Johnson Controls VSD Series II Installation Guide

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VSD Series II
Installation Manual
Effective October 2012 New Information
Important Notice–Please Read
The product discussed in this literature is subject to terms and conditions outlined in Johnson Controls Inc. selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Johnson Controls 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 Controls Inc. or Eaton Electrical 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® VSD Series II Drive
VSD Series II
Warranty and Liability Information
In accordance with details on next page, Johnson Controls Inc. warrants the product delivered in the Johnson Controls shipping package to be free from defects in material and workmanship, under normal use and service. Products that fail during this period will be repaired or replaced at Johnson Controls discretion, with the same or a functionally equivalent product, provided the original purchaser (A) returns the failed product, and (B) provides proof of original date of purchase. The original purchaser of the product must obtain a Johnson Controls Return Material Authorization (RMA) number prior to returning any defective product. (When purchased through an Authorized Distributor, the Distributor should supply an RMA number to their customer.)
The maximum liability of this warranty is limited to the purchase price of the product. In no event, regardless of cause, shall Johnson Controls Inc. or Eaton Electrical Inc. be liable (a) for penalties or penalty clauses of any description, or (b) for certification not otherwise specifically provided herein and/or indemnification of purchaser or others for costs, damages or expenses, each arising out of or related to the product or services of any order or (c) for any damages resulting from loss of profits, use of products or for any incidental indirect or consequential damages, even if advised of the possibility of such damages.
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VSD Series II
Standard Warranty
Subject to the limitations and conditions stated herein, that all new Series II VSD products shall be free from defects in material and workmanship and shall deliver their rated output as indicated on the nameplates for a period of thirty (30) months from date of shipment.
This warranty shall provide coverage for replacement parts only and does not cover failure or damage due to storage, installation, operation or maintenance not in conformance with Johnson Controls recommendations and industry standard practice or due to accident, misuse, abuse or negligence. In addition, this warranty does not cover reimbursement for labor, including any removal/installation expenses which may be incurred in connection with repair or replacement, unless otherwise agreed upon by Johnson Controls.
Warranty with Certified Start-Up
Provided the equipment is commissioned by an authorized EATON® service provider (including individuals certified through Johnson Controls VSD Start-up/
Commissioning Certification Training
new Series II VSD products shall be free from defects in material and workmanship and shall deliver their rated output as indicated on the nameplates for a period of thirty-nine (39) months
from date of shipment.
This warranty shall provide coverage for replacement parts and on-site labor, including any removal/installation expenses associated with the warranty claim.
), JOHNSON CONTROLS warrants that all
Return Authorization/General Returns
Product Description Credit
Open, Type 1, Type 12 Drives 100%
®
Intellipass Custom Engineered Drives and Obsolete Products 0%
1. JOHNSON CONTROLS agrees to accept VSD Open products for return and
2. JOHNSON CONTROLS agrees to accept VSD Intellipass and Intellidisconnect
3. JOHNSON CONTROLS shall promptly refund or credit said customer for any
and Intellidisconnect Type 1, Type 12 and Type 3R Enclosed Branded Drives 85%
without penalty or restocking charge. JOHNSON CONTROLS will issue a 100% credit—provided the product is in its original unopened package and is returned within 120 days of receipt of product by JOHNSON CONTROLS.
Drives with a 15% restocking fee provided the product is in its original unopened package and is returned within 120 days of receipt of product by JOHNSON CONTROLS.
and all payments made by the buyer for such product(s). The buyer will be responsible for all freight charges associated with products authorized for return to JOHNSON CONTROLS.
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Support Services
The goal of Johnson Controls is to ensure your greatest possible satisfaction with the operation of our products. We are dedicated to providing fast, friendly, and accurate assistance. Whether it’s by phone, fax, or e-mail, you can access support information listed below.
You should contact your local Johnson Controls Sales Representative for product pricing, availability, ordering, expediting, and repairs.
Web Site
Use the Johnson Controls Web site to find product information.
Web Site Address
www.johnsoncontrols.com –> HVAC Controls –> 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
VSD Series II
For emergency assistance, contact: Eaton Technical Resource Center
Voice: 877-ETN-CARE (386-2273) (8:00 a.m.–5:00 p.m. EST) FAX: 828-651-0549 e-mail: TRC@Eaton.com
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VSD Series II
Table of Contents
SAFETY
Before Commencing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Definitions and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Hazardous High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
ENGINEERING
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Electrical Power Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety and Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 EMC Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Motor and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM OVERVIEW
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Selection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service and Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
VSD SERIES II OVERVIEW
How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Catalog Number Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Power Ratings and Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION REQUIREMENTS
Standard Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 NEMA Type 1/12 Open Drives (1–250 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Power Wiring Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 EMC Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Checking the Cable and Motor Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
APPENDIX A
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
APPENDIX B
Cable Power and Motor Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
APPENDIX C
Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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List of Figures
Drive System (PDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 AC Power Networks with Grounded Center Point
(TN-/TT Networks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 EMC Environment and Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Parallel Connection of Several Motors to One Frequency Inverter . . . . . . . . . . . . . . . . 6 Example of a Motor Ratings Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Star and Delta Circuit Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 V/Hz-Characteristic Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bypass Motor Control (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 VSD Series II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description of the VSD Series II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Block Diagram, Elements of VSD Series II Frequency Inverters . . . . . . . . . . . . . . . . . . 10 Selection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Approval Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Carton Labels (U.S. and Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mounting Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Input Power and Motor Cable Stripping Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Wiring the VSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 VSD Series II Variable Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 EMC-Compliant Setup (Example: VSD Series II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Cable Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Locations of the EMC-Jumpers in Frames FS4 to FS6 . . . . . . . . . . . . . . . . . . . . . . . . . 33 Three-Phase Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Connection to Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removing the Jumper, FS5 as Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Grounding Bar Location, FS8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removing the EMC Jumper, FS7 and FS8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Detaching the DC Grounding Bus Bar from Frame, FS7 . . . . . . . . . . . . . . . . . . . . . . . . 36 Molex Connector Placement, FS9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Removing the EMC Jumper, FS9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Product Modified Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FS4 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 FS4 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 FS5 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 FS5 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 FS6 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 FS6 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FS7 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 FS7 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 FS8 Dimension Drawing IP00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FS8 Dimension Drawing IP2154 Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 FS8 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FS9 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 FS9 Dimension Drawing IP2154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 FS9 Dimension Drawing Flange Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
VSD Series II
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VSD Series II
List of Tables
Identification on the Residual-Current Circuit-Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assignment of Frequency Inverters to Example Motor Circuit . . . . . . . . . . . . . . . . . . . 7 Maintenance Measures and Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VSD Series II Open Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 NEMA Type 1/IP21 or NEMA Type 12/IP54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 NEMA Type 1/IP21 or NEMA Type 12/IP54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VSD Series II Variable Speed Drive Option Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Space Requirements for Mounting the VSD Series II VSD and Airflow . . . . . . . . . . . . 20 Mounting Drive Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Power Connection Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spacing Between Parallel Motor Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Maximum Cable Length by Frame Size without DV/DT Protected C2 Ratings . . . . . . . 23 Input Power and Motor Cable Stripping and Wire Lengths . . . . . . . . . . . . . . . . . . . . . . 24 International EMC Protection Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 VSD Series II Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Standard I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Relay Board 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Relay Board 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 North America Cable and Fuse Sizes—208–240 Vac Ratings . . . . . . . . . . . . . . . . . . . . 43 North America Cable and Fuse Sizes—380–480 Vac Ratings . . . . . . . . . . . . . . . . . . . . 44 International Cable and Fuse Sizes 380–480 Vac Ratings . . . . . . . . . . . . . . . . . . . . . . . 45
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Safety
Warning! Dangerous Electrical Voltage!
Before Commencing the Installation
Disconnect the power supply of the device
Ensure that devices cannot be accidentally restarted
Verify isolation from the supply
Earth and short circuit the device
Cover or enclose any adjacent live components
Follow the engineering instructions (IL04020001E) for the device concerned
Only suitably qualified personnel in accordance with EN 50110-1/-2 (VDE 0105 Part 100) may work on this device/system
Before installation and before touching the device ensure that you are free of electrostatic charge
The functional earth (FE, PES) must be connected to the protective earth (PE) or the potential equalization. The system installer is responsible for implementing this connection
Connecting cables and signal lines should be installed so that inductive or capacitive interference does not impair the automation functions
Install automation devices and related operating elements in such a way that they are well protected against unintentional operation
Suitable safety hardware and software measures should be implemented for the I/O interface so that an open circuit on the signal side does not result in undefined states in the automation devices
Ensure a reliable electrical isolation of the extra-low voltage of the 24V supply. Only use power supply units complying with IEC 60364-4-41 (VDE 0100 Part 410) or HD384.4.41 S2
Deviations of the input voltage from the rated value must not exceed the tolerance limits given in the specifications, otherwise this may cause malfunction and dangerous operation
Emergency stop devices complying with IEC/EN 60204-1 must be effective in all operating modes of the automation devices. Unlatching the emergency-stop devices must not cause a restart
Devices that are designed for mounting in housings or control cabinets must only be operated and controlled after they have been installed and with the housing closed. Desktop or portable units must only be operated and controlled in enclosed housings
VSD Series II
Measures should be taken to ensure the proper restart of programs interrupted after a voltage dip or failure. This should not cause dangerous operating states even for a short time. If necessary, emergency-stop devices should be implemented
Wherever faults in the automation system may cause injury or material damage, external measures must be implemented to ensure a safe operating state in the event of a fault or malfunction (for example, by means of separate limit switches, mechanical interlocks, and so on)
Depending on their degree of protection, variable speed drives may contain live bright metal parts, moving or rotating components, or hot surfaces during and immediately after operation
Removal of the required covers, improper installation, or incorrect operation of motor or variable speed drive may cause the failure of the device and may lead to serious injury or damage
The applicable national accident prevention and safety regulations apply to all work carried out on live variable speed drives
The electrical installation must be carried out in accordance with the relevant regulations (for example, with regard to cable cross sections, fuses, PE)
Transport, installation, commissioning, and maintenance work must be carried out only by qualified personnel (IEC 60364, HD 384 and national occupational safety regulations)
Installations containing variable speed drives must be provided with additional monitoring and protective devices in accordance with the applicable safety regulations. Modifications to the variable speed drives using the operating software are permitted
All covers and doors must be kept closed during operation
To reduce hazards for people or equipment, the user must include in the machine design measures that restrict the consequences of a malfunction or failure of the drive (increased motor speed or sudden standstill of motor). These measures include:
Other independent devices for monitoring safety-related variables (speed, travel, end positions, and so on)
Electrical or non-electrical system-wide measures (electrical or mechanical interlocks)
Never touch live parts or cable connections of the variable speed drive after it has been disconnected from the power supply. Due to the charge in the capacitors, these parts may still be live after disconnection. Fit appropriate warning signs
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VSD Series II
Safety
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).
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.
Warnings and Cautions
CAUTION
When selecting the cable cross-section, take the voltage drop under load conditions into account.
The consideration of other standards (for example, VDE 0113 or VDE 0289) is the responsibility of the user.
CAUTION
The specified minimum PE conductor cross-sections (EN 50178, VDE 0160) must be maintained.
WARNING
With frequency inverters, only AC/DC sensitive residual current circuit breakers (RCD type B) are to be used (EN 50178, IEC 755).
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
Residual current circuit breakers (RCD) are only to be installed between the AC power supply network and the frequency inverter.
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
If you are connecting multiple motors on one frequency inverter, you must design the contactors for the individual motors according to utilization category AC-3.
Selecting the motor contactor is done according to the rated operational current of the motor to be connected.
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
A changeover between the frequency inverter and the input supply must take place in a voltage-free state.
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VSD Series II
WARNING
The frequency inverter outputs (U, V, W) must not be connected to the input voltage (destruction of the device, risk of fire).
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
Switch S1 must switch only when frequency inverter T1 is at zero current.
WARNING
Carry out wiring work only after the frequency inverter has been correctly mounted and secured.
WARNING
Electric shock hazard—risk of injuries!
Carry out wiring work only if the unit is de-energized.
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
Fire hazard!
Only use cables, protective switches, and contactors that feature the indicated permissible nominal current value.
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
Ground contact currents in frequency inverters are greater than 3.5 mA (AC). According to product standard IEC/EN 61800-5-1, an additional equipment grounding conductor must be connected, or the cross-section of the equipment grounding conductor must be at least 0.39 in
2
(10 mm2).
WARNING
The components in the frequency inverter’s power section remain energized up to five (5) minutes after the supply voltage has been switched off (intermediate circuit capacitor discharging time).
Pay attention to hazard warnings!
DANGER
5 MIN
WARNING
Do not perform any modifications on the AC drive when it is connected to mains.
CAUTION
Before connecting the AC drive to mains make sure that the EMC protection class settings of the drive are appropriately made.
VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com ix
VSD Series II
x VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
Engineering
Introduction
This chapter describes the most important features in the energy circuit of a drive system (PDS
Power Drive System) that you should take into consideration in your project planning.
=
Drive System (PDS)
L1 L2
L3 PE
I > I > I >
RCD
L1 L2
L3 PE
Item Number Description
1 Network configuration, input voltage, input frequency,
interaction with p.f. correction systems
2 Breakers, fuses, and cable cross-sections 3 Protection of persons and domestic animals with
residual-current protective devices
4 Input contactor 5 Frequency inverter: mounting, installation; power connection;
EMC measures; circuit examples
6 Motor reactor, dv/dt filter, sine-wave filter 7 Motor protection; thermistor 8 Cable lengths, motor cables, shielding (EMC) 9 Motor and application, parallel operation of multiple motors
on a frequency inverter, bypass circuit; DC braking
Engineering
PE U V W
M
~
3
#
PES
PES
VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com 1
Engineering
Electrical Power Network
Input Connection and Configuration
The VSD Series II frequency inverters can be connected and operated with all control-point grounded AC power networks (see IEC 60364 for more information).
AC Power Networks with Grounded Center Point (TN-/TT Networks)
L1 L2 L3 N PE
While planning the project, consider a symmetrical distribution to the three external conductors, if multiple frequency inverters with single-phase supplies are to be connected. The total current of all single-phase consumers is not to cause an overload of the neutral conductor (N-conductor).
The connection and operation of frequency inverters to asymmetrically grounded TN networks (phase-grounded Delta network “Grounded Delta”, USA) or non-grounded or high-resistance grounded (over 30 ohms) IT networks is only conditionally permissible.
If the VSD Series II frequency inverters are connected to an asymmetrically grounded network or to an IT network (non-grounded, insulated), the internal interference suppression filter must be disconnected (unscrew the screw marked EMC, see “Installation in IT System” on Page 33). The required filtering for electromagnetic compatibility (EMC) is then no longer present.
Measures for electromagnetic compatibility are mandatory in a drive system in order to meet the legal requirements for EMC and low voltage regulations.
Good grounding measures are a prerequisite for the effective insert of further measures such as shielding or filters. Without respective grounding measures, further steps are superfluous.
L1 L2 L3 PEN
Input Voltage and Frequency
The standardized input voltages (IEC 60038, VDE017-1) for energy suppliers (EVU) guarantee the following conditions at the transition points:
Deviation from the rated value of voltage: maximum ±10%
Deviation in voltage phase balance: maximum ±3%
Deviation from rated value of the frequency: maximum ±4%
The broad tolerance band of the VSD Series II frequency inverter considers the rated value for European as (EU: U (USA: U
For the bottom voltage value, the permitted voltage drop of 4% in the consumer circuits is also taken into account, therefore a total of U
The permitted frequency range is 50/60 Hz (48 Hz –0% –66 Hz +0%).
= 230V/400V, 50 Hz) and American as
LN
= 240V/480V, 60 Hz) standard voltages:
LN
230V, 50 Hz (EU) and 240V, 60 Hz (USA) at HMX32
400V, 50 Hz (EU) and 480V, 60 Hz (USA) at HMX34_
–14%.
LN
200V device class (HMX32): 208V –10% to 240V +10% (188V –0% to 264V +0%)
400V device class (HMX34): 380V –10% to 480V +10% (342V –0% to 528V +0%)
2 VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
Engineering
Voltage Balance
Because of the uneven loading on the conductor, and with the direct connection of greater power ratings, deviations from the ideal voltage form and asymmetrical voltages can be caused in three-phase AC power networks. These asymmetric divergences in the input voltage can lead to different loading of the diodes in input rectifiers with three-phase supplied frequency inverters, and as a result, an advance failure of this diode.
In the project planning for the connection of three-phase supplied frequency inverters (HMX32, HMX34), consider only AC power networks that handle permitted asymmetric divergences in the input voltage +3%.
If this condition is not fulfilled, or symmetry at the connection location is not known, the use of an assigned main choke is recommended.
Total Harmonic Distortion (THD)
The THD (Total Harmonic Distortion) is a measurement for the occurring harmonic distortion of the sinusoidal oscillation (input power side) input variables with the frequency inverter. It is given in percent of the total value.
2
U
U+
=
K
2
-----------------------------------------------------------------------------------------------------------
2
U
2
U+
1
++
2
2
2
U
++
+
3
4
2
U
2
U
3
4
... U
... U
++
2
n
100%
2
n
Idle Power Compensation Devices
Compensation on the power supply side is not required for VSD Series II frequency inverters. From the AC power supply network, they take on very little reactive power of the fundamental harmonics (cos ~ 0.98).
In the AC power networks with non-choked idle current compensation devices, current deviations can enable parallel resonance and undefinable circumstances.
In the project planning for the connection of frequency inverters to AC power networks with undefined circumstances, consider using main chokes.
U
= fundamental component
1
THD k = 0.1 K = 10% ~ –20 dB (THD suppression)
THD
2
2
U
U+
2
----------------------------------------------------------------------------------------------------=
2
U
++
+
3
4
U
1
... U
2
n
With VSD Series II frequency inverters, the permitted value for the total harmonic distortion THD is >120%.
VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com 3
Engineering
Safety and Switching
Fuses and Cable Cross-Sections
The fuses and wire cross-sections allocated for power-side connections depend on the rated input current I frequency inverter (without input reactor).
LN
of the
CAUTION
When selecting the cable cross-section, take the voltage drop under load conditions into account.
The consideration of other standards (for example, VDE 0113 or VDE 0289) is the responsibility of the user.
The national and regional standards (for example VDE 0113, EN 60204) must be observed and the necessary approvals (for example UL) at the site of installation must be fulfilled.
When the device is operated in a UL-approved system, use only UL-approved breakers, fuses, fuse bases, and cables.
The leakage currents to ground (to EN 50178) are greater than 3.5 mA. The connection terminals marked PE and the housing must be connected with the ground circuit.
CAUTION
The specified minimum PE conductor cross-sections (EN 50178, VDE 0160) must be maintained.
Choose the cross-section of the PE conductor in the motor lines at least as large as the cross-section of the phase lines (U, V, W).
Cables and Fuses
The cross-sections of the cables and line protection fuses used must correspond with local standards.
For an installation in accordance with UL guidelines, the fuses and copper cable that are UL-approved and have a heat-resistance of 167° to 194°F (75° to 90°C) are to be used.
Use power cables with insulation according to the specified input voltages for the permanent installation. A shielded cable is not required on the input side.
A completely (360°) shielded low impedance cable is required on the motor side. The length of the motor cable depends on the RFI class and must not exceed 500 ft (153m) without additional filtering.
Residual-Current Device (RCD)
RCD (Residual Current Device): Residual current device, residual current circuit breaker (FI circuit breaker).
Residual current circuit breakers protect persons and animals from the existence (not the origination) of impermissibly high contact voltages. They prevent dangerous, and in some cases deadly injuries caused by electrical accidents, and also serve as fire prevention.
WARNING
With frequency inverters, only AC/DC sensitive residual current circuit breakers (RCD type B) are to be used (EN 50178, IEC 755).
Identification on the Residual-Current Circuit-Breakers
AC/DC sensitive (RCD, type B)
Frequency inverters work internally with rectified AC currents. If an error occurs, the DC currents can block a type A RCD circuit breaker from triggering and therefore disable the protective functionality.
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
Residual current circuit breakers (RCD) are only to be installed between the AC power supply network and the frequency inverter.
Safety-relevant leakage currents can occur while handling and when operating the frequency inverter, if the frequency inverter is not grounded (because of a fault).
Leakage currents to ground are mainly caused by foreign capacities with frequency inverters; between the motor phases and the shielding of the motor cable and via the Y-capacitors of the noise filter. The size of the leakage current is mainly dependent upon the:
length of the motor cable
shielding of the motor cable
height of the pulse frequency (switching frequency of the inverter)
design of the noise filter
grounding measures at the site of the motor
4 VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
Engineering
The leakage current to ground is greater than 3.5 mA with a frequency inverter. Based on the requirements of EN 50178, an increased ground (PE) has to be connected. The cable cross-section must be at least 10 mm
2
or consist of two
separately connected ground cables.
Residual current circuit breakers must be suitable for:
the protection of installations with DC current component in case of fault scenario (RCD type B)
high leakage currents (300 mA)
brief discharges of pulse current spikes
Input Contactor
The input contactor enables an operational switching on and off of the supply voltage for the frequency inverter, and switching off in case of a fault.
The input contactor is designed based on the input current (I
) of the frequency inverter and the utilization category
LN
AC-1 (IEC 60947). Input contactors and the assignment to VSD Series II frequency inverters are explained in the appendix.
While planning the project, make sure that inching operation is not done via the input contactor of the frequency inverter on frequency-controlled drives, but through a controller input of the frequency inverter.
The maximum permitted operating frequency of the input voltage with the VSD Series II frequency inverter is one time per minute (normal operation).
EMC Measures
Electrical components in a system (machine) have a reciprocal effect on each other. Each device not only emits interference but is also affected by it. The interference can be produced by galvanic, capacitive, and/or inductive sources, or by electromagnetic radiation. In practice, the limit between line-conducted interference and emitted interference is around 30 MHz. Above 30 MHz, cables and conductors act like antennas that radiate electromagnetic waves.
Electromagnetic compatibility (EMC) for frequency controlled drives (variable speed drives) is implemented in accordance with product standard IEC/EN 61800-3. This includes the complete power drive system (PDS), from the input supply to the motor, including all components, as well as cables (see figure on Page 1 ). This type of drive system can consist of several individual drives.
The generic standards of the individual components in a PDS compliant with IEC/EN 61800-3 do not apply. These component manufacturers, however, must offer solutions that ensure standards-compliant use.
In Europe, maintaining the EMC guidelines is mandatory.
A declaration of conformity (CE) always refers to a “typical” power drive system (PDS). The responsibility to comply with the legally stipulated limit values and thus the provision of electromagnetic compatibility is ultimately the responsibility of the end user or system operator. This operator must also take measures to minimize or remove emission in the environment concerned (see figure below). He must also use means to increase the interference immunity of the devices of the system.
With their high interference immunity up to category C2, VSD Series II frequency inverters are ideal for use in commercial networks (1st environment).
EMC Environment and Category
Public Medium-Voltage Supply Grid
Public Measuring Point
Category C1
Low-Voltage
Supply Grid
Category C1/C2 Category C3/C4 Category C3/C4
st
Enviroment 2nd Enviroment
1
Industry Grid 1
Industry Grid 2
VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
5
Engineering
Motor and Application
Motor Selection
General recommendations for motor selection:
Use three-phase powered asynchronous motors with short-circuit rotors and surface cooling, also called asynchronous motors or standard motors for the frequency-controlled drive system (PDS). Other specifications such as external rotor motors, slip-ring motors, reluctance motors, synchronous or servo motors can also be run with a frequency inverter, but normally require additional planning and discussion with the motor manufacturer
Use only motors with at least heat class F (311°F [155°C] maximum steady state temperature)
Four-pole motors are preferred (synchronous speed: 1500 min
Take the operating conditions into account for S1 operation
–1
at 50 Hz or 1800 min
–1
at 60 Hz)
(IEC 60034-1)
When operating multiple motors in parallel on one frequency inverter, the motor output should not be more than three power classes apart
Ensure that the motor is not overdimensioned. If a motor in speed control mode is underdimensioned, the motor rating must only be one rating level lower
Connecting Motors in Parallel
The VSD Series II frequency inverters allow parallel operation of several motors using multi-pump application control mode:
Multi-pump application: several motors with the same or different rated operational data. The sum of all motor currents must be less than the frequency inverter’s rated operational current
Multi-pump application: parallel control of several motors. The sum of the motor currents plus the motors’ inrush currents must be less than the frequency inverter’s rated operational current
Parallel operation at different motor speeds can be implemented only by changing the number of pole pairs and/ or changing the motor’s transmission ratio.
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
If you are connecting multiple motors on one frequency inverter, you must design the contactors for the individual motors according to utilization category AC-3.
Selecting the motor contactor is done according to the rated operational current of the motor to be connected.
Parallel Connection of Several Motors to One Frequency Inverter
Q12Q11
F1
U1 V1 W1 U1 V1 W1 U1 V1 W1
M
M1
3
˜
F2
M
M2
3
˜
Q13
F3
M3
M
3
˜
Connecting motors in parallel reduces the load resistance at the frequency inverter output. The total stator inductance is lower and the leakage capacity of the lines greater. As a result, the current distortion is greater than in a single-motor circuit. To reduce the current distortion, you should use motor reactors (see [1] in figure above) in the output of the frequency inverter.
The current consumption of all motors connected in parallel must not exceed the frequency inverter’s rated output current I2N.
Electronic motor protection cannot be used when operating the frequency inverter with several parallel connected motors. You must, however, protect each motor with thermistors and/or overload relays.
The use of a motor protective circuit breaker at the frequency inverter’s output can lead to nuisance tripping.
6 VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
Motor and Circuit Type
The motor’s stator winding can be connected in a star or delta configuration, in accordance with the rated operational data on the nameplate.
Example of a Motor Ratings Plate
3.5/2
cos
A
0.79
/400 V230
0.75S1
kW
RPM
1430 50 Hz
Engineering
Because of the higher thermal loading, using only the next higher motor output according to the list (1.1 kW) is recommended. The motor (in this example) therefore still has
1.47-fold higher output compared with the listed output (0.75 kW).
With the 87-Hz characteristic curve, the motor also works in the range from 50 to 87 Hz with an unattenuated field. The pull-out torque remains at the same level as in input operation with 50 Hz.
The heat class of the motor must be at least F in 87-Hz operation.
Star and Delta Circuit Types
U1 V1 W1
W2 U2 V2
U1 V1 W1
W2 U2 V2
V/Hz-Characteristic Curve
U2 (V)
400
230
The three-phase motor with the rating plate based on the figure shown above, can be run in a star or delta connection. The operational characteristic curve is determined by the ratio of motor voltage and motor frequency, in this case.
87-Hz Characteristic Curve
In the delta circuit with 400V and 87 Hz, the motor shown in
0
8750
f
max
The following table shows the allocation of possible frequency inverters depending on the input voltage and the type of circuit.
f (Hz)
the figure above was released with three times-fold output (~1.3 kW).
Assignment of Frequency Inverters to Example Motor Circuit (See Figure Above)
Frequency Inverters VS3D7210B-00000 VS3D4410B-00000 VS4D8410BB-00000
Rated operational current 3.7A 3.4A 4.8A Input voltage 3 AC 230V 3 AC 400V 3 AC 400V Motor circuit Delta Star Delta V/Hz-characteristic curve

Motor current 3.5A 2.0A 3.5A Motor voltage (ratings plate) 230V 400V 230V Motor speed 1430 min
–1
Motor frequency 50 Hz 50 Hz 87 Hz
Notes
Star connection: 400V, 50 Hz.
Delta connection: 230V, 50 Hz.
Delta connection: 400V, 87 Hz.
Note the permitted limit values of the motor.
1430 min
–1
2474 min
–1
VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
7
Engineering
Bypass Operation
If you want to have the option of operating the motor with the frequency inverter or directly from the input supply, the input branches must be interlocked mechanically.
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
A changeover between the frequency inverter and the input supply must take place in a voltage-free state.
WARNING
The frequency inverter outputs (U, V, W) must not be connected to the input voltage (destruction of the device, risk of fire).
Bypass Motor Control (Example)
L2
L3
L1
Q1
>
I>I>I
Q11
L1 L2 L3
CAUTION
Debounced inputs may not be used in the safety circuit diagram.
Switch S1 must switch only when frequency inverter T1 is at zero current.
Contactors and switches (S1) in the frequency inverter output and for the direct start must be designed based on utilization category AC-3 for the rated operational current of the motor.
Connecting EX Motors
Note the following when connecting explosion-protected motors:
The frequency inverter must be installed outside the EX area
Note the branch- and country-specific standards for explosion-protected areas (ATEX 100a)
Note the standards and information of the motor manufacturer regarding operation on frequency inverters— for example, if motor reactors (du/dt-limiting) or sinus filters are specified
Temperature monitors in the motor windings (thermistor, thermo-Click) are not to be connected directly to frequency inverters but must be connected via an approved trigger apparatus for EX areas
2
UVW
T1
S1
M
M1
3~
Item Number Description
1
Input/bypass contactor Output contactor
8 VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
System Overview
Component Identification
VSD Series II Description of the VSD Series II
1
4
5
2
BYPA
SS
Ba
c k
HOA
OK
2 se
c .
STOP RES
ET
S TA
R
T
12
BY
PASS
HOA
Back
OK
2
se
c.
ST
OP
RE
S
E
T
ST
ART
System Overview
3
Item Number Description
1
Frequency inverter VS
I/O option boards
Motor reactor DEX-LM3, sinusoidal filter SFB400
Keypad
3
4
Item Number Description
1
Mounting holes
2 Device fan 3 Front cover 4 Power terminals 5 Keypad with display
Features
The VSD Series II frequency inverter converts the voltage and frequency of an existing AC network into a DC voltage. This DC voltage is used to generate a three-phase AC voltage with adjustable frequency and assigned amplitude values for the variable speed control of three-phase asynchronous motors.
2
3
4
VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
9
System Overview
Block Diagram, Elements of VSD Series II Frequency Inverters
R+
R–
L1
L2
L3
PE
+
EMC
U/T1
V/T2
W/T3
PE
M
3
~
Item Number Description
1
Supply L1, L2/N, L3, PE, input supply voltage U 200V class, three-phase input connection (3 AC 230V/240V)
= Ue at 50/60 Hz:
LN
400V class, three-phase input connection (3 AC 400V/480V)
2 Internal interference suppression filter, category C2 to IEC/EN 61800-3
EMC-connection of internal interference suppression filter to PE
3 Rectifier bridge, converts the AC voltage of the electrical network into DC voltage 4 DC link with charging resistor, capacitor and switching mode power supply unit
(SMPS = Switching Mode Power Supply): DC link voltage U
with three-phase input connection (3 AC): UDC = 1.41 x U
DC
LN
5 Inverter. The IGBT based inverter converts the DC voltage of the DC link (UDC) into a three-phase AC voltage (U2) with variable amplitude and
frequency (f
6 Motor connection U/T1, V/T2, W/T3 with output voltage U
230V: 3.7–310A
). Sinusoidal pulse width modulation (PWM) with V/f control can be switched to speed control with slip compensation
2
(0–100% Ue) and output frequency f2 (0–320 Hz) output current (I2):
2
480V: 3.4–310A 100% at an ambient temperature of 104°F (40°C) with an overload capacity of 110% for 60s every 600s and a starting current of 200% for 2s every 20s
7 Keypad with control buttons, graphic display, control voltage, control signal terminals, microswitches, and interface for the PC interface module
(option)
8 Three-phase asynchronous motor, variable speed control of three-phase asynchronous motor for assigned motor shaft power values (P
230V: 0.55–90 kW (230V, 50 Hz) or 0.75–125 hp (230V, 60 Hz)
):
2
480V: 1.1–160 kW (400V, 50 Hz) or 1.5–250 hp (460V, 60 Hz)
9 DC link—chokes, to minimize current harmonics
10 VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com
Selection Criteria
The frequency inverter [3] is selected according to the supply voltage U the assigned motor [2]. The circuit type ( / ) of the motor must be selected according to the supply voltage [1]. The rated output current I greater than/equal to the rated motor current.
Selection Criteria
3
of the input supply [1] and the rated current of
LN
of the frequency inverter must be
e
U, I, f
BACK RES
ET
LO
C
REM
OK
I
1
2
System Overview
When connecting multiple motors in parallel to the output of a frequency inverter, the motor currents are added geometrically—separated by effective and idle current components. When you select a frequency inverter, make sure that it can supply the total resulting current. If necessary, for dampening and compensating the deviating current values, motor reactors or sinusoidal filters must be connected between the frequency inverter and the motor.
The parallel connection of multiple motors in the output of the frequency inverter is only permitted with V/Hz­characteristic curve control.
If you connect a motor to an operational frequency inverter, the motor draws a multiple of its rated operational current. When you select a frequency inverter, make sure that the starting current plus the sum of the currents of the running motors will not exceed the rated output current of the frequency inverter.
Switching in the output of the frequency inverter is only permitted with V/Hz-characteristic curve control.
400/690V /
7.5
1410 50 Hz
kW
min
15.2/8.8A
cos
0.82
–1
When selecting the drive, the following criteria must be known:
Type of motor (three-phase asynchronous motor)
Input voltage = rated operating voltage of the motor (for example, 3 AC~400V)
Rated motor current (guide value, dependent on the circuit type and the supply voltage)
Load torque (quadratic, constant)
Starting torque
Ambient temperature (rated value 122°F [50°C])
VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com 11
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