

34051200

SP)

(JJS-200)

P5

100 (75)

124

34043400 (LPJ-200-

34051200 (JJS-200)

34046000 (FNQ-

00002051

P5

SP)

R-0.60)

(JJS-250)

125 (90)

156

34042300 (LPJ-250-

00002051 (JJS-250)

34046000 (FNQ-

SP)

R-0.60)

Table 3.4 Drive Fuses 460 V

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3-3

				Installation			Vertical Bypass/Non Bypass Panel
							600 V AC
						Panel			Transformer
							Main Fuse	Drive Fuse	Fuse	Panel	Drive Fuse
					UL Motor	(FC102/202/322)
				HP (KW)			(FC102/202/322)	(FC102/202/322)	(FC102/202/322)	(FC302) Non	(FC302) Danfoss
					Current	Non Bypass &
							Danfoss (Bussman)	Danfoss (Bussman)	Danfoss	Bypass	(Bussman)
						Bypass
									(Bussman)
3		3		15 (11)	17		34035500 (LPJ-30-	176F9076 (JJS-35)		P2	176F9076
							SP)				(JJS-35)
				20 (15)	22	P2	34042600 (LPJ-35-	176F9076 (JJS-35)			176F9077
							SP)				(JJS-45)
				25 (18.5)	27		34042700 (LPJ-45-	176F9077 (JJS-45)			176F8954
							SP)				(JJS-50)
				30 (22)	32		34035700 (LPJ-50-	176F8954 (JJS-50)		P3	176F8956
							SP)				(JJS-60)
				40 (30)	41	P3	34035800 (LPJ-60-	176F8956 (JJS-60)			176F8958
							SP)				(JJS-80)
				50 (37)	52		176U5037 (LPJ-80-	176F8958 (JJS-80)			176F8959
							SP)				(JJS-100)
										P4
				60 (45)	62		34043000 (LPJ-100-	176F8959 (JJS-100)			176F8961
							SP)				(JJS-125)
						P4
				75 (55)	77		34043100 (LPJ-125-	176F8961 (JJS-125)			176F9078
							SP)				(JJS-150)
										P5
				100 (75)	99		34043200 (LPJ-150-	176F9078 (JJS-150)	34053600 (FNQ-		130G0488
							SP)		R-0.50)		(JJS-175)
						P5
				125 (90)	125		34043400 (LPJ-200-	130G0488 (JJS-175)	34053600 (FNQ-
							SP)		R-0.50)

Table 3.5 Drive Fuses 600 V

3-4	MG.13.A1.22 - VLT® is a registered Danfoss trademark

Installation	Vertical Bypass/Non Bypass Panel

3.1.3 Internal Main Panel Fuses

Use only the specified fuse or an equivalent replacement for the internal main fuses. See the specifications label inside the cover of the unit for acceptable replacement main fuses. A sample of this can be seen in Table 3.6.

Fuse	Description	Manufacturer	Part Number/Size
					3		3
F13A & C	Primary Transformer	Bussmann	FNQ-R-0.50
F15A, B, & C	Main Fuses	Bussmann	LPJ-30-SP
F16A, B, & C	Drive Fuses	Bussmann	JJS-35
F900, F901,F902	SMPS - Power Supply	Bussmann	FWH-020A6F, 500V

Table 3.6 Sample Fuse Rating Label

3.2 Mechanical Installation

3.2.1 Lifting

Check the weight of the unit before attempting to lift. Ensure that the lifting device is suitable for safely lifting the panel. If necessary, plan for a hoist, crane or forklift with appropriate rating to move the units.

3.2.2 Hoist or Overhead Lift

•Use a solid steel spreader bar for lifting. Slide the spreader bar through the two (2) lifting holes on the panel. Lifting rings are 0.59in (15mm) in diameter (see Figure 3.1). If VFD mounting screws interfere with the spreader bar, lifting hooks can be used instead of the lifting bar.

•Connect the spreader bar to a hoist or other lifting device.

•Carefully lift the unit and secure it to the wall. Refer to 8 Appendix for dimensional drawings to determine fasteners size and location.

3.2.3 Forklift

•Only a competent lift operator with additional support personnel should attempt moving the unit.

•Carefully position forklift and ensure stability prior to lift.

3.2.4 Shipping Weights

Weights listed in Table 3.7 are approximate for base units. Options can add or reduce weight of unit. Weights listed are in lbs.

Frame	Non Bypass Panel	Bypass Panel
P2	36	84
P3	66	106
P4	106	167
P5	155	248
Table 3.7 Approximate Shipping Weights
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Figure 3.1 Proper Lifting Method

MG.13.A1.22 - VLT® is a registered Danfoss trademark

3-5

Installation

Vertical Bypass/Non Bypass Panel

3.3				Cooling
			•	Only mount the drive and panel vertically.	50.8 [2.0] min
			•	Panels rely on the ambient air for cooling. It is
				important to observe the limitations on ambient
3		3
				air temperature. The maximum ambient
				temperature for all bypass panels is 40°C and
				45°C for non bypass panels. Derating concerns
				start above 3300 feet elevation above sea level.
			•	Most panels may be mounted side-by-side
				without additional side clearance. However, the

P2 (B3 frame size) units require 1.5 in. minimum clearance between units (see Figure 3.2).

CEILING

AIRFLOW

•Top and bottom clearance is required for cooling (see Figure 3.3). Generally, 2 to 10 inches (50 to

250mm) minimum clearance is required, depending upon the hp (kW) of the unit. See the dimensional drawings in 8 Appendix for specific requirements.

•No additional back plate is required for drives

with the bypass and non bypass panels.

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101.6 [4.0] min

AIRFLOW

FLOOR

Figure 3.3 Cooling Airflow

Figure 3.2 Side Cooling Clearance

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3-6	MG.13.A1.22 - VLT® is a registered Danfoss trademark

Installation	Vertical Bypass/Non Bypass Panel

3.4 Electrical Installation

WARNING

EQUIPMENT HAZARD!

Rotating shafts and electrical equipment can be hazardous. It is strongly recommended that all electrical work conform to all national and local regulations. Installation, start-up and maintenance should be performed only by qualified personnel. Failure to follow local regulations could result in death or serious injury.

•Motor control equipment and electronic controls are connected to hazardous line voltages. Extreme care should be taken to protect against electrical hazard.

•Correct protective grounding of the equipment must be established. Ground currents are higher than 3mA.

•A dedicated ground wire is required.

•Wear safety glasses whenever working on electric control or rotating equipment.

NOTE!

Make all power connections with a minimum of 60°C/ 140°F rated copper wire.

WARNING

INDUCED VOLTAGE!

Run output motor cables from multiple drives separately. Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately could result in death or serious injury.

NOTE!

Run input power, motor wiring and control wiring in three separate metallic conduits or raceways for high frequency noise isolation. Failure to isolate power, motor and control wiring could result in less than optimum drive and associated equipment performance.

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

At least three separate conduits must be connected to the panel (Figure 3.4).

•Power into the panel (and ground back to the distribution panel)

•Power from the panel to the motor and earth insulated motor ground

•Control wiring

Control wiring should always be isolated from the high

voltage power wiring. 3 3

Avoid getting metal chips into electronics.

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

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Stop

Start

Speed	Line Power	Motor

Control

Figure 3.4 Power Connections

MG.13.A1.22 - VLT® is a registered Danfoss trademark

3-7

Installation	Vertical Bypass/Non Bypass Panel

3.4.1 Component Identification & Customer Connection

Mechanical layout drawings are intended to provide the installer or equipment user with component identification and location for that specific unit. Figure 3.5 represents a typical layout drawing. Table 3.8 provides definitions for drawing reference designators. (Not all reference designators are shown.)

3	3	26
		17
		19 (ECB OPTION ONLY)
		CUST. CONNECTION
		ECB CONTROL WIRES
		CUST. CONNECTION
		DRIVE CONTROL
		TERMINALS

		18 (EMB2 OPTION ONLY)
		CUST. CONNECTION
	CUSTOMER CONNECTION	EMB2 CONTROL WIRES
	TERMINAL BLOCK 1
14	(EMB2 OPTION ONLY)	1
	7
15 (EMB2 OPTION ONLY)
	10	2
	4,5,6
27
	12	11
	8	13
	CUST. CONNECTION
	INPUT & OUTPUT
	GROUND
	CUST. CONNECTION	CUST. CONNECTION
	INPUT POWER	POWER TO MOTOR
	L1 L2 L3	T1 T2 T3

Figure 3.5 P2 Bypass Mechanical Layout Diagram

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ID	Device	Definition	ID	Device	Definition
1	24 V DC	Panel 24 V DC SMPS	15	S1	Auto Bypass Selector Switch
2	HPC	High Pot Connector	16	TF	120 V AC control transformer
3	F13	T1 primary fuse	17	VFD	Variable frequency drive
4	CB1	Main Circuit Breaker	18	EMB2	Control Module
5	DS1	Main or Drive Disconnect	19	ECB	Control Module
6	F15	Main fuse	20	TB1-C	Terminal block 1 - Control
7	F16	Drive fuse	21	TB1-P	Terminal block 1 - Power
8	GND	Ground terminal	22	PR1	Control Relay for M1 Contactor
9	LCP	LCP	23	PR2	Control Relay for M2 Contactor
10	M1	Drive Input contactor	24	PR3	Control Relay for M3 Contactor
11	M2	Drive Output contactor	25	UVM	Under voltage module
12	M3	Bypass contactor	26	TC	Top Cover
13	OL1	Overload for Motor	27	DH	Disconnect Handle
14	PL1	Bypass indicator light

Table 3.8 Reference Designator Definitions

3-8	MG.13.A1.22 - VLT® is a registered Danfoss trademark

Installation	Vertical Bypass/Non Bypass Panel

27

Figure 3.6 P2 Non Bypass Mechanical Layout Diagram.

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3 3

17

CUST. CONNECTION

DRIVE CONTROL

TERMINALS

CUSTOMER CONNECTION

TERMINAL BLOCK 1

7

21 5

CUST. CONNECTION

POWER TO MOTOR

T1 T2 T3

8

CUST. CONNECTION

INPUT AND OUTPUT GROUND

CUST. CONNECTION

INPUT POWER

L1 L2 L3

See Table 3.8 for reference designator definitions.

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3-9

Installation	Vertical Bypass/Non Bypass Panel

				26
				<![if ! IE]> <![endif]>130BX375.12
3	3		CUST. CONNECTION
		CUST. CONNECTION	EMB2 / ECB CONTROL WIRES
		DRIVE CONTROL
		TERMINALS	18 OR 19
		17
			2
	(EMB2 OPTION ONLY) 14
	(EMB2 OPTION ONLY) 15	7	1
		10	11
	27
		4,5,6
			13	CUST. CONNECTION
				OUTPUT GROUND
		12	8

CUST. CONNECTION	CUST. CONNECTION	CUST. CONNECTION
INPUT POWER	INPUT GROUND	POWER TO MOTOR
L1 L2 L3		T1 T2 T3

Figure 3.7 P3 Bypass Mechanical Layout Diagram.

See Table 3.8 for reference designator definitions.

3-10	MG.13.A1.22 - VLT® is a registered Danfoss trademark