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.
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.
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.
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
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
1.2.1 Three-contactor Bypass 2-1
1.3 Bypass Options
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
1.5 Switch Mode Power Supply
1.5.1 Control Transformer 2-3
1.6 Disconnects
2-1
2-1
2-2
2-3
2-3
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
1.7.1 Power Fusing 2-6
2 Pre-installation
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
2.2.1 Airborne Liquids 3-2
2.2.2 Airborne Solids 3-2
2.2.3 Corrosive Chemicals 3-2
3 Installation
3.1.1 Tools Required 4-1
2-6
3-1
3-2
4-1
3.1.2 Drive Fuses 4-1
3.1.3 Internal Main Panel Fuses 4-5
3.2 Mechanical Installation
MG.13.A1.22 - VLT® is a registered Danfoss trademark
4-5
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
3.4 Electrical Installation
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
4.1.1 Inspection Prior to Start Up 5-2
4.1.2 Start Up Procedure 5-2
4-6
4-7
5-1
5 Electromechanical Bypass (EMB2) Operation
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
6.1 Electronically Controlled Bypass (ECB) Operation
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
6-1
7-1
7-1
MG.13.A1.22 - VLT® is a registered Danfoss trademark
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
7.1.1 Option Panel Alarm and Warnings 8-1
8 Appendix
8.1.1 Dimensions 9-1
8.1.2 Mechanical Diagrams 9-2
8.1.3 Typical Wiring Diagrams 9-6
8-1
9-1
MG.13.A1.22 - VLT® is a registered Danfoss trademark
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
MG.13.A1.22 - VLT® is a registered Danfoss trademark
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
MG.13.A1.22 - VLT® is a registered Danfoss trademark
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.
Overview
1.1.2
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.
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 Electrome-
chanical Bypass (EMB2) Operation and ECB in 6 Electronically
Controlled Bypass (ECB) Operation of this manual.
Typical Bypass Operation
1.1.3
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.
1 1
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
MG.13.A1.22 - VLT® is a registered Danfoss trademark 1-1
T3
T2
T1
CUSTOMER SUPPLIED
AC MOTOR.
INPUT
POWER
EARTH
GROUND
TYPE 1 ENCLOSURE
130BX360.11
W/98
U/96
V/97
VFD
L1
L2
L3
Fuse
Fuse
Fuse
DISCONNECT
DS1
DRIVE
1L1
1L2
1L3
2L1
2L2
2L3
L2/92
L1/91
L3/93
Introduction Vertical Bypass/Non Bypass Panel
Contactor Drive Mode OFF Bypass
11
M1 Closed Open Open Closed
M2 Closed Open Open Open
M3 Open Open Closed Closed
Table 1.1 Contactor Operation
Figure 1.1 Basic Non Bypass Circuit
Mode
1.3 Bypass Options
1.3.1 Common Run/Stop with Bypass
Test Mode
Basic Fire Mode in Bypass
1.3.4
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
Allows a remote signal to initiate operation in either drive
control or bypass depending upon the position of the
bypass selector switch.
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
1.3.2 Automatic Bypass
ignored when in fire mode.
This feature automatically transfers the motor from drive to
1.3.5 Advanced Fire Mode in Bypass
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
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.
may prevent or delay bypass operation.
Overload Protection
1.3.6
Run Permissive in Bypass
1.3.3
This thermally activated device provides mechanical
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.
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.
1-2 MG.13.A1.22 - VLT® is a registered Danfoss trademark
W/98
U/96
V/97
Fuse
Fuse
Fuse
Fuse
Fuse
INPUT
POWER
2T1
2T2
2T3
M2
M3
CUSTOMER
SUPPLIED
AC MOTOR
1T1
1T3
1T2
OL1
T1
T3
T2
MK902
2
6
24 V DC SMPS
MK901
1
5
MK903 MK904
374
8
- +
EARTH
GROUND
Type 1 Enclosure
VFD
EARTH
GROUND
2L3
M1
2L1
2L2
L2/92
L1/91
L3/93
TRANSFORMER
CONTROL
600V
600V
3L3
3L1
3L2
130BX361.11
MAIN DISCONNECT
DS1
Fuse
Fuse
Fuse
1L1
1L2
1L3
L2
L3
L1
Introduction Vertical Bypass/Non Bypass Panel
Control Features EMB2 ECB
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
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
6 Electronically Controlled Bypass (ECB) Operation for the
ECB.
Table 1.2 Bypass Configurations
1 1
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.
Figure 1.2 Basic Bypass Circuit
Control Transformer
1.5.1
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
MG.13.A1.22 - VLT® is a registered Danfoss trademark 1-3
Introduction Vertical Bypass/Non Bypass Panel
the option panel door can be opened. (Bypass
11
1.6.2
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.
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.
Mode Selector Switch
1-4 MG.13.A1.22 - VLT® is a registered Danfoss trademark
130BX363.10
130BX365.10
130BX362.10
130BX364.10
Introduction Vertical Bypass/Non Bypass Panel
1.6.3 Panel Configurations
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
1 1
Drive plus both of the following:
1. Fuses
2. Disconnect
Table 1.3 Tier Definitions and Features
Drive with bypass:
1. Fuses
2. Disconnect/Circuit Breaker
3. Contactors
4. Power Supply
5. Control Module
MG.13.A1.22 - VLT® is a registered Danfoss trademark 1-5
Introduction Vertical Bypass/Non Bypass Panel
1.6.4 Panel Voltage and Frame Ratings
11
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
(B3 - Drive)
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
(B4 - Drive)
Volts VAC HP (KW)
208 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
(C3 - Drive)
Volts VAC HP (KW)
208 25 (18.5) - 40 (30)
230 30 (22) - 40 (30)
460 & 600 60 (45) - 75 (55) 60 (45) - 75 (55) 50 (37) - 60 (45)
Panel P5)
(C4 - Drive)
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)
Bypass Non Bypass
FC102/202/322 FC102/202/322 FC302
Bypass Non Bypass
FC102/202/322 FC102/202/322 FC302
20 (15) - 25 (18.5) 15 (11) - 20 (15)
Bypass Non Bypass
FC102/202/322 FC102/202/322 FC302
30 (22) - 40 (30) 25 (18.5) - 30 (22)
Bypass Non Bypass
FC102/202/322 FC102/202/322 FC302
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).
1-6 MG.13.A1.22 - VLT® is a registered Danfoss trademark
130BX366.10
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.
2.1.2
Pre-installation Check
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, Δ-run motors must be wired
•
permanently for run.
2
2
Figure 2.1 Sample Panel Label
Ensure that the model number and power match the order
and intended use for the drive.
MG.13.A1.22 - VLT® is a registered Danfoss trademark 2-1
Installation Site Check
2.1.3
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
2
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
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.
2.2 Harsh 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.
Airborne Liquids
2.2.1
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.
Airborne Solids
2.2.2
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.
Corrosive Chemicals
2.2.3
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.
Drive Fuses
3.1.2
Spreader bar capable of lifting up to 750 lbs.
Max diameter 0.5 in.
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
TOOLS
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
HP (KW)
7.5 (5.5) 24.2
10 (7.5) 30.8
15 (11) 46.2
20 (15) 59.4 P3
25 (18.5) 74.8
30 (22) 88
40 (30) 114
50 (37) 143
UL Motor
Current
(FC102/202/322)
Non Bypass &
Bypass
P3 - Non Bypass P4
- Bypass
Panel
P2
P4
Main Fuse
(FC102/202/322)
Danfoss (Bussman)
34035600 (LPJ-40-
SP)
34035700 (LPJ-50-
SP)
34042800 (LPJ-70-
SP)
34042900 (LPJ-90-
SP)
34043100 (LPJ-125-
SP)
34043200 (LPJ-150-
SP)
34043300 (LPJ-175-
SP)
34042300 (LPJ-250-
SP)
Drive Fuse
(FC102/202/322)
Danfoss (Bussman)
176F8953 (JJN-50)
176F8953 (JJN-50)
176F8955 (JJN-60)
176F8957 (JJN-80)
176F8960 (JJN-125)
176F8960 (JJN-125)
174N6538 (JJN-150)
174N6839 (JJN-200)
Transformer Fuse
(FC102/202/322)
Danfoss (Bussman)
34046200 (FNQ-
R-1.25)
Panel
(FC302)
Non
Bypass
P2
P3
P4
P5
Drive Fuse
(FC302) Danfoss
(Bussman)
176F8953
(JJN-50)
176F8955
(JJN-60)
176F8957
(JJN-80)
176F8960
(JJN-125)
176F8960
(JJN-125)
174N6538
(JJN-150)
174N6839
(JJN-200)
174N6840
(JJN-250)
3 3
60 (45) 169
Table 3.2 Drive Fuses 208 V
P5
34042300 (LPJ-250-
SP)
MG.13.A1.22 - VLT® is a registered Danfoss trademark 3-1
174N6840 (JJN-250)
34046200 (FNQ-
R-1.25)
Installation Vertical Bypass/Non Bypass Panel
230 V AC
Panel
HP (KW)
7.5 (5.5) 22
33
10 (7.5) 28
15 (11) 42
20 (15) 54
25 (18.5) 68
30 (22) 80
40 (30) 104
50 (37) 130
60 (45) 154
UL Motor
Current
(FC102/202/322)
Non Bypass &
Bypass
P2
P3
P4
P5
Main Fuse
(FC102/202/322)
Danfoss (Bussman)
34042600 (LPJ-35-
SP)
34042700 LPJ-45-
SP
34042800 (LPJ-70-
SP)
34042900 (LPJ-90-
SP)
34043000 (LPJ-100-
SP)
34043100 (LPJ-125-
SP)
34043200 (LPJ-150-
SP)
34043400 (LPJ-200-
SP)
34042300 (LPJ-250-
SP)
Drive Fuse
(FC102/202/322)
Danfoss (Bussman)
176F8953 (JJN-50)
176F8953 (JJN-50)
176F8955 (JJN-60)
176F8957 (JJN-80)
176F8960 (JJN-125)
176F8960 (JJN-125)
174N6538
(JJN-150)
174N6839
(JJN-200)
174N6840
(JJN-250)
Transformer Fuse
(FC102/202/322)
Danfoss (Bussman)
34046200 (FNQ-
R-1.25)
34046200 (FNQ-
R-1.25)
Panel
(FC302)
Non
Bypass
P2
P3
P4
P5
Drive Fuse
(FC302) Danfoss
(Bussman)
176F8953
(JJN-50)
176F8955
(JJN-60)
176F8957 JJN-80
176F8960
(JJN-125)
176F8960
(JJN-125)
174N6538
(JJN-150)
174N6839
(JJN-200)
174N6840
(JJN-250)
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
HP (KW)
15 (11) 21
20 (15) 27
25 (18.5) 34
30 (22) 40
40 (30) 52
50 (37) 65
60 (45) 77
75 (55) 96
100 (75) 124
125 (90) 156
UL Motor
Current
Panel
(FC102/202/322)
Non Bypass &
Bypass
P2
P3
P4
P5
Main Fuse
(FC102/202/322)
Danfoss (Bussman)
34042600 (LPJ-35-
SP)
34035600 (LPJ-40-
SP)
34035700 (LPJ-50-
SP)
34035800 (LPJ-60-
SP)
176U5037 (LPJ-80-
SP)
34043000 (LPJ-100-
SP)
34043100 (LPJ-125-
SP)
34043200 (LPJ-150-
SP)
34043400 (LPJ-200-
SP)
34042300 (LPJ-250-
SP)
Drive Fuse
(FC102/202/322)
Danfoss (Bussman)
176F8952 (JJS-40)
176F8952 (JJS-40)
176F8954 (JJS-50)
176F8956 (JJS-60)
176F8958 (JJS-80)
176F8959 (JJS-100)
176F8961 (JJS-125)
176F9078 (JJS-150)
34051200 (JJS-200)
00002051 (JJS-250)
Transformer
Fuse
(FC102/202/322
) Danfoss
(Bussman)
34046000 (FNQ-
R-0.60)
34046000 (FNQ-
R-0.60)
Panel
(FC302) Non
Bypass
P2
P3
P4
P5
Drive Fuse
(FC302) Danfoss
(Bussman)
176F8952
(JJS-40)
176F8954
(JJS-50)
176F8956
(JJS-60)
176F8958
(JJS-80)
176F8959
(JJS-100)
176F8961
(JJS-125)
176F9078
(JJS-150)
34051200
(JJS-200)
00002051
(JJS-250)
3 3
Table 3.4 Drive Fuses 460 V
MG.13.A1.22 - VLT® is a registered Danfoss trademark 3-3
Installation Vertical Bypass/Non Bypass Panel
600 V AC
Panel
HP (KW)
15 (11) 17
UL Motor
Current
(FC102/202/322)
Non Bypass &
Bypass
33
20 (15) 22
25 (18.5) 27
30 (22) 32
40 (30) 41
50 (37) 52
60 (45) 62
75 (55) 77
100 (75) 99
125 (90) 125
P2
P3
P4
P5
Main Fuse
(FC102/202/322)
Danfoss (Bussman)
34035500 (LPJ-30-
SP)
34042600 (LPJ-35-
SP)
34042700 (LPJ-45-
SP)
34035700 (LPJ-50-
SP)
34035800 (LPJ-60-
SP)
176U5037 (LPJ-80-
SP)
34043000 (LPJ-100-
SP)
34043100 (LPJ-125-
SP)
34043200 (LPJ-150-
SP)
34043400 (LPJ-200-
SP)
Drive Fuse
(FC102/202/322)
Danfoss (Bussman)
176F9076 (JJS-35)
176F9076 (JJS-35)
176F9077 (JJS-45)
176F8954 (JJS-50)
176F8956 (JJS-60)
176F8958 (JJS-80)
176F8959 (JJS-100)
176F8961 (JJS-125)
176F9078 (JJS-150)
130G0488 (JJS-175)
Transformer
Fuse
(FC102/202/322)
Danfoss
(Bussman)
34053600 (FNQ-
R-0.50)
34053600 (FNQ-
R-0.50)
Panel
(FC302) Non
Bypass
P2
P3
P4
P5
Drive Fuse
(FC302) Danfoss
(Bussman)
176F9076
(JJS-35)
176F9077
(JJS-45)
176F8954
(JJS-50)
176F8956
(JJS-60)
176F8958
(JJS-80)
176F8959
(JJS-100)
176F8961
(JJS-125)
176F9078
(JJS-150)
130G0488
(JJS-175)
Table 3.5 Drive Fuses 600 V
3-4 MG.13.A1.22 - VLT® is a registered Danfoss trademark
130BX367.10
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
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 3
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.
Forklift
3.2.3
Shipping Weights
3.2.4
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
Only a competent lift operator with additional
•
support personnel should attempt moving the
unit.
Carefully position forklift and ensure stability prior
•
to lift.
MG.13.A1.22 - VLT® is a registered Danfoss trademark 3-5
Figure 3.1 Proper Lifting Method
38.1 [1.5]
130BX368.10
50.8 [2.0] min
101.6 [4.0] min
FLOOR
CEILING
AIRFLOW
AIRFLOW
130BX369.12
Installation Vertical Bypass/Non Bypass Panel
3.3 Cooling
Only mount the drive and panel vertically.
•
Panels rely on the ambient air for cooling. It is
•
important to observe the limitations on ambient
33
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).
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.
Figure 3.2 Side Cooling Clearance
Figure 3.3 Cooling Airflow
3-6 MG.13.A1.22 - VLT® is a registered Danfoss trademark
Motor
Line Power
Stop
Start
Speed
Control
130BX370.10
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.
•
Control wiring should always be isolated from the high
voltage power wiring.
Avoid getting metal chips into electronics.
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
3 3
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.
Follow the connection procedures as illustrated in the
drawing provided with the unit.
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).
MG.13.A1.22 - VLT® is a registered Danfoss trademark 3-7
Figure 3.4 Power Connections
(EMB2 OPTION ONLY)
(ECB OPTION ONLY)
(EMB2 OPTION ONLY)
(EMB2 OPTION ONLY)
CUST. CONNECTION
INPUT POWER
L1 L2 L3
CUST. CONNECTION
POWER TO MOTOR
T1 T2 T3
CUST. CONNECTION
EMB2 CONTROL WIRES
14
15
17
7
10
4,5,6
12
8
19
18
1
2
11
13
130BX372.12
27
26
CUST. CONNECTION
DRIVE CONTROL
TERMINALS
CUSTOMER CONNECTION
TERMINAL BLOCK 1
CUST. CONNECTION
INPUT & OUTPUT
GROUND
CUST. CONNECTION
ECB CONTROL WIRES
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.)
33
Figure 3.5 P2 Bypass Mechanical Layout Diagram
ID
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
Device Definition ID Device Definition
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
CUST. CONNECTION
INPUT POWER
L1 L2 L3
CUST. CONNECTION
POWER TO MOTOR
T1 T2 T3
5
7
17
CUSTOMER CONNECTION
TERMINAL BLOCK 1
21
8
130BX374.11
27
26
CUST. CONNECTION
DRIVE CONTROL
TERMINALS
CUST. CONNECTION
INPUT AND OUTPUT GROUND
Installation Vertical Bypass/Non Bypass Panel
3 3
Figure 3.6 P2 Non Bypass Mechanical Layout Diagram.
Table 3.8 for reference designator definitions.
See
MG.13.A1.22 - VLT® is a registered Danfoss trademark 3-9
(EMB2 OPTION ONLY)
(EMB2 OPTION ONLY)
CUST. CONNECTION
EMB2 / ECB CONTROL WIRES
CUST. CONNECTION
INPUT POWER
L1 L2 L3
CUST. CONNECTION
POWER TO MOTOR
T1 T2 T3
14
15
18 OR 19
2
1
11
13
8
12
4,5,6
10
7
17
130BX375.12
27
26
CUST. CONNECTION
OUTPUT GROUND
CUST. CONNECTION
DRIVE CONTROL
TERMINALS
CUST. CONNECTION
INPUT GROUND
Installation Vertical Bypass/Non Bypass Panel
33
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
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