Johnson Controls JC-VSD Factory Packaged (FP) Series II Installation Guide

Download

Code No. LIT-12012114

Installation Manual

Effective July 2015

JC-VSD Factory Packaged (FP) Series II drive frames 4–8, Type 1 and 3R

Johnson Controls variable speed drives

Disclaimer of warranties and limitation of liability

The product discussed in this literature is subject to terms and conditions outlined in Johnson Control Inc. selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Johnson Control Inc. selling policy.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN

In no event will Johnson Control Inc. be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice.

Cover Photo: Johnson Controls variable speed drives

Safety

Read and follow all safety information shown in the JC-VSD Series II Installation Manual LIT-12011775.

Johnson Controls variable speed drives LIT-12012114—July 2015 www.johnsoncontrols.com i

Johnson Controls variable speed drives

Table of contents

SAFETY

Definitions and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Hazardous high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

GENERAL INFORMATION

Catalog/style numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

COMPONENT DIAGRAMS

IntelliPass and IntelliDisconnect—typical component locations . . . . . . . . . . . . 3

STANDARD FACTORY WIRED COMPONENTS

Drive isolation fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Manual bypass switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Space heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Plug-in options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Auxiliary contacts (bypass only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

High temperature option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DIMENSIONS AND MOUNTING

WIRING

Wiring schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Conduit plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Input power wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Motor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Ground wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

INITIAL STARTUP

IntelliDisconnect operation

(starting/stopping of the motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

IntelliPass operation

(starting/stopping of the motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Switch operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SA bus operation and setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

INTELLIPASS/INTELLIDISCONNECT TECHNICAL INFORMATION

Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

ADDITIONAL HELP

Website address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Johnson Controls product sales operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

ii Johnson Controls variable speed drives LIT-12012114—July 2015 www.johnsoncontrols.com

Johnson Controls variable speed drives

List of figures

Figure 1. JC-VSD FP Series II master product part number matrix—

IntelliPass/IntelliDisconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Figure 2. JC-VSD FP Series II IntelliPass/IntelliDisconnect carton label . . . . . . . . . . . . . 2

Figure 3. JC-VSD FP Series II IntelliPass/IntelliDisconnect nameplate . . . . . . . . . . . . . 2

Figure 4. Type 1 IntelliDisconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 5. Type 1 IntelliPass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 6. Type 3R IntelliDisconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 7. Type 3R IntelliPass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 8. Type 1 Micro Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 9. Fused disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 10. Door 3-position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 11. Larger framed bypass contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 12. Lower framed bypass contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 13. Option PCB cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 14. Type 1 IntelliDisconnect dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 15. Type 1 IntelliDisconnect knockout dimensions . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 16. Type 1 IntelliPass dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Figure 17. Type 1 IntelliPass knockout dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 18. Type 3R IntelliDisconnect dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Figure 19. Type 3R IntelliDisconnect knockout dimensions . . . . . . . . . . . . . . . . . . . . . . 20

Figure 20. Type 3R IntelliPass dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Figure 21. Type 3R IntelliPass knockout dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figure 22. Type 1 Micro Disconnect dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Figure 23. Type 1 Micro Disconnect knockout dimensions . . . . . . . . . . . . . . . . . . . . . . 24

Figure 24. Type 1 IntelliDisconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Figure 25. Type 1 IntelliPass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 26. Type 3R IntelliDisconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Figure 27. Type 3R IntelliPass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 28. Type 1 Micro Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Figure 29. Lower frame incoming lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 30. Larger frame incoming lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 31. IntelliDisconnect motor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Figure 32. IntelliPass motor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Figure 33. Typical ground stud and label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 34. Terminal block access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 35. Startup Wizard prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 36. Enable bypass for IntelliPass models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 37. Disable bypass for IntelliPass models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 38. Keypad shown in drive mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Figure 39. Keypad shown in bypass mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Figure 40. Keypad with bypass and drive mode option . . . . . . . . . . . . . . . . . . . . . . . . . 36

Figure 41. Keypad shown in run mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Figure 42. Keypad already in bypass mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Figure 43. Parameter menu for automatic reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 44. Menu selecting auto bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 45. Menu selecting reset/bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Johnson Controls variable speed drives LIT-12012114—July 2015 www.johnsoncontrols.com iii

Johnson Controls variable speed drives

List of figures, continued

Figure 46. Displaying going into auto bypass after fault . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 47. Hand/Off/Auto parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 48. Off menu selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 49. Monitoring menu in STOP mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 50. JC-VSD Series II drive SA bus interface card VS-XMX-CS . . . . . . . . . . . . . . 39

List of tables

Table 1. hp rating and fuse rating (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table 2. Space heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Table 3. Auxiliary contacts (bypass only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Table 4. Option PCB cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Table 5. Enclosure size and frame size based on

voltage and horsepower (208/230 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Table 6. Enclosure size and frame size based on

voltage and horsepower (480 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 7. Type 1 Micro Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 8. Type 1 IntelliDisconnect dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 9. Type 1 IntelliDisconnect knockout dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 10. Type 1 IntelliPass dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table 11. Type 1 IntelliPass knockout dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Table 12. Type 3R IntelliDisconnect dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 13. Type 3R IntelliDisconnect knockout dimensions . . . . . . . . . . . . . . . . . . . . . . . 20

Table 14. Type 3R IntelliPass dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 15. Type 3R IntelliPass knockout dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 16. Type 1 Micro Disconnect dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 17. Type 1 Micro Disconnect knockout dimensions . . . . . . . . . . . . . . . . . . . . . . . 24

Table 18. Input wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Table 19. Output wiring details—IntelliDisconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table 20. Output wiring details—IntelliPass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table 21. Terminal block designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Table 22. SA bus setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Table 23. Object list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Table 24. Short-circuit rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

iv Johnson Controls variable speed drives LIT-12012114—July 2015 www.johnsoncontrols.com

Safety

Johnson Controls variable speed drives

Definitions and symbols

WARNING

This symbol indicates high voltage. It calls your attention to items or operations that could be dangerous to you and other persons operating this equipment. Read the message and follow the instructions carefully.

This symbol is the “Safety Alert Symbol.” It occurs with either of two signal words: CAUTION or WARNING, as described below.

WARNING

Indicates a potentially hazardous situation which, if not avoided, can result in serious injury or death.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, can result in minor to moderate injury, or serious damage to the product. The situation described in the CAUTION may, if not avoided, lead to serious results. Important safety measures are described in CAUTION (as well as WARNING).

Warnings and cautions

This manual contains clearly marked cautions and warnings which are intended for your personal safety and to avoid any unintentional damage to the product or connected appliances.

Please read the information included in cautions and warnings carefully.

Hazardous high voltage

WARNING

Motor control equipment and electronic controllers are connected to hazardous line voltages. When servicing drives and electronic controllers, there may be exposed components with housings or protrusions at or above line potential. Extreme care should be taken to protect against shock.

Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person in case an emergency occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic controllers or rotating machinery.

Johnson Controls variable speed drives LIT-12012114—July 2015 www.johnsoncontrols.com v

General information

This document provides supplement information to the JC-VSD Series II Installation Manual LIT-12011772 specific to the JC-VSD FP Series II IntelliPass® and IntelliDisconnect® products. These products are offered with input/output voltages of 208, 230, and 480 Vac with hp ranges from 1 to 125 hp. Both UL Type 1 and Type 3R enclosures are available.

For drive setup and operation, i.e., application, keypad use, drive and motor parameters setup, see the Quick Start Guide LIT-12011775 included with the drive. The drive Startup Wizard can be used to complete the process. For more information on speed control and other JC-VSD Series II drive features, see JC-VSD Series II Application Manual LIT-12011771. The Application Manual and can be found at http://www.johnsoncontrols.com

Catalog/style numbering

Figure 1. JC-VSD FP Series II master product part number matrix—IntelliPass/IntelliDisconnect

General information

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 1

General information

Cat. No.

JC-VSD FP Series II

JCI OEM Part #:

Assembled in USA

Style No:

CRN4567456

3-4292-0104A

AOMS2345234

Qty

GO34656

Cust.Ref No:

-40°C to 70°C (-40°F to 158°F)

Max HP:

Storage Temp:

AOMS No:

www.johnsoncontrols.com

YK011111B-00000

Order No:

024-39261-003

152503

Disconnect Non-Fused

3 Hp @ 208VAC 11A

Rev B

Tag #:

9545151

40°C

Short Circuit Ratings: Schematic:

Catalog No:

Max Ambient Temp:

Order No:

See manuals for more information:

Field installed conductors must be copper rated at 75°C.

For Assistace Call 1-800-524-1330 #611461

Max HP:

Enclosure:

Disconnect Non-Fused

Type 1

JCI OEM Part #:

AOMS No:

Assembled in USAW

Serial No:

www.johnsoncontrols.com

GO3463745 SN65461

AOMS24356457

153003

Style No:

YK011111B-00000

024 39261 004

3-4292-0104A

JC-VSD FP Series II Rev B

LIT12011773

and

3 Hp @ 208VAC 11A

65KA

LIT12011772

024 39261 002Outline DWG:

024 39261 003

Identification

Figure 2. JC-VSD FP Series II IntelliPass/IntelliDisconnect carton label

Figure 3. JC-VSD FP Series II IntelliPass/IntelliDisconnect nameplate

2 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Component diagrams

JC-VSD Series II

Lockout disconnect handle

Quarter turn latches

Fused disconnect with fuse holder

IntelliPass and IntelliDisconnect—typical component locations

Figure 4. Type 1 IntelliDisconnect

Component diagrams

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 3

Component diagrams

JC-VSD Series II

Quarter turn latches

Cover controls

Lockout disconnect handle

Terminal block access

Overload protection relay

Fused disconnect with fuse holder

Bypass and drive contactor

Isolation disconnect

Control power transformer

Figure 5. Type 1 IntelliPass

4 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 6. Type 3R IntelliDisconnect

Remote mount keypad

Quarter turn latches

Lockable disconnect handle

Disconnect with fuse holders

JC-VSD Series II

Heater

Control power transformer

Component diagrams

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 5

Component diagrams

Cover controls

Quarter turn latches

Lockable disconnect handle

Terminal block access

Overload protection relay

Bypass and drive contactor

Disconnect with fuse holder

Heater

Remote mount keypad

Isolation disconnect

JS-VSD Series II

Control power transformer

Figure 7. Type 3R IntelliPass

6 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 8. Type 1 Micro Disconnect

Lockable disconnect handle

Quarter turn latches

Fuse holder

Disconnect

JS-VSD Series II Micro

Component diagrams

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 7

Standard factory wired components

The IntelliPass and IntelliDisconnect have the following factory installed options. Any additional option are sold separately. See part numbering matrix for ordering information.

Drive isolation fuses

This option is available for both the IntelliPass and IntelliDisconnect Fused Disconnect designs 208/230 V up to 50 hp and 480 V models up to 125 hp.

Three power fuses are supplied wired to the drive input. They are provided between the disconnect device and drive. The fuses are not used in the bypass mode. The fuses are for drive protection only. They are listed in the following table and the Type J are sized according. See IntelliDisconnect or Typical IntelliPass schematic.

Table 1. hp rating and fuse rating (A)

hp 208 V fuse 230 V fuse 460 V fuse

110106

2202010

3252510

5303020

7.5606025

10 60 60 30

15 60 100 30

20 100 100 60

25 100 100 60

30 200 200 60

40 200 200 125

50 200 200 150

60 N/A N/A 175

75 N/A N/A 200

100 N/A N/A 200

125 N/A N/A 200

Figure 9. Fused disconnect

8 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Standard factory wired components

Manual bypass switch

This option is available on the IntelliPass models only. This option includes a 3-position door mounted selector switch— marked VFD / OFF / BYP. This switch manually overrides the bypass control from the system (keypad) and puts unit in bypass. See typical IntelliPass schematic.

When the door switch is in the drive position, the JC-VSD Series II Drive logic controls the motor and the keypad selects the operation (drive or bypass), the control source and place (HOA, KEYPAD, or Terminal block).

When the door switch is moved to bypass, the drive output contactor will be forced open and the bypass contactor will be forced closed. The motor will immediately start and run full speed across the line regardless of the state of the system or drive. The keypad display will show “Bypass”. When the switch is moved back to the drive position, drive operation is restored after a system restart.

Figure 10. Door 3-position switches

Figure 11. Larger framed bypass contactor

Figure 12. Lower framed bypass contactor

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 9

Standard factory wired components

Space heater

Type 3R enclosures only

This option aids in preventing or reducing condensation from forming in the enclosure when the drive is inactive. See selection table below for the size of heater that is installed in each enclosure size. A control transformer and fusing is also provided to power the heater. See schematics for more information. The heater includes a user adjustable thermostat for variable temperature control and an internal fan.

Table 2. Space heater

Type 3R IntelliDisconnect enclosure size

C1 150 D1 150

C2 150 D2 150

C3 150 D3 150

C4 150 D4 250

C5 250 D5 250

C6 250 D6 250

Heater size (W) 120 V rated

Type 3R IntelliPass enclosure size

Heater size (W) 120 V rated

Setting the thermostat

The heater is controlled by an adjustable thermostat. Set the thermostat to the desired temperature. It is recommended not to exceed 75 °F for most applications. The heater is active at all times when the main disconnect is closed including when in the Drive, Off, or Bypass operation. However, depending on the setting of the thermostat, the internal heat generated by the system when in operation should be enough to turn off the heater. Generally the heater requires no maintenance because the fan bearings are permanently lubricated and sealed.

10 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Standard factory wired components

Plug-in options

Auxiliary contacts (bypass only)

The bypass and drive contactor come installed with auxiliary contacts. The configuration is used for bypass operation. There are open NO and NC contacts on each the bypass and drive contactor that can be used for customer use. See table below for open contact configuration based on voltage and horsepower.

Table 3. Auxiliary contacts (bypass only)

Bypass contactor (B) Drive contactor (M)

Voltage hp rating

208 / 203 V 1–4 B 1 1 N/A 1 NO is wired to terminal

5–10 C 1 1

15–20 D N/A 1

25–30 F N/A 1

40–50 G N/A 1

480 V 1–7.5 B 1 1

10–20 C 1 1

25–40 D N/A 1

50–60 F N/A 1

75–125 G N/A 1

Contactor frame

Number of NC available

Number of NO available

Number of NC available

Number of NO available

block access 23 / 24

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 11

Standard factory wired components

Option PCB cards

A number of plug-in cards are available to expand I/O and communications. The SA Bus communication card is the only factory installed option. Reference the catalog matrix for ordering. All other cards are sold separately.

Figure 13. Option PCB cards

High temperature option

For NEMA Type 3R enclosures, vent covers are shipped loose inside the enclosure. These vent covers would need to be installed when the high temperature option is utilized. The vent cover would be installed on the outside bottom of the enclosure to cover the vents.

Also see JC-VSD Series II Installation Manual LIT-12011772 for more information on control wiring, control board layout and option PCBs.

Table 4. Option PCB cards

Part number Description

VS-XMX-B1 I/O Expander Card, 6 DI/DO, Slot D/E VS-XMX-B1

VS-XMX-B2 I/O Expander Card 2 x RO + Thermistor, Slot D/E

VS-XMX-B4 I/O Expander Card 1 x AI, 2 x AO (isolated), Slot D/E

VS-XMX-B5 I/O Expander Card 3 x RO, Slot D/E VS-XMX-B5

VS-XMX-B9 I/O Expander Card 1 x RO, 5 x DI (42-240VAC), Slot D/E

VS-XMX-BF I/O expander Card, 1 x AO, 1 x DO, 1 x RO, Slot D/E

VS-XMX-C4 lonworks

VS-XMX-CS SA Bus, slot D/E

VS-XMX-B2

VS-XMX-B4

VS-XMX-B9

VS-XMX-BF

, Slot D/E VS-XMX-C4

12 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Dimensions and mounting

The IntelliPass / IntelliDisconnect physical dimensions are based on the enclosure frame size. See following table to determine the enclosure frame size based on horsepower and voltage.

●

Weights and lifting provisions are on the dimension section and with the drawing provided with the unit

●

Attach “load-rated” hooks or shackles to lifting eyes on back panel

●

Always maintain a maximum of 45 degrees between the

The hardware to mount the Intellipass / IntelliDisconnect units, all frame sizes, is as follows:

●

3/8-16 Grade 5 Hex Head Bolt, with 3/8 lock washer and 3/8 flat washer. QTY 4 of each required. Torque to 20 lb-ft

Use the tables below to determine enclosure size and frame size based on voltage and horsepower. Enclosure dimensions differ between Type 1 IntelliDisconnect, Type 1 IntelliPass, Type 3R IntelliDisconnect, Type 3R IntelliPass, Type 1 Micro Disconnect.

lifting cables and the vertical plane

●

Do not pass ropes or cables through the lifting eyes as sharp edges may cause excessive wear and possible failure

●

Select or adjust rigging lengths to compensate for unequal weight distribution of the load to keep unit in the upright position

Table 5. Enclosure size and frame size based on voltage and horsepower (208/230 V)

hp Base drive Type 1 disconnect Type 1 bypass Type 3R disconnect Type 3R bypass

1 FS4 A1-4 B1-4 C1-4 D1-4

2 FS4 A1-4 B1-4 C1-4 D1-4

3 FS4 A1-4 B1-4 C1-4 D1-4

5 FS5 A1-5 B1-5 C1-5 D1-5

7.5 FS5 A2-5 B2-5 C2-5 D2-5

10 FS5 A2-5 B2-5 C2-5 D2-5

15 FS6 A3-6 B3-6 C3-6 D3-6

20 FS6 A3-6 B3-6 C3-6 D3-6

25 FS7 A4-7 B4-7 C4-7 D4-7

30 FS7 A4-7 B4-7 C4-7 D4-7

40 FS7 A4-8 B4-8 C4-8 D4-8

50 FS8 A6-8 B6-8 C6-8 D6-8

60FS8————

75FS8————

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 13

Dimensions and mounting

Table 6. Enclosure size and frame size based on voltage and horsepower (480 V)

hp Base drive Type 1 disconnect Type 1 bypass Type 3R disconnect Type 3R bypass

1 FS4 A1-4 B1-4 C1-4 D1-4

2 FS4 A1-4 B1-4 C1-4 D1-4

3 FS4 A1-4 B1-4 C1-4 D1-4

5 FS4 A1-4 B1-4 C1-4 D1-4

7.5 FS4 A1-4 B1-4 C1-4 D1-4

10 FS5 A2-5 B2-5 C2-5 D2-5

15 FS5 A2-5 B2-5 C2-5 D2-5

20 FS5 A3-5 B3-5 C3-5 D3-5

25 FS6 A3-6 B3-6 C3-6 D3-6

30 FS6 A3-6 B3-6 C3-6 D3-6

40 FS6 A4-6 B4-6 C4-6 D4-6

50 FS7 A4-7 B4-7 C4-7 D4-7

60 FS7 A4-7 B4-7 C4-7 D4-7

75 FS7 A4-7 B4-7 C4-7 D4-7

100 FS8 A5-8 B5-8 C5-8 D5-8

125 FS8 A6-8 B6-8 C6-8 D6-8

Table 7. Type 1 Micro Disconnect

hp 208/230 V 480 V

0.5 M1-1 M1-1

0.75 M1-2 M1-1

1 M1-2 M1-1

1.5 M1-2 M1-2

2— M1-2

14 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 14. Type 1 IntelliDisconnect dimensions

Dimensions and mounting

Table 8. Type 1 IntelliDisconnect dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size H H1 W W1 D D1

Weight in lb (kg)

A1-4 20.61 (523.5) 19.75 (501.7) 8.65 (219.7) 6.75 (171.5) 10.40 (264.2) 8.96 (227.6) 34 (15)

A1-5 30.00 (762.0) 29.00 (736.6) 8.65 (219.7) 6.75 (171.5) 11.18 (284.0) 9.74 (247.4) 54 (25)

A2-5 30.00 (762.0) 29.00 (736.6) 8.65 (219.7) 6.75 (171.5) 11.18 (284.0) 9.74 (247.4) 54 (25)

A3-5 20.61 (523.5) 19.75 (501.7) 8.65 (219.7) 6.75 (171.5) 10.40 (264.2) 8.96 (227.6) 54 (25)

A3-6 32.50 (825.5) 31.50 (800.1) 10.40 (264.2) 7.50 (190.5) 11.41 (289.8) 9.97 (253.2) 101 (46)

A4-6 41.03 (1042.2) 39.50 (1003.3) 12.40 (315.0) 10.50 (266.7) 13.67 (347.2) 11.97 (304.0) 113 (51)

A4-7 41.55 (1055.4) 39.50 (1003.3) 12.40 (315.0) 10.50 (266.7) 13.94 (354.1) 12.25 (311.2) 200 (91)

A4-8 44.04 (1118.6) 39.50 (1003.3) 12.00 (304.8) 10.50 (266.7) 15.86 (402.8) 14.17 (359.9) 363 (165)

A5-8 44.05 (1118.9) 42.06 (1068.3) 12.00 (304.8) 10.50 (266.7) 15.86 (402.8) 14.17 (359.9) 363 (165)

A6-8 47.65 (1210.3) 46.50 (1181.1) 16.00 (406.4) 14.50 (368.3) 15.86 (402.8) 14.17 (359.9) 363 (165)

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 15

Dimensions and mounting

Figure 15. Type 1 IntelliDisconnect knockout dimensions

Table 9. Type 1 IntelliDisconnect knockout dimensions

Approximate dimensions in inches (mm)

Enclosure sizeABCDE FG

A1-4 1.12 (28.4) 3.74 (95.0) 4.24 (17.7) 4.77 (121.2) 6.27 (159.3) 7.77 (197.4) 0.875 1.109 & 0.875

A1-5 1.12 (28.4) 3.74 (95.0) 4.24 (17.7) 5.55 (141.0) 7.05 (179.1) 8.55 (217.2) 0.875 1.109 & 0.875

A2-5 1.12 (28.4) 3.74 (95.0) 4.24 (17.7) 5.55 (141.0) 7.05 (179.1) 8.55 (217.2) 0.875 1.109 & 0.875

A3-5 1.12 (28.4) 3.74 (95.0) 4.24 (17.7) 4.77 (121.2) 6.27 (159.3) 7.77 (197.4) 0.875 1.375 & 1.109

A3-6 1.00 (25.4) 3.63 (92.2) 5.03 (127.8) 5.79 (147.1) 7.29 (185.2) 8.79 (223.3) 0.875 1.375 & 1.109

A4-6 1.55 (39.4) 1.55 (39.4) 7.67 (194.8) 5.99 (152.1) 7.74 (196.6) 9.24 (234.7) 10.74 (272.8) 0.875 1.735 & 1.375

A4-7 1.55 (39.4) 1.55 (39.4) 7.67 (194.8) 6.27 (159.3) 8.02 (203.7) 9.52 (241.8) 11.02 (280.0) 0.875 1.735 & 1.375

A4-8 2.47 (62.7) 3.47 (88.1) 8.47 (215.1) 5.96 (151.4) 9.58 (243.3) 11.08 (281.4) 12.58 (319.5) 0.875 1.735 & 1.375

A5-8 2.53 (64.3) 3.53 (89.7) 8.53 (216.7) 5.96 (151.4) 9.58 (243.3) 11.08 (281.4) 12.58 (319.5) 0.875 1.984 & 1.734

A6-8 4.53 (115.1) 5.53 (140.5) 10.53 (267.5) 5.96 (151.4) 9.58 (243.3) 11.08 (281.4) 12.58 (319.5) 0.875 1.984 & 1.734

Conduit 1, 2 & 3

Conduit 4 & 5

16 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 16. Type 1 IntelliPass dimensions

Dimensions and mounting

Table 10. Type 1 IntelliPass dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size H H1 W W1 D D1

Weight in lb (kg)

B1-4 23.00 (584.2) 21.75 (552.5) 16.28 (413.5) 14.75 (374.7) 15.70 (398.8) 14.26 (362.2) 64 (29)

B1-5 23.00 (584.2) 21.75 (552.5) 16.28 (413.5) 14.75 (374.7) 15.70 (398.8) 14.26 (362.2) 88 (40)

B2-5 30.00 (762.0) 29.00 (736.6) 16.28 (413.5) 14.75 (374.7) 15.70 (398.8) 14.26 (362.2) 88 (40)

B3-5 31.50 (800.1) 30.50 (774.7) 19.13 (485.9) 17.75 (450.9) 15.70 (398.8) 14.26 (362.2) 88 (40)

B3-6 31.50 (800.1) 30.50 (774.7) 19.13 (485.9) 17.75 (450.9) 15.70 (398.8) 14.26 (362.2) 145 (66)

B4-6 39.50 (1003.3) 38.25 (971.6) 30.13 (765.3) 28.75 (730.3) 17.42 (442.5) 15.73 (399.5) 158 (72)

B4-7 42.75 (1085.9) 38.25 (971.6) 30.13 (765.3) 28.75 (730.3) 17.42 (442.5) 15.73 (399.5) 262 (119)

B4-8 42.90 (1089.7) 38.25 (971.6) 30.13 (765.3) 28.75 (730.3) 17.42 (442.5) 15.73 (399.5) 455 (207)

B5-8 44.00 (1117.6) 42.75 (1085.9) 33.13 (841.5) 31.75 (806.5) 17.42 (442.5) 15.73 (399.5) 455 (207)

B6-8 44.00 (1117.6) 42.75 (1085.9) 33.13 (841.5) 31.75 (806.5) 17.42 (442.5) 15.73 (399.5) 455 (207)

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 17

Dimensions and mounting

Figure 17. Type 1 IntelliPass knockout dimensions

Table 11. Type 1 IntelliPass knockout dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size A B C D Conduit 1 Conduit 2 Conduit 3

B1-4 1.75 (44.5) 4.75 (120.7) 7.75 (196.9) 9.70 (246.4) 1.109 1.109 1.375 & 1.109

B1-5 1.75 (44.5) 4.75 (120.7) 7.75 (196.9) 9.70 (246.4) 1.109 1.109 1.375 & 1.109

B2-5 1.75 (44.5) 4.75 (120.7) 7.75 (196.9) 9.78 (248.4) 1.109 1.109 1.375 & 1.109

B3-5 2.13 (54.1) 5.13 (130.3) 8.13 (206.5) 9.78 (248.4) 1.109 1.109 1.984 & 1.109

B3-6 2.13 (54.1) 5.13 (130.3) 8.13 (206.5) 9.78 (248.4) 1.109 1.109 1.984 & 1.109

B4-6 6.15 (156.2) 10.15 (257.8) 14.00 (255.6) 10.26 (260.6) 1.109 1.109 1.964 & 1.109

B4-7 6.15 (156.2) 10.15 (257.8) 14.00 (255.6) 10.26 (260.6) 1.109 1.109 1.964 & 1.109

B4-8 6.15 (156.2) 10.15 (257.8) 14.00 (255.6) 10.26 (260.6) 1.109 1.109 1.964 & 1.109

B5-8 6.09 (154.7) 11.09 (281.7) 16.09 (408.7) 10.11 (256.8) 1.375 2.469 & 1.984 2.469 & 1.984

B6-8 6.09 (154.7) 11.09 (281.7) 16.09 (408.7) 10.11 (256.8) 1.375 2.469 & 1.984 2.469 & 1.984

Enclosure size— drive frame size E F G H Conduit 4 Conduit 5 Conduit 6

B1-4 1.83 (46.5) 4.83 (122.7) 7.83 (198.9) 10.26 (260.6) 1.109 1.109 1.375 & 1.109

B1-5 1.83 (46.5) 4.83 (122.7) 7.83 (198.9) 10.26 (260.6) 1.109 1.109 1.375 & 1.109

B2-5 1.75 (44.5) 4.75 (120.7) 7.75 (196.9) 9.78 (248.4) 1.109 1.109 1.375 & 1.109

B3-5 2.13 (54.1) 5.13 (130.3) 8.13 (206.5) 9.78 (248.4) 1.109 1.109 1.984 & 1.109

B3-6 2.13 (54.1) 5.13 (130.3) 8.13 (206.5) 9.78 (248.4) 1.109 1.109 1.984 & 1.109

B4-6 6.09 (154.7) 10.08 (256.0) 14.00 (255.6) 10.11 (256.8) 1.109 1.109 1.964 & 1.109

B4-7 6.09 (154.7) 10.08 (256.0) 14.00 (255.6) 10.11 (256.8) 1.109 1.109 1.964 & 1.109

B4-8 6.09 (154.7) 10.08 (256.0) 14.00 (255.6) 10.11 (256.8) 1.109 1.109 1.964 & 1.109

B5-8 6.09 (154.7) 11.09 (281.7) 16.09 (408.7) 10.11 (256.8) 1.375 2.469 & 1.984 2.469 & 1.984

B6-8 6.09 (154.7) 11.09 (281.7) 16.09 (408.7) 10.11 (256.8) 1.375 2.469 & 1.984 2.469 & 1.984

18 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 18. Type 3R IntelliDisconnect dimensions

Dimensions and mounting

Table 12. Type 3R IntelliDisconnect dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size H H1 H2 H3 H4 H5 W W1 D D1

C1-4 22.79

(578.9)

C1-5 22.79

(578.9)

C2-5 29.79

(756.7)

C3-5 31.72

(805.7)

C3-6 31.72

(805.7)

C4-6 53.67

(1363.2)

C4-7 53.67

(1363.2)

C4-8 53.67

(1363.2)

C5-8 53.67

(1363.2)

C6-8 53.67

(1363.2)

3.75 (95.25)

4.10 (104.1)

0.70 (17.78)

3.37 (85.6)

1.87 (47.5)

2.20 (55.9)

11.25 (285.8)

14.10 (358.1)

9.87 (250.7)

12.87 (326.9)

11.87 (301.5)

13.95 (354.3)

18.75 (476.25)

24.10 (612.1)

19.03 (483.4)

22.37 (568.2)

21.87 (555.5)

25.70 (652.8)

— — 15.13

(384.3)

— — 15.13

(384.3)

-— — 15.13 (384.3)

28.20

(716.3)

28.20

(716.3)

31.87

(809.5

31.87

(809.5)

31.87

(809.5)

31.87

(809.5)

37.45

(951.2)

— 18.13

-— 18.13

41.37

)

(1050.8)

41.37 (1050.8)

49.20 (1249.7)

(460.5)

17.63 (447.8

17.63 (447.8)

21.38 (543.1)

22.88 (581.2)

14.19 (360.4)

17.19 (436.6)

16.61

)

(421.9)

16.61 (421.9)

20.36 (517.1)

21.86 (555.2)

14.24 (361.7)

16.11 (409.2)

18.11 (460.0)

21.11 (539.2)

11.48 (291.6)

13.36 (339.3)

15.36 (390.1)

18.36 (466.3)

Weight in lb (kg)

46 (21)

63 (29)

66 (30)

113 (51)

128 (58)

226 (103)

378 (172)

405 (184)

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 19

Dimensions and mounting

Figure 19. Type 3R IntelliDisconnect knockout dimensions

Table 13. Type 3R IntelliDisconnect knockout dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size A B C D Conduit 1 Conduit 2 Conduit 3

C1-4 4.99 (126.7) 7.99 (202.9) 10.99 (279.1) 6.07 (154.2) 1.375 & 1.109 1.109 1.109

C1-5 4.99 (126.7) 7.99 (202.9) 10.99 (279.1) 6.07 (154.2) 1.375 & 1.109 1.109 1.109

C2-5 4.99 (126.7) 7.99 (202.9) 10.99 (279.1) 6.57 (166.9) 1.375 & 1.109 1.109 1.109

C3-5 7.99 (202.9) 10.99 (279.1) 13.99 (355.3) 6.57 (166.9) 1.109 1.109 1.734 & 1.109

C3-6 7.99 (202.9) 10.99 (279.1) 13.99 (355.3) 6.57 (166.9) 1.109 1.109 1.734 & 1.109

C4-6 6.49 (164.8) 9.49 (241.0) 12.49 (317.2) 7.58 (192.5) 1.984 & 1.109 1.109 1.109

C4-7 6.49 (164.8) 9.49 (241.0) 12.49 (317.2) 7.58 (192.5) 1.984 & 1.109 1.109 1.109

C4-8 6.49 (164.8) 9.49 (241.0) 12.49 (317.2) 7.58 (192.5) 1.984 & 1.109 1.109 1.109

C5-8 6.24 (158.5) 10.74 (272.8) 15.24 (387.1) 8.08 (205.2) 2.469 & 1.948 2.469 & 1.948 1.375

C6-8 7.74 (196.6) 12.24 (310.9) 16.74 (425.2) 11.08 (281.4) 2.469 & 1.984 2.469 & 1.984 1.375

20 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 20. Type 3R IntelliPass dimensions

Dimensions and mounting

Table 14. Type 3R IntelliPass dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size H H1 H2 H3 H4 H5 W W1 D D1

D1-4 22.87

(580.9)

D1-5 22.87

(580.9)

D2-5 22.87

(580.9)

D3-5 30.74

(780.8)

D3-6 30.74

(780.8)

D4-6 48.67

(1236.2)

D4-7 48.67

(1236.2)

D4-8 48.67

(1236.2)

D5-8 48.67

(1236.2)

D6-8 50.17

(1274.3)

1.25 (31.8)

1.00 (25.4)

3.25 (82.6)

1.75 (44.5)

2.00 (50.8)

8.75 (222.3)

8.50 (215.9)

13.25 (336.6)

10.25 (260.4)

11.50 (292.1)

13.00 (330.2)

16.25 (412.8)

16.00 (406.4)

23.25 (590.6)

18.75 (476.3)

21.00 (533.4)

24.00 (609.6)

— — 18.13

(460.5)

— — 18.13

(460.5)

— — 18.13

(460.5)

— — 21.13

(536.7)

— — 21.13

(536.7)

27.25

(692.2)

27.25

(692.2)

27.25

(692.2)

30.50

(774.7)

35.00

(889.0)

35.75 (908.1)

40.00 (1016.0)

46.00 (1168.4)

28.13 (714.5

28.13 (714.5)

32.13 (816.1)

17.19 (436.6)

20.19 (512.8)

27.11

)

(688.6)

27.11 (688.6)

31.19 (792.2)

17.23 (437.6)

18.11 (460.0)

22.11 (561.6)

14.48 (367.8)

15.36 (3

90.1)

15.36 (390.1)

19.36 (491.7)

Weight in lb (kg)

80 (36)

104 (47)

164 (74)

183 (83)

291 (132)

485 (220)

526 (239)

532 (242)

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 21

Dimensions and mounting

Figure 21. Type 3R IntelliPass knockout dimensions

Table 15. Type 3R IntelliPass knockout dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size A B C D Conduit 1 Conduit 2 Conduit 3

D1-4 4.06 (103.1) 7.06 (179.3) 10.06 (255.5) 9.62 (244.3) 1.109 1.109 1.375 & 1.109

D1-5 4.06 (103.1) 7.06 (179.3) 10.06 (255.5) 9.62 (244.3) 1.109 1.109 1.375 & 1.109

D2-5 4.06 (103.1) 7.06 (179.3) 10.06 (255.5) 9.62 (244.3) 1.109 1.109 1.375 & 1.109

D3-5 4.06 (103.1) 7.06 (179.3) 10.06 (255.5) 9.62 (244.3) 1.109 1.109 1.375 & 1.109

D3-6 4.06 (103.1) 7.06 (179.3) 10.06 (255.5) 9.62 (244.3) 1.109 1.109 1.375 & 1.109

D4-6 6.06 (153.9) 10.56 (268.2) 15.06 (382.5) 11.13 (282.7) 1.109 1.109 1.984 & 1.109

D4-7 6.06 (153.9) 10.56 (268.2) 15.06 (382.5) 11.13 (282.7) 1.109 1.109 1.984 & 1.109

D4-8 6.06 (153.9) 10.56 (268.2) 15.06 (382.5) 11.13 (282.7) 1.109 1.109 1.984 & 1.109

D5-8 6.06 (153.9) 10.56 (268.2) 15.06 (382.5) 11.13 (282.7) 1.375 2.469 & 1.984 2.469 & 1.984

D6-8 6.06 (153.9) 10.56 (268.2) 15.06 (382.5) 11.13 (282.7) 1.375 2.469 & 1.984 2.469 & 1.984

22 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 22. Type 1 Micro Disconnect dimensions

Dimensions and mounting

Table 16. Type 1 Micro Disconnect dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size H H1 W W1 D D1

Weight in lb (kg)

M1-1 19.78 (502.4) 19.03 (483.4) 9.59 (243.6) 5.25 (133.4) 8.61 (218.7) 7.19 (182.6) 13.9 (6.3)

M1-2 19.78 (502.4) 19.03 (483.4) 9.59 (243.6) 5.25 (133.4) 8.61 (218.7) 7.19 (182.6) 15.4 (7.0)

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 23

Dimensions and mounting

Figure 23. Type 1 Micro Disconnect knockout dimensions

Table 17. Type 1 Micro Disconnect knockout dimensions

Approximate dimensions in inches (mm)

Enclosure size— drive frame size A B C D E F Conduit 1, 2, 3 & 4

M1-1 4.28 (108.7) 5.78 (146.8) 3.28 (83.3) 3.78 (96.0) 4.78 (121.4) 7.90 (200.7) 1.125 & 0.875

M1-2 4.28 (108.7) 5.78 (146.8) 3.28 (83.3) 3.78 (96.0) 4.78 (121.4) 7.90 (200.7) 1.125 & 0.875

24 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Wiring

Wiring schematic

A schematic is included with each product. The schematic number can be found on the product nameplate.

Typical schematics are shown on the next few pages.

Notes

●

Power and motor leads must be in separate conduit

●

Do not run control wires in same conduit as input power or motor wires

●

Two grounding points are provided, input ground and output ground

●

Ground unit properly – improper grounding could damage the unit

Wiring

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 25

Wiring

Figure 24. Type 1 IntelliDisconnect

26 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 25. Type 1 IntelliPass

Wiring

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 27

Wiring

Figure 26. Type 3R IntelliDisconnect

28 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Figure 27. Type 3R IntelliPass

Wiring

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 29

Wiring

Figure 28. Type 1 Micro Disconnect

30 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Wiring

Conduit plates

There are removable top and bottom conduit plates on drives frames size 8 on designations A4, A5, and A6 (Type 1 IntelliDisconnect) configurations to allow for easier wiring and conduit connections.

Input power wiring

Input power connection are made to the disconnect device. Input power connection points are identified by Label (L1, L2, and L3).

Both the IntelliDisconnect and IntelliPass systems provide an input disconnect by using a UL Listed, R9 rotary disconnect fusible or non-fusible as indicated below. These devices provide a disconnect function and branch protection. In non-fusible systems, the disconnect is paired with fused for short circuit protections.

Figure 29. Lower frame incoming lines

Figure 30. Larger frame incoming lines

Input wiring details

Table 18. Input wiring

Voltage hp Wire range Torque (lb-in)

Non-fused disconnect type

208/230 V 1–5 #14–#10 25

7.5–10 #14–#10 28

15–20 #12–2/0 35

25 #6–300 kcmil 160

30–40 #6–300 kcmil 160

480 V 1–15 #14–#10 25

20–30 #14–#10 28

40–125 #6–300 kcmil 160

Fused disconnect type

208/230 V 1–5 #14–#10 25

7.5–10 #14–#10 28

15–20 #12–2/0 35

25 #12–#1 35

30–40 #6–3/0 200

480 V 1–15 #14–#10 25

20–30 #14–#10 28

40–125 #6–3/0 200

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 31

Wiring

Motor wiring

Motor connection points are identified by a label (T1, T2, and T3). See output wiring table in technical section for wiring and torque information. For IntelliDisconnect models, the motor wiring is direct to the drive output terminals. For IntelliPass models, the motor wiring is directly to the output of the overload protection relay on the bypass contactor.

Figure 31. IntelliDisconnect motor wiring

Figure 32. IntelliPass motor wiring

Table 19. Output wiring details—IntelliDisconnect

Voltage hp Drive frame size Torque (lb-in)

208/230 V 1–3 4 4.5

5–10 5 11

15–20 6 35

25–30 7 88

40–50 8 170

480 V 1–7.5 4 4.5

10–20 5 11

25–40 6 35

50–75 7 88

100–125 8 170

Micro

208/230/480 V 0.5–2 FS1 / FS2 4.5

Table 20. Output wiring details—IntelliPass

Voltage hp Torque (lb-in)

208/230 V 1–3 15

5–10 15

15–20 28

25–50 90

480 V 1–7.5 15

10–20 15

25–40 28

50–125 90

32 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Wiring

Ground wiring

Ground studs are provided and marked with label. Hardware is also supplied.

Figure 33. Typical ground stud and label

Frames 1 through 5 have ground lugs supplied for wire size 14 to 2/0.

Frame 6 with drive frame size 8 has ground lugs supplied for wire size 3/0.

Control wiring

All customer wiring points are supplied on a terminal block strip. This terminal strip allows easy access to the drives control terminals and auxiliary contacts. The control I/O terminals must be tightened to 4.5 lb (0.5 Nm). Please see table below for terminal block designation.

Figure 34. Terminal block access

Table 21. Terminal block designation

Terminal block Description

AI1 Analog Input Voltage (Range 0–10 Vdc)–2

COM Analog Input Common–3

AO1 Output Frequency–18

COM (AGND) Analog Output–19

SHD GND–7

15 Safety 3

16 Safety 3–Run Permissive IP Interlock–10

25 RO3 Drive Fault Output–32

27 RO3 Drive Fault Output–33

2 Run/Time Clock Start/Stop Command

3 Run/Time Clock Start/Stop Command

4 Electronic Bypass connection points

5 Electronic Bypass connection points

6 Electronic Bypass connection points

7 Safety 1 and 2 connection points

8 Safety 1 and 2 connection points

9 Safety 1 and 2 connection points

22 Drive Contactor (Run Output)–53

24 Drive Contactor (Run Output)–54

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 33

Initial startup

When the IntelliPass or IntelliDisconnect is first powered up, the Startup Wizard command should be displayed.

Figure 35. Startup Wizard prompt

Follow the Quick Setup guide LIT-12011773 to set up drive for your specific application with the following exceptions: When the Bypass screen appears, set it to “Enabled” for IntelliPass models and “Disabled” for IntelliDisconnect models.

Figure 36. Enable bypass for IntelliPass models

IntelliDisconnect operation (starting/stopping of the motor)

IntelliDisconnect operation is the identical to a standard JCI-VSD Series II open drive. The only difference is that an input disconnect is provided. For more information on speed control and other drive features, see Application Manual LIT-12011771. See option sections for more information on operation of IntelliDisconnect options, i.e., drive output contactor.

IntelliPass operation (starting/stopping of the motor)

The IntelliPass operation is similar to the IntelliDisconnect but has the added feature of a built-in drive bypass. This section gives basic information on operations for controlling the starting and stopping of the motor in both the drive and bypass modes. For more information on speed control and other drive features, see Application Manual LIT-12011771.

The IntelliPass has 2 modes:

●

Drive mode (normal VFD operation)

●

Bypass mode (across the line)

The mode is selected via the keypad. The actual starting and stopping of the motor is determined by the HOA selection and the control place selections. The control place is defined as the location from where the drive is started and stopped. The control place can be: keypad start button, I/O contacts wired to the logic terminal blocks, Fieldbus control or PC. See Quick Start Guide LIT-12011775 or Application Manual LIT-12011771 for more information.

The only exception is the use of the drive—bypass 3-position switch for manual operation. This will override the drive logic and can start the motor in Bypass immediately.

Switch operation

Figure 37. Disable bypass for IntelliPass models

34 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

HOA switch

Auto position = the drive will follow a run command from the runtime clock wired to terminal block 2 and 3.

Hand position = this will force a run command to the drive. This is true in both bypass and drive mode.

VFD- OFF-BYP

VFD position = the drive will run in normal drive operation.

BYP position = the drive will go into bypass mode. The bypass contactor will close and the drive contactor will open.

When in the VFD position, the bypass can be selected electronically from the keypad or from external communications such as SA Bus.

Initial startup

Drive mode

When the IntelliPass is in the drive mode, the text “E-Energy” is shown on status bar. (If E-Energy function is not active, the text “Ready” will be shown.)

Figure 38. Keypad shown in drive mode

When the system is first commanded to run, the output contactor M is energized and the motor is connected to the drive. The “M” contactor is controlled by the IntelliPass logic via Relay 2 output. The “M” contactor will always be energized while the VFD-OFF-BYP switch is in the VFD position unless the bypass command is electronic. The speed of the motor is determined by the speed set point of the JCI-VSD Series II Drive. When the JCI-VSD Series II is commanded to stop, the drive will reduce the speed of the motor and when the motor speed reaches zero, the output contactor “M” is de-energized and the motor is disconnected from the IntelliPass. The output contactor also opens immediately if there is a drive fault.

The IntelliPass system is also interlocked. When the output contact “M” is energized, the bypass contactor “B” is prevented from being energized by electrical interlocks in each contactor coil control circuit and a logic interlock built in to the IntelliPass software.

Bypass mode

When the IntelliPass is in the bypass mode, the text “Bypass” is shown on status bar. When bypass is selected electronically, if selected via the VFD-OFF-BYP switch, the drive will not be ready. “E-Energy” will be flashing.

Figure 39. Keypad shown in bypass mode

When the system is commanded to run in the bypass mode, the motor is connected to the line through the bypass contactor (B). The “B” contactor is controlled by the drive logic via a Relay 1 output.

The bypass mode can be selected in 3 ways:

●

Manually via the drive logic controls (i.e., keypad, fieldbus, or I/O)

●

Automatically after a drive fault; if the auto bypass feature is active

●

Manually by a door switch; manually using the manual bypass switch

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 35

Initial startup

Manual bypass

Manual bypass can be activated either by using the bypass button on the keypad, by using a digital input on the control terminal block or from the fieldbus. The user can toggle between bypass and drive modes by pressing the keypad bypass button or the terminal block inputs. Once in the bypass mode, the start command can be given through any control place (I/O, keypad, and fieldbus) in the same manner as starting in the drive mode.

Using the keypad to select bypass mode

When the bypass button is pressed, the following options are shown to the user. Select the desired mode by using the arrow keys and pressing the OK key.

Figure 40. Keypad with bypass and drive mode option

Figure 41. Keypad shown in run mode

Figure 42. Keypad already in bypass mode

The user can toggle between modes by pressing the bypass button again. If bypass button is pressed while the drive is running, the keypad will display “Bypass is not allowed”. The system must be stopped to allow a change from drive to bypass mode. Likewise if the system is running in bypass and the bypass key is pressed, the display will indicate “Motor Running in Bypass.” To change state back to drive, the system must be stopped. The keypad will display bypass in the status display when in the bypass mode and ready or E-Energy when in the drive mode.

Using the digital input to select bypass

If the digital input (Force Bypass) is used to enable the

bypass mode, the drive will ramp to zero speed. Once the

drive stops, the bypass mode is active and the keypad will display the bypass mode. The bypass and motor will start when a valid start command is received. Note that the Force Bypass function is the factory default for Digital Input #6 P2.3.6.2 located at TB16 on the control module and is also factory wired to the M1 Manual Bypass option if supplied.

mode

Using the fieldbus to select bypass mode

The fieldbus command works the same as the digital input.

36 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Initial startup

Auto bypass operation

The drive can also be bypassed automatically if certain faults occur. When the selected fault occurs, the drive is first stopped. Then, depending on the automatic reset parameter, the drive is either bypassed instantly or the fault is first tried to reset. If the reset fails, the motor is automatically started in bypass.

Figure 43. Parameter menu for automatic reset

Figure 44. Menu selecting auto bypass

Figure 45. Menu selecting reset/bypass

When the drive goes to auto bypass, the keypad displays “Going into Auto Bypass” for 10 seconds. After the delay, the drive goes to the bypass mode and starts the motor (the run command must still be present). When the fault condition is not active, the drive is set back to drive mode automatically and the bypass running signal is reset. The drive returns to the normal operation.

Figure 46. Displaying going into auto bypass after fault

Automatic reset selections

0 = Not used

1 = Auto Bypass (Visible only if Bypass is enabled)

2 = Reset faults

3 = Reset/Bypass (Visible only if Bypass is enabled)

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 37

Initial startup

Activate the automatic reset functions with this parameter

For option 1, if the drive faults, the drive switches automatically to bypass and leaves the fault active on the drive. For option 3, the drive will first try to auto reset the faults but if not successful, it will then switch to bypass. Option 2 just tries to reset the fault without going into bypass. See the application manual for more information on auto reset operation.

Manual bypass (forced)

The IntelliPass also has a forced manual bypass option. This is controlled by a door mounted Drive / Off / Bypass switch. The door switch will start the motor in bypass following the HOA switch run commands. Switch to the Hand position to start bypass immediately. This switch manually overrides the system (keypad) and forces the unit into bypass mode even if the drive is in operative or removed from the system.

HOA control

The keypad HOA button is used for fast and easy changing between Hand, Off and Auto control places to change the speed set point source. HOA control works in both the drive and bypass modes of operation. However, speed set point has no functions when in bypass because the motor runs full speed across the line. The drive should remain in Auto mode during normal operation.

There are four parameters for selecting a control source and reference source for them: P2.1.3 HOA Control Source, P2.1.4 Start Source Hand, P2.1.5 Speed Set point Hand, P2.1.6 Start Source Auto & P2.1.7 Speed Set point Auto. The Start Source selections are: Keypad, I/O Terminal, I/O 3-wire & Fieldbus Ctrl. For the drive mode, the Speed set point the selections are: Keypad Ref, Fieldbus, AI1, AI2, AI1+AI2, & PID1 (if PID is activated). See Quick Start Guide LIT-12011773 or Application Manual LIT-12011771 for more information.

When control place Off is selected, the drive cannot be started anywhere. It prohibits the start command for both drive and bypass. Bypass may force started in the HOA off mode by using the door switch.

Figure 48. Off menu selection

Figure 47. Hand/Off/Auto parameter

Control place is defined as the location from where the drive or bypass is started and stopped. Hand and auto are two different control places.

Figure 49. Monitoring menu in STOP mode

38 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Key parameters related to proper IntelliPass bypass operation

The following parameters are related to Bypass functionality and are factory default set. Changing them will affect proper IntelliPass operation.

●

P2.1.2 Bypass: This parameter is for activating the bypass functionality. It is factory enabled. If disabled, the Bypass keypad button is inactive and some parameters may be hidden. This is part of the Startup Wizard.

●

P2.3.2.2.1 (RO1 Function) set to Bypass Run. This signal is active if the bypass mode has been selected and the run command is active—this relay output controls the bypass contactor it should not be changed.

●

P2.3.2.2.5 (RO2 Function) set to Run. This signal is active if the drive mode has been selected and the run command is active—this relay output controls the output contactor and should not be changed.

SA bus operation and setup

Initial startup

Wiring SA bus

Wire the SA bus as shown below.

If this is the last device on the line, set the X4 termination resistor to ON.

Table 22. SA bus setup

SA bus terminal Wire Color

3SA– Black

4SA+ Blue

5 Common White

N/C SA Power Red

Figure 50. JC-VSD Series II drive SA bus interface card VS-XMX-CS

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 39

Initial startup

Programming

1. Ensure the correct fieldbus protocol is selected. a. Navigate: P4.4.3.1 b. Main Menu R I/O Hardware R OPTCS R Parameters R Comm. Protocol

2. Set the slave address. a. Navigate: P4.4.3.2 b. Main Menu R I/O Hardware R OPTCS R Parameters R Slave Address

3. Set the Start Source Auto to “Fieldbus.” a. Navigate: P2.1.6 b. Main Menu R Parameters R Basic Parameters R StartSourceAuto

4. Set the Speed Set Point Auto to “Fieldbus.” a. Navigate: P2.1.7 b. Main Menu R Parameters R Basic Parameters R SpeedSetptAuto

40 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Control

1. To run the VSD in drive mode, write a 1 to VSD-C and a speed reference in percent to VSD-O.

2. To run in bypass mode, write a 1 to VSD-BYPASS and a 1to VSD-C.

Table 23. Object list

Object name

VSD-C VSD-O VSD-S

VSD-BYPASS VSD-RESET

VSD-KWH VSD-SPEED VSD-FREQ VSD-% VSD-HOA VSD-FAULT

Object description Port function NetDeviceRefAttrID I/O Units States text Set members

VSD Command VSD Output VSD Status

VSD Bypass Drive VSD Reset Drive Fault

VSD Kilowatt Hours VSD Motor Speed VSD Output Frequency VSD Speed Feedback VSD Control Mode VSD Fault Code

Run/Stop Output Status

Bypass Enable Reset Drive Fault

Kilowatt Hours Motor Speed Frequency Speed Setpoint Control Mode Fault Code

Drive Command Reference Command Drive Running

Bypass Enable Reset Drive Fault

Kilowatt Hours Motor Speed Output Frequency Speed Setpoint Control Mode Fault Code

Output Output Input

Output Output

Input Input Input Input Input Input

kWh rpm Hz %

Off/On

Inactive/Active Off/Reset

Hand Off Auto Drive Fault

Initial startup

0=Off, 1=On

0=Inactive, 1=Active 0=Off, 1=Reset

0=Hand, 1=Off, 2=Auto 0=No Fault 1=Over Current 2=Over Voltage 3=Ground Fault 4=Bypass Overload 5=Charging Switch 6=Emergency Stop 7=Saturation Trip 8=System Fault 9=Under Voltage 10=Input Line Supervision 11=Output Phase Supervision 12=System Fault 13=Drive Heatsink Under Temp 14=Drive Heatsink Over Temp 15=Motor Stalled 16=Motor Overload Temp 17=Motor Underload 18=External Fault 19=Comm Bus Fault 20=Drive Fault

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 41

IntelliPass/IntelliDisconnect technical information

See JCI-VSD Series II Installation Manual LIT-12011775 for additional data.

●

Enclosure: Type 1 or Type 3R as ordered

●

Max. Ambient Temp: 40 °C

●

Wire temperature rating of field installed conductors: use 75 °C copper conductors only

Table 24. Short-circuit rating

Frame Voltage Available current

4–8 208 Vac, 280 Vac,

480/277 Vac

100,000 A

42 Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com

Additional help

Website address

www.johnsoncontrols.com R HVAC Controls R Variable Speed Drives

Johnson Controls product sales operation

Call the Johnson Controls PSO Team if you need assistance with placing an order, stock availability or proof of shipment, expediting an existing order, emergency shipments, product price information and returns (including warranty returns).

Voice: 1-800-ASK-JNSN [275-5676] (US); 1-800-321-4023 (CA) FAX: 1-800-356-1191 (US); 1-800-321-4024 (CA)

Support Hours of Operation: Monday–Friday, 6:30 a.m.–5:30 p.m. CST (No evening or weekend Customer Service hours)

If you are in the U.S. or Canada, you can take advantage of our toll-free line for technical assistance. Technical support engineers are available for calls during regular business hours.

Johnson Controls Field Support Center 1-888-281-3792 Monday–Friday, 7:30 a.m.–5:30 p.m. CST email:CGFieldSupportCenter@jci.com

Additional help

Johnson Controls Variable Speed Drives LIT-12012114—July 2015 www.johnsoncontrols.com 43

Controls Group

507 E Michigan Street PO Box 423 Milwaukee, WI 53201

Eaton Technology

All trademarks are property of their respective owners.

Johnson Controls JC-VSD Factory Packaged (FP) Series II Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual