Siemens SED2 VFD User Manual

SED2 VFD Electronic Bypass Options

Operating Instructions

Item Number 125-3208, Rev. FA

SED2 VFD Electronic

Bypass Option

Operating Instructions

NOTICE

The information contained within this document is subject to change without notice and should not be construed as a commitment by Siemens Building Technologies, Inc. Siemens Building Technologies, Inc. assumes no responsibility for any errors that may appear in this document.

All software described in this document is furnished under a license and may be used or copied only in accordance with the terms of such license.

WARNING

The Siemens Building Technologies SED2 Variable Frequency Drives are shipped without EMC line filters. (The EMC filter is most commonly used in Europe.) Where local codes or customer/installation requirements dictate, separately orderable Class A line filters are available. More stringent Class B line filters are also available for most models. Installation of these filters satisfies the requirements for the EU's EMC directive.

SERVICE STATEMENT

Control devices are combined to make a system. Each control device is mechanical in nature and all mechanical components must be regularly serviced to optimize their operation. All Siemens Building Technologies, Inc. branch offices and authorized distributors offer Technical Support Programs that will ensure your continuous, trouble-free system performance.

For further information, contact your nearest Siemens Building Technologies, Inc. representative.

CREDITS

Product or company names mentioned herein may be the trademarks of their respective owners.

Copyright © 2007 by Siemens Building Technologies, Inc.

TO THE READER

Your feedback is important to us. If you have comments about this manual, please submit them to [e-mail]

Country of Origin: US

Table of Contents

Table of Contents
How to Use this Manual................................................................................................	1
Manual Organization..................................................................................................	1
Manual Notations.......................................................................................................	1
Where To Send Comments .......................................................................................	2
Reference Documents ...............................................................................................	2
Safety Instructions........................................................................................................	3
Electronic Bypass Option Overview ...........................................................................	4
General Description ...................................................................................................	4
Controller Board.........................................................................................................	5
Contactors..................................................................................................................	6
Keypad Functions ......................................................................................................	6
Installation Instructions ...............................................................................................	9
Environmental Conditions..........................................................................................	9
Mechanical Installation ..............................................................................................	9
Inspection ................................................................................................................	9
Dimensions and Weights ........................................................................................	9
Mounting..................................................................................................................	10
Electrical Installation ..................................................................................................	12
Startup Procedures.......................................................................................................	19
Safety Precautions.....................................................................................................	19
Installation Inspection ................................................................................................	19
Power-On...................................................................................................................	19
Quick Commissioning ................................................................................................	21
Additional Parameter Settings ...................................................................................	31
Flying Start ..............................................................................................................	31
Automatic Restart....................................................................................................	33
Vdc Controller..........................................................................................................	36
Pulse Frequency .....................................................................................................	37
Motor Data Identification .........................................................................................	38
Reset to Factory Defaults........................................................................................	40
Required SED2 Parameter Settings ............................................................................	41

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SED2 VFD Electronic Bypass Option Operating Instructions

Application Feature Setup ...........................................................................................	42
Overview ....................................................................................................................	42
Auto Bypass without Interlock....................................................................................	42
Description ..............................................................................................................	42
Settings ...................................................................................................................	43
Example SED2 Settings..........................................................................................	43
Interlock .....................................................................................................................	44
Description ..............................................................................................................	44
Settings ...................................................................................................................	44
Wiring Example for Interlock ...................................................................................	46
Essential Services......................................................................................................	46
Description ..............................................................................................................	46
Settings ...................................................................................................................	47
Wiring Example for Essential Services ...................................................................	47
Interlock and Auto Bypass on VFD Fault...................................................................	48
Description ..............................................................................................................	48
Settings ...................................................................................................................	48
Wiring Example for Interlock and Auto Bypass on VFD Fault ................................	48
Technical Specifications ..............................................................................................	49
Troubleshooting............................................................................................................	51
Power-on Initialization Failure (Unit Fault Condition) ...............................................	51
Override Jumper ........................................................................................................	52
Fuses .........................................................................................................................	52

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How to Use this Manual

How to Use this Manual

Manual Organization

This manual contains the following sections:

•How to Use this Manual, describes the organization of this manual and the symbols used throughout this manual.

•Safety Instructions, provides general guidelines for your safety and to prevent equipment damage.

•Electronic Bypass Option Overview, describes the Electronic Bypass Option Controller board, inputs, outputs, contactors, and keypad.

•Installation Instructions, provides mounting information and details on electrical connections.

•Startup Procedures, provides step-by-step procedures to start up the Electronic Bypass Option.

•Required SED2 Parameter Settings, lists SED2 parameter settings necessary for operation of the Electronic Bypass Option.

•Application Feature Setup, describes application features and provides the necessary parameter settings.

•Technical Specifications, lists Electronic Bypass Option and SED2 VFD specifications.

•Troubleshooting, provides guidelines for troubleshooting the Electronic Bypass Option.

Manual Notations

Notation	Symbol	Meaning
WARNING:		Indicates that personal injury/loss of life may occur if you do
		not perform a procedure as specified.
CAUTION:		Indicates that equipment damage, or loss of data may occur if
		you do not perform a procedure as specified.
NOTES:	(no symbol)	Provides other important information or helpful hints.

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SED2 VFD Electronic Bypass Option Operating Instructions

Where To Send Comments

Your feedback is important to us. If you have comments about this manual, please submit them to [e-mail].

Reference Documents

The following SED2 documentation is available from your local Siemens Building Technologies, Inc. representative:

•SED2 VFD Startup Operation, and Maintenance Manual (125-3201), provides operating instructions and procedures for the SED2.

•SED2 VFD Parameter Reference Guide (125-3214), provides descriptions of SED2 parameters.

•SED2 VFD Submittal Sheet (154-042), provides a synopsis of the SED2 product line, accessories, and technical data.

•SED2 VFD Electronic Bypass Options Submittal Sheet (154-051), provides a comprehensive overview of the SED2 Electronic Bypass option.

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Safety Instructions

Safety Instructions

The following guidelines are provided for your safety, to prevent damage, and to extend the service life of the SED2 product and any connected equipment. Read this information carefully. Specific Warnings, Cautions, and Notes are provided in the relevant sections of this manual.

WARNING:

•The SED2 uses hazardous voltages and controls potentially dangerous rotating mechanical parts. Non-compliance with warnings or failure to follow the instructions contained in this manual can result in loss of life, severe personal injury, or serious damage to property/equipment.

•Only authorized personnel should work on this equipment, and only after becoming familiar with all local regulations and ordinances; safety notices; and installation, operation, and maintenance procedures in this manual. Successful and safe operation of this equipment depends upon its proper handling, installation, operation, and maintenance.

•Before carrying out any installation and commissioning procedures, you must read all safety instructions and warnings, including all warning labels attached to the equipment. Make sure that the warning labels are kept in a legible condition and ensure missing or damaged labels are replaced.

•Observe the regulations of Safety Code VBG 4.0 (in particular, “Permissible Deviations when Working with Live Parts”) whenever measuring or testing is performed on live equipment. Also, use suitable electronic tools.

•Only use this equipment for the purpose specified by the manufacturer. Unauthorized modifications and the use of spare parts and accessories that are not sold or recommended by the manufacturer of the equipment can cause fires, electric shocks, and injuries.

•Prevent the general public from accessing or approaching this equipment.

NOTE: Keep these Operating Instructions near the equipment and available to all users.

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SED2 VFD Electronic Bypass Option Operating Instructions

Electronic Bypass Option Overview

General Description

During normal operation in a typical application, the input and output contactors close and the SED2 operates the motor (Figure 1). The bypass contactor provides the ability to operate the motor on utility power and eliminate the SED2 from the motor control circuit. The SED2 Electronic Bypass Option also allows you to select features that enhance the control of the contactors and the outputs that report operation.

The SED2 Electronic Bypass (E-Bypass) Option consists of a SED2 VFD, and a bypass enclosure with electronic controls (Figure 2). The electronic controls include:

•Controller board

•Keypad

•Step-down power transformer

•Contactors:

−Bypass

−Output

−Input (optional)

•Overload (current) relay

•Reactor (optional)

•Disconnect switch (or optional circuit breaker)

BYPASS OVERLOAD

CONTACTOR RELAY

VFD0093R1

VFD

MOTOR

CONTACTOR

CONTACTOR

INPUT

OUTPUT

Figure 1. Functional Block Diagram of

Typical Electronic Bypass Option.

CONTROLLER	SED2 VFD
BOARD

KEYPAD (DOOR MOUNTED)

			INPUT
			CONTACTOR
		STEP-DOWN
		POWER	REACTOR
		TRANSFORMER
			(OPTIONAL)
		OUTPUT
		CONTACTOR
		BYPASS
		CONTACTOR
			DISCONNECT
			SWITCH
	VFD0094R1		(OR OPTIONAL
		OVERLOAD	CIRCUIT BREAKER
			SHOWN)
		(CURRENT)
		RELAY

• Fuses (optional)

Figure 2. Typical SED2 E-Bypass Components.

•Cable harnesses

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Electronic Bypass Option Overview

Controller Board

The Controller board is the foundation of the SED2 Electronic Bypass Option. It controls communications to and from the SED2, keypad, isolated digital inputs, relay/digital outputs, and contactors (Figure 3).

VFD0095R1

SED2 INTERFACE

Supports two SED2 non-isolated, digital relay outputs and three SED2 digital inputs. The maximum current draw for a relay output is 2 mA and

the voltage between the digital output source and return lines is 24V. The Controller board provides unregulated, non-isolated 24V to power the SED2 digital inputs.

BASIC SANITY TEST INDICATOR

Provides indication of initialization and normal operation.

KEYPAD INTERFACE

Supports inputs and outputs from the Electronic Bypass Option keypad. The keypad provides user interface indicators and push buttons.

FACTORY USE ONLY

Connector J8 is for factory use only.

DIGITAL INPUTS

Supports six isolated digital inputs for customer use. The inputs require a contact closure capable of providing a low impedance path at currents less than 20 mA.

DIGITAL RELAY OUTPUTS

Supports six digital relay outputs for customer use. Each relay has a maximum rating of 2A at 120 Vac.

OVERRIDE JUMPER

DIP SWITCHES

The Controller board DIP switches enable/disable the Electronic Bypass Option features.

J4

CONTROLLER

BOARD

				J3	MCU
			J8
	ON			OFF
SW1				J2

J1

TRANSFORMER

F1

J6

J7

J5

CONTACTOR POWER

CONTROLS

ON
5		5
OPTIONS 3 4			3 4
2		2
	ON
1		1

OFF

Not used, factory test selector switch #2; leave this switch OFF.

Not used, factory test selector switch #1; leave this switch OFF.

Interlock selector switch; requires SED2 programming.

Automatic Bypass selector switch; requires SED2 programming.

Essential Services selector switch.

SW1

When the switch is ON the option is enabled; when the switch is OFF the option is disabled.

Figure 3. Controller Board Inputs and Outputs.

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SED2 VFD Electronic Bypass Option Operating Instructions

Contactors

The Controller board provides two or three relay contact circuits controlled by the Electronic Bypass Option: bypass, input, and output contactors. Each circuit includes a NO relay. Controller board connector J7 enables circuit connections. The relay circuits route power to the SED2 and the motor via the contactors. Controlling the contactors through the relay circuits is the main function of the Controller board.

Bypass Contactor – The bypass relay on the Controller board controls the bypass contactor. The output and bypass relays are interconnected to 120 Vac Hot. This enables a safety circuit that prevents the bypass and output contactors from simultaneously being energized.

Output Contactor – The output relay on the Controller board controls the output contactor.

Input Contactor – The input relay on the Controller board controls the optional input contactor.

Keypad Functions

VFD0096R1

			Bypass		VFD			Bypass
	Input		Hand		Input	Input		Hand
	Contactor		Start		On/Off	Contactor		Start
	Bypass					Bypass
	Contactor					Contactor
	VFD					VFD
Enable	Overload		Remote		Enable	Overload		Remote
			Start					Start
	Relay					Relay
	Output					Output
	Contactor					Contactor
	Motor					Motor
STOP	AutoBypassEnabled		VFDFault		STOP	AutoBypassEnabled		VFDFault
RESET			SafetyFault		RESET			SafetyFault
				VFD0097R1
	EssentialServices		OverloadFault			EssentialServices		OverloadFault
	Enable	Commanded Proofed				Enable	Commanded Proofed
INTERLOCKSTARTLOGIC					INTERLOCKSTARTLOGIC

2-CONTACTOR KEYPAD 3-CONTACTOR KEYPAD

Figure 4. E-Bypass Keypad Indicators and Pushbuttons.

The keypad provides user interface indicators and pushbuttons. The following table describes specific pushbutton and indicator functions:

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Electronic Bypass Option Overview

Pushbutton/Indicator

		VFD0098R1	Input
			On/Off
		VFD0099R1	Enable
		VFD0100R1	Hand
			Start
		VFD0101R1	Remote
			Start
		VFD0102R1	STOP
			RESET
			VFDFault
	VFD0103R1	SafetyFault
		OverloadFault
			VFDFault
	VFD0104R1	SafetyFault
		OverloadFault
			VFDFault
	VFD0105R1	SafetyFault
		OverloadFault
VFD0106R1	AutoBypassEnabled
		EssentialServices

AutoBypassEnabled

VFD0107R1	EssentialServices

Description

The Input On/Off pushbutton is supplied with the optional drive input contactor. In VFD mode, this switch does nothing. In bypass mode, this switch closes/opens the input contactor, switching the SED2 power on/off.

Enables SED2 operation by closing the input and output contactors.

Manually enables bypass mode operation by ensuring that the output contactor is open and then closing the bypass contactor.

Activates the bypass mode and operates the bypass contactor according to the status of the Remote Start input on the Controller board.

Opens the output and bypass contactors, disconnecting the motor.

When a VFD Fault is indicated, the VFD Fault indicator lights and the VFD Fault Relay output on the Controller Board is triggered.

The Safety Fault indicator lights when either of the Remote Safety inputs on the Controller board opens. The motor is prohibited from operating in either the VFD or bypass modes while either of these contacts is open.

EXCEPTION: Essential Services ignores a Safety Fault.

NOTE: If not using the Remote Safety feature, hard wire the two Remote Safety inputs.

If the Electronic Bypass Option current overload relay trips, the Overload Fault indicator lights and the motor will not run in bypass mode.

When the Auto Bypass DIP switch is enabled, the Auto Bypass Enabled indicator is on steady. Bypass operation is automatically initiated by the SED2.

When Auto Bypass is active, the Auto Bypass Enabled indicator flashes.

When the Essential Services DIP switch is enabled, the Essential Services indicator is on steady.

When the Essential Services input is open, normal operation is indicated as the output contactor remains closed to keep the motor running and the Essential Services indicator is on steady.

When the Essential Services input is closed, the bypass contactor closes and the Essential Services indicator flashes.

Nothing can interrupt the Essential Services mode except for the Essential Services input opening.

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SED2 VFD Electronic Bypass Option Operating Instructions

VFD0108R1

Pushbutton/Indicator

Description

When the Interlock DIP switch is enabled, the Interlock Start Logic Enable indicator is on steady. Any call to start the motor in either VFD or bypass modes will not start the motor; instead it will close the Programmable Output relay on the Controller board.

The Programmable Output can be used to actuate another device. When

INTERLOCKSTARTLOGIC Enable Commanded Proofed this occurs, the Interlock Start Logic Commanded indicator also lights, and the Interlock Start Logic Proofed indicator flashes.

A contact closure from this other device is wired to the Interlock Start on the Controller board which then starts the motor and turns the Interlock Start Logic Proofed indicator on steady. This feature is also called damper end switch relay logic.

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Installation Instructions

Installation Instructions

Environmental Conditions

Install the Electronic Bypass Option in a heated, indoor controlled environment that is free of moisture and conductive contaminants such as condensation and dust. The air entering the unit for ventilation/cooling must be clean and free from corrosive gases.

The ambient temperature must be between 14°F and 104°F (-10°C to 40°C) and the relative humidity must be 0% to 95% noncondensing. Do not mount unit in direct sunlight.

Mechanical Installation

Inspection

1.As you unpack the Electronic Bypass Option, check for shipping damage. In the event of damage, contact the transport company.

2.Locate the Electronic Bypass Option nameplate and confirm that the unit is configured to the installation requirements.

3.Verify the delivery is complete. If not, contact the supplier.

Dimensions and Weights

Figure 5 shows overall and mounting dimensions for the Electronic Bypass Option. Figures 6 through 8 show conduit locations.

Approximate weights are as follows.
	Bypass	Weight lb (kg)
	Frame Size
	A	45	(20)
	B	55	(25)
	C	75	(34)
	D	150 (68)
	E	180 (82)
	F	470	(213)

NOTE: Exact weight will be affected by actual horsepower/voltage and selected power options.

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SED2 VFD Electronic Bypass Option Operating Instructions

Mounting

1.To ensure safe installation, verify that the surface of the mounting location is level.

2.Mount the Electronic Bypass Option vertically with the SED2 operator panel, Electronic Bypass Option keypad, and disconnect accessible.

= Protective Shield
		Depth
		With
		Handle
Depth		9.6 (24)
With	13.2	1.5
Handle
9.6 (24)	(34)	(3.8)
34		48
		(122)
(86)
		10.5 TYP
		(27)
	12.4	1.5
	(31)	(3.8)

Frame Size

A and B

							Depth
							With
11.5							Handle
		1				10.4 (26)
(29)		(2.5)				2
						(5)

	53.5
	(136)
	11 TYP
	(28)
10.6	2
(27)	(5)
Frame
Size C

20.82.9

(53)(7.4) 4

(10)

	11.5 TYP
	(29)
19.9	3.4
(51)	(8.6)
Frame
Size D

Depth			20.8			2.9
With
Handle				(53)		(7.4) 3
12.2 (31)										(7.6)

	58.5
	(149)
		10 TYP
		(25)
	19.9	5.5
VFD0127R2	(51)	(14)
	Frame Size E

		45.5						Depth
								17.4
	(116)
								(44)

57.5

(146)

Frame Size F

NOTE: It is recommended to leave 6 inches (15 cm) around the top and sides of the unit.

Figure 5. E-Bypass Dimensions in Inches (Centimeters).

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Installation Instructions

VFD0201R1

1/2 (1.3) AND 3/4 (1.9) CONDUIT KNOCKOUTS

3/4 (1.9) AND 1 (2.5) CONDUIT KNOCKOUTS

6

(15.2)

3-5/8

(9.2)

2-1/8

(5.3)

9-1/2

(24.1)

Figure 6. Frame Sizes A through C Conduit Locations. Viewed from Bottom; Dimensions in Inches (Centimeters).

1/2 (1.3) AND 3/4 (1.9) CONDUIT KNOCKOUTS

1-1/4 (3.2) AND 1-1/2 (3.8) CONDUIT KNOCKOUTS (3)

	8
	(20.3)
	4
	(10.2)
	2-3/4
VFD0202R1	(6.9)
	8-1/2	(40.7)
	(21.7)	16

Figure 7. Frame Sizes D and E Conduit Locations. Viewed from Bottom;

Dimensions in Inches (Centimeters).

VFD0203R1

				20-3/8
			15-3/8	(51.7)
		13-5/8	(39.1)
	11-7/8	(34.6)
7-3/8	(30.1)
(18.7)

4-1/4

(10.8)

3/4 (1.9) AND 1 (2.5) CONDUIT KNOCKOUTS (3)

3 (7.6) CONDUIT KNOCKOUTS (2)

Figure 8. Frame Size F Conduit Locations. Viewed from Top; Dimensions in Inches (Centimeters).

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SED2 VFD Electronic Bypass Option Operating Instructions

Electrical Installation

See Figure 9 for all Electronic Bypass Option wiring.

1.Route shielded twisted pair (recommended wire type) cable, 24 gauge minimum control wiring in conduit through knockout and into housing (Figures 10 through 12). Connect control wiring per job-specific drawings.

NOTES:

•Terminate shield at control device.

•Control wiring is 12 to 26 AWG and tightening torque is 5 lb-in.

2.If applicable, route communications wiring (P1) in conduit through knockout and into housing (Figures 10 through 12). Continue to route communications wiring to SED2 and terminate per SED2 VFD Startup, Operation, and Maintenance Manual (125-3201).

3.Route motor wiring in conduit through knockout and into housing (Figures 10 through 12). Connect motor wiring to motor overload and ground lug. See Tables 1 through 4 for wire sizes and tightening torques.

4.Route input power wiring in conduit through knockout and into housing (Figures 10 through 12). Connect input power wiring to disconnect switch and ground lug or to circuit breaker and ground lug. See Tables 1 through 4 for wire sizes and tightening torques.

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