Johnson Controls VSD Series Quick Start Guide

November 2009

Eaton’s Technology

VSD Series Quick Start Guide

Open Drive

IMPORTANT: This guide is intended to provide a quick reference to

the VSD Series drive’s Application Software features for start-up, programming and service. It does not replace the need to thoroughly read and understand the User Manual.

Table of Contents

Description Page

NEMA Type 1/12 Open Drives (1 – 250 HP) . . . . . . . . . . . . . . 2

NEMA Type 1 IntelliPass/IntelliDisconnect Drive . . . . . . . . . 5

Enclosed NEMA Type 12/3R . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Appendix A — Main Control Board Wiring . . . . . . . . . . . . . 15

Appendix B — Interlock Damper Start Example

Using 4 – 20 mA Control Signal . . . . . . . . . . . . . . . . . . . 16

Appendix C — Interlock Damper Start Example

Using PID Duct Static Control Signal . . . . . . . . . . . . . . . 17

Appendix D — Bypass Wiring Diagram . . . . . . . . . . . . . . . . 18

Appendix E — Keypad Navigation . . . . . . . . . . . . . . . . . . . . 19

Appendix F — Main Menu Navigation . . . . . . . . . . . . . . . . . 20

Appendix G — Start-Up Wizard . . . . . . . . . . . . . . . . . . . . . . . 21

Appendix H — Static Checking . . . . . . . . . . . . . . . . . . . . . . . 25

Appendix I — Fault and Warning Codes . . . . . . . . . . . . . . . . 27

Bypass Drive

VSD Series Quick Start Guide

NEMA Type 12

General

Upon receipt of the unit, verify that the catalog number and unit options stated on the shipping container match those stated on the order/purchase form.

Inspect the equipment upon delivery. Report any carton damage to the carrier prior to accepting the delivery. Have this information noted on the freight bill. Johnson Controls is not responsible for damage incurred in shipping.

Unpacking

Remove all packing material from the unit. Be sure to remove all packing material from lug location. Also, make sure no packing material is left behind that would block the airﬂow to the fan.

Check the unit for any signs of shipping damage. If damage to the product is found after unpacking, report it to the freight company. Retain the packing materials for the carrier to review.

Storage

It is recommended that the unit be stored in its original shipping box/crate until it is to be installed.

The unit should be stored in a location where:

•

The ambient temperature is between -40°F and 158°F (-40°C and 70°C)

•

The relative humidity is between 0% and 95%, non-condensing

•

The environment is dry, clean, and non-corrosive

•

The unit will not be subjected to high shock or vibration conditions

NEMA Type 3R

Technical Support Phone Numbers

Branch: 800-281-3792 (Option 1)

Third Party (ABCS/DIST): 800-445-4757 (Option 1)

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Mandatory Ground Wiring (See Appendix D on Page 18)

Be sure to pull low impendance ground wiring from customer power to drive and ground wire from drive to motor.

Utility Drive Motor Ground

(Inside Motor Conduit Box)

VSD Series Quick Start Guide

NEMA Type 1/12 Open Drives (1 – 250 HP)

Table 1: Control Wiring Instructions

Mounting Drive

1. Mount Drive (See Table below for dimensions.)

VSD Series Open Drive Dimensions

Frame Size

FR4 230V 3/4 – 3 12.9

FR5 230V 5 – 7-1/2 16.5

FR6 230V 10 – 15 22.0

FR7 230V 20 – 30 24.8

FR8 480V 75 – 125 29.7

FR9

FR10 480V 250 – 350 44

Voltage hp (VT) Approximate Dimensions in Inches (mm) Weight

H1 H2 H3 D1 D2 D3 W1 W2 R1 dia. R2 dia.

480V 1 – 5

480V 7-1/2 – 15

480V 20 – 30

575V 2 – 25

480V 40 – 60

575V 30 – 40

575V

480V 150 – 200 45.3

575V 100 – 150

575V 200 – 300

50 – 75

(327)

(419)

(558)

(630)

(755)

(1150)

(1120)

12.3 (313)

16.0 (406)

21.3 (541)

24.2 (614)

28.8 (732)

44.1 (1120)

33.5 (850)

Power Wiring

Notice

Do not discard the plastic bag containing the wiring plate.

2. Remove the bottom cover by rotating the cover toward you on the base hinges, then lifting the cover away from the base.

11.5 (292)

15.4 (391)

20.4 (519)

23.3 (591)

28.4 (721)

— 14.3

— 23.6

7.5 (190)

8.4 (214)

9.3 (237)

10.1 (257)

11.3 (288)

(362)

(600)

Figure 1:

2.5 (64)

2.7 (68)

1.3 (34)

5.4 (137)

NA NA 23.6

5.0 (126)

5.8 (148)

6.7 (171)

7.5 (189)

11.0 (279)

8.8 (224)

5.0 (128)

5.7 (144)

7.7 (195)

9.3 (237)

11.2 (285)

18.9 (480)

(600)

W1 W2

3.9 (100)

5.8 (148)

7.5 (190)

10.0 (255)

15.7 (400)

16.7 (425).9(23)

.5 (13)

.7 (18)

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Knockouts

Lbs. (kg)

.3 (7)

.4 (9)

.47 (12)

11 (5)

17.9 (8.1)

40.8 (18.5)

77.2 (35)

127.8 (58)

321.9 (146)

550.7 (250)

Power Wiring

3. Locate the plastic bag shipped with the drive containing the wiring plate, and remove the wiring plate.

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NEMA Type 1/12 Open Drives (1 – 250 HP)

Table 1: Control Wiring Instructions (continued)

Power Wiring

4. If conduit is being used, attach the wiring plate to it.

5. Pass the motor and input power wires/cables through the holes of the wiring plate.

6. If shielded cable is used, connect the shields of the input line power cable and the motor cable to the motor and power ground terminals of the VSD Series drive.

Power Wiring/Grounding

7. Wire power terminals, motor terminals, and grounding terminals per diagram. Power and Motor leads must be in separate conduit.

Note: Do not wire motor loads to B- B+ R-. This will cause

damage.

VSD Series Quick Start Guide

GROUND WIRING

•

Run motor cables in separate conduit. DO NOT RUN CONTROL WIRES in same conduit

•

Cables sized per NEC.

•

Provide low impedance ground between drive and

•

motor.

Utility Drive Motor Ground

IMPORTANT: Improper grounding could result in damage to the motor and/or drive and could void warranty

Control Wiring

8. Wire the control terminals following the details for the speciﬁc option boards shown on the following pages.

Note: For ease of access, the option board terminal blocks can

be unplugged for wiring.

Note: If using conduit or Seal Tite for control wiring for Frame

4, you must order NEMA Type 12 kit.

(Inside Motor Conduit Box)

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VSD Series Quick Start Guide

NEMA Type 1/12 Open Drives (1 – 250 HP)

Table 1: Control Wiring Instructions (continued)

Control Wiring

9. Wire control to the OPTA9 Control Board and OPTA2.

Note: Drive default is programmed for Damper Interlock.

Note: Option Boards OPTC2 (N2/XT/SA Bus) and OPTC4

(LonWorks) are optional.

Mandatory Ground Wiring

Be sure to pull low impendance ground wiring from customer power to drive and ground wire from drive to motor.

Utility Drive Motor Ground

I/O Connection

Run 110 Vac and 24 Vdc Control wiring in separate

•

conduit. Communication wire to be shielded.

•

RS-232 Keypad cable less than 20 feet.

•

(Inside Motor Conduit Box)

Incoming Power

Optional CB

Note: Must pull

dedicated ground wire to drive and motor.

+1DV

Vin+

GND

Lin+

Lin–

24Vout

GND

DIN1

DIN2

DIN3

CMA

24Vout

GND

DIN4

DIN5

DIN6

CMB

Lout+

Lout–

DO1

Reference Output

Analog Input Voltage (Range 0-10V DC)

I/O Ground

Analog Input Current (Range 4-20mA)

Control Voltage Output I/O Ground Start/Stop External Fault

Run Permisive Damper Interlock

DIN1-DIN3 Common Control Voltage Output I/O Ground Speed Select 1 Fire Mode Bypass Overload Fault DIN4-DIN6 Common Output Frequency Analog Output Digital Output Ready

A B C D

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November 2009

Note:

See Figure 3 for Dip X1, X2, X3, X6 Switch settings.

Start-Up Wizard

X1 Jumper Setting

Analog Input 1 (AI1)

0 to 10V* Voltage Input

0 to 20 mA Current Input

0 to 10V (Differential) Voltage Input

-10 to 10V Voltage Input

Note:

Optional Communication Cards can be supplied with the Drive or as a Field Option.

Figure 2:

X2 Jumper Setting

Analog Input 2 (AI2)

0 to 20 mA*

C D

Current Input

0 to 10V Voltage Input

0 to 10V (Differential) Voltage Input

-10 to 10V Voltage Input

C D

X1X3X2

C D

X6 Jumper Setting

Analog Output 1 (A01)

0 to 20 mA* Current Output

0 to 10V Voltage Output

CMA and CMB Grounding

* Designates Default Jumper Settings

X3 Jumper Setting

CMB Connected to Ground* CMA Connected to Ground

CMB Isolated from Ground CMA Isolated from Ground

CMB and CMA Internally Connected and Isolated from Ground

Figure 3: Option Board A9 Location and Settings

See Appendix G .

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VSD Series Quick Start Guide

NEMA Type 1 IntelliPass/IntelliDisconnect Drive

Circuit Breaker Endplate

Circuit Breaker

Extension Bar

Circuit Breaker

Ribbon

Cable Hinge

Output & Bypass

Contactor*

24V DC Power Supply *

Optional 3rd Input Contactor *

Contactor Overload *

Manual/Auto Reset *

24V DC Motor Overload Terminal Block *

* IntelliPass only.

Optional 3rd Contactor S1 Switch * (provided for drive isolation)

Figure 4: Identiﬁcation of NEMA Type 1 Components

Figure 5: VSD Series IntelliPass/IntelliDisconnect Drive Dimensions

Ground Studs

Drive Enclosure Endplate (located at bottom)

Table 2: VSD Series NEMA Type 1 IntelliPass/IntelliDisconnect Drive Dimensions

Drive Horsepower (VT)

208V, 1 – 3 hp 230V, 1 – 3 hp 480V, 1 – 7-1/2 hp

208V, 5 – 7-1/2 hp 230V, 5 – 10 hp 480V, 10 – 20 hp

208V, 10 – 20 hp 230V, 15 and 20 hp 480V, 25 – 40 hp

208V, 25 and 30 hp 230V, 25 and 30 hp 480V, 50 – 75 hp

If mounting two or more IntelliPass Drives next to each other, make sure to use the proper spacing between the drives for hinged door operation.

Frame

Approximate

Size

Dimensions in Inches (mm)

ABC D

FR4 5.04

FR5 5.50

FR6 7.50

FR7 9.10

(128)

(140)

(191)

(231)

18.25 (464)

23.25 (591)

29.38 (746)

37.53 (953)

13.24 (336)

15.25 (387)

Approx. Weight in lbs. (kg)

21 (9.5) 5.3 (134.6)

35 (15.9) 5.7 (144.8)

67 (30.4) 7.5 (190.5)

108 (49.0) 9.0 (228.6)

Distance Between Drives in Inches (mm)

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VSD Series Quick Start Guide

NEMA Type 1 IntelliPass/IntelliDisconnect Drive

Table 3: Bypass Power Wiring Instructions — NEMA Type 1

Mounting Drive

1. Mount drive per dimensions. (See Page 5 .)

2. Verify that the main power source is removed upstream.

3. Using a ﬂat-blade screwdriver, remove the four screws securing the outer cover of the drive and remove the cover.

4. Using the same screwdriver, remove the two center screws securing the side cover.

5. Make sure there is adequate room, and open the hinged side cover.

Power Wiring

6. Using a ﬂat-blade screwdriver, remove the screws securing the endplate at the bottom of the drive enclosure, and remove the endplate.

7. Using a Greenlee conduit cutter (recommended), cut one or more holes in the endplate, located at the bottom of the drive’s enclosure, for the motor and power leads.

Note: If bringing the power leads in through the top of the

drive’s enclosure, go to step 8. If not, proceed to step 10.

Outer Cover

Bottom Endplate

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Two Screws on Side Cover

Power Wiring

8. Using a ﬂat-blade screwdriver, remove the screws securing the endplate for the circuit breaker enclosure, and remove the endplate.

9. Using a Greenlee conduit cutter (recommended), cut one hole in the circuit breaker endplate for the power leads.

Power Wiring

10. Calibrate the circuit breaker amperage, so it is 1.25 times the amperage on the motor nameplate, by turning the red set screw located below the circuit breaker extension bar. See the circuit breaker user’s manual supplied with the drive.

11. Connect the incoming power leads to circuit breaker terminals labeled L1, L2 and L3. Cables sized per NEC.

12. Using the torque wrench, tighten each terminal to the torque value found in the appropriate user’s manual supplied with the drive.

POWER WIRING

Run cabling in separate metal conduit or wiring tray.

•

DO NOT RUN CONTROL WIRING with incoming

•

power wiring. Provide low impedance ground connection to drive

•

chassis. DO NOT CONNECT to B+, B-, R terminals.

•

Incoming Power Leads

Circuit Breaker Set Screw

Circuit Breaker Extension Bar

Circuit Breaker Endplate

Circuit Breaker Terminals

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NEMA Type 1 IntelliPass/IntelliDisconnect Drive

Table 3: Bypass Power Wiring Instructions — NEMA Type 1 (continued)

Motor Wiring

13. Use your ﬁrst and second ﬁngers and simultaneously push down to release the two orange retaining clips (one on each side of the 24V DC motor overload terminal block).

14. If necessary, use a ﬂat-blade screwdriver to carefully remove the terminal block in a straight plane to avoid damaging it.

Motor Wiring

15. Connect the motor leads to the motor overload terminals labeled 1TA, 1TB and 1TC.

16. Using the appropriate metric Allen wrench (2.5 mm, 3 mm or 4 mm), tighten each overload terminal per the speciﬁcations in the contactor user’s manual.

MOTOR WIRING

An SAE allen wrench will damage the terminals, and the motor overload will need to be replaced (not covered by warranty).

17. Using the torque wrench, tighten each terminal to the torque value found in the appropriate user’s manual supplied with the drive.

18. Reinsert the motor overload terminal block.

Motor Leads

VSD Series Quick Start Guide

Motor Overload Terminals

Grounding

19. Use a ﬂat-blade screwdriver to connect the motor ground wire to the ground stud (located at either the top or bottom of the drive’s enclosure). (Mandatory) Ground connection main power ground must be connected to other ground screws.

GROUND WIRING

Run motor cables in separate conduit.

•

DO NOT RUN CONTROL WIRES in same conduit

•

Cables sized per NEC. Provide low impedance ground between drive and

•

motor.

Utility Drive Motor Ground

IMPORTANT: Improper grounding could result in damage to the motor and/or drive and could void warranty

LIT-1201858

(Inside Motor Conduit Box)

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Motor Ground Stud

VSD Series Quick Start Guide

NEMA Type 1 IntelliPass/IntelliDisconnect Drive

Table 3: Bypass Power Wiring Instructions — NEMA Type 1 (continued)

Setting Overload

20. Lift to open the cover on the motor overload, and use a 1/8" ﬂat-blade screwdriver to set the overload amperage to match the value on the motor nameplate.

21. Turn the auto/manual reset (factory default is manual) on the motor overload 90° to the auto position.

Control Wiring

22. Use a ﬂat-blade screwdriver to carefully remove the lowvoltage I/O terminal block.

23. Insert the incoming control leads into the terminal block. Refer to the electrical schematic supplied with the drive.

24. Reinsert the I/O terminal block into the control board.

25. Verify that all other wires to the terminal block are connected.

26. Terminate control wiring to the OPTA9 and OPTA2 board (Terminals 1 – 26).

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Auto/Manual Reset

CONTROL WIRING

Run 110 Vac and 24 Vdc control wiring in separate

•

conduit.

•

Communication wire must be shielded. RS-232 keypad cable must be less then 25 feet.

•

OptionalOptional

Customer Ground

Drive Ground

Start/Stop

Speed Select 1

Fire Mode Bypass Overload Fault

Drive Ground

Motor Ground

Note: See Figure 3

for Dip X1, X2, X3, X6 Switch settings.

Note: Optional COMM cards can be supplied

Note: with the drive or as a field option.

Figure 6: VSD Series IntelliPass with Three Contactors

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NEMA Type 1 IntelliPass/IntelliDisconnect Drive

able 3: Bypass Power Wiring Instructions — NEMA Type 1 (continued)

Static Check

27. Make sure power is off, and perform static checks as described in Table 7 (for the inverter) and Table 9 (for the DC bus). Refer to

Page 25, Appendix H.

Note: Static check shown is for L3 and B+ terminals.

28. Once the pre-power static checks are completed, reinstall the drive’s outer and side covers, tightening all the screws.

High Voltage is present on L1, L2, L3, B-, B+, BT, T1, T2, T3.

Starting Drive

29. Make sure that the drive’s 3rd contactor S1 switch, if present, is in the ON position (shown in OFF position).

Note: The bypass mode operates with the switch in the OFF position, however the drive will not run. Yet the keypad will operate.

(for the converter) , Table 8

WARNING

VSD Series Quick Start Guide

L1, L2, L3 B-, B+, BT T1, T2, T3

Starting Drive

30. Turn the circuit breaker handle in a clockwise direction.

WARNING

High Voltage

• Always work with another person.

• Be sure equipment is properly grounded.

• Wear safety glasses.

Start-Up Wizard

Circuit Breaker Handle

See Appendix G.

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