Trane TR200 User Manual

August 2011

BAS-SVX49A-EN

Operators Guide

TR200 Vertical Bypass/Non Bypass Panel

SAFETY WARNING

Only qualiﬁed personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires speciﬁc knowledge and training. Improperly installed, adjusted or altered equipment by an unqualiﬁed person could result in death or serious injury. When working on the equipment, ovserve all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.

Safety

WARNING

EQUIPMENT HAZARD!

The vertical bypass/non bypass panel contains dangerous voltages when connected to mains voltage. It is strongly recommended that all electrical work conform to the National Electrical Code (NEC) and all national and local regulations. Installation, start-up and maintenance should be performed only by qualified personnel. Failure to follow the NEC or local regulations could result in death or serious injury.

Motor control equipment and electronic controls are connected to hazardous mains voltages. Extreme care should be taken to protect against shock. The user must be protected against supply voltage and the motor must be protected against overload in accordance with applicable national and local regulations. Be sure equipment is properly grounded. Wear safety glasses whenever working on electric control or rotating equipment.

Warning against unintended start

WARNING

UNINTENDED START!

When the vertical bypass/non bypass panel is connected to AC input power, the motor may start at any time. The drive, panel, motor, and any driven equipment must be in operational readiness. Failure to be in operational readiness when panel and drive are connected to AC input power could result in death, serious injury, or equipment or property damage.

Grounding Correct protective grounding of the equipment must be established in accordance with national and local codes. Ground currents are higher than 3mA.

Safety Guidelines

1. Disconnect the drive and vertical bypass/non bypass panel from mains before commencing service work

2. DO NOT touch electrical parts of the vertical bypass/non bypass panel or drive when mains is connected. After mains has been disconnected, wait 15 minutes before touching any electrical components or read the label on vertical bypass/non bypass panel.

3. The user must be protected against supply voltage and the motor must be protected against overload in accordance with applicable national and local regulations.

4. While programming parameters, the motor may start without warning. Activate the [Off] key on the keypad when changing parameters.

5. The [Off] key on the keypad does not isolate the drive from mains voltage and is not to be used as a safety switch.

When the vertical bypass/non bypass panel is connected to mains, the motor may be started by means of an external switch, a serial bus command, an input reference signal, or a cleared fault condition. Use appropriate cautions to guard against an unintended start.

WARNING

GROUNDING HAZARD!

For operator safety, it is important to ground drive, vertical bypass panel, and motor properly. Follow the grounding guidelines of local and national codes. Failure to follow grounding guidelines could result in death or serious injury.

BAS-SVX49A-EN

Contents

1 Introduction

1.1.1 Purpose of the Manual 2-1

1.1.2 Overview 2-1

1.1.3 Typical Bypass Operation 2-1

1.2 Bypass Circuits

1.2.1 Three-contactor Bypass 2-1

1.3 Bypass Options

1.3.1 Common Run/Stop with Bypass 2-2

1.3.2 Automatic Bypass 2-2

1.3.3 Run Permissive in Bypass 2-2

1.3.4 Basic Fire Mode in Bypass 2-2

1.3.5 Advanced Fire Mode in Bypass 2-2

1.3.6 Overload Protection 2-2

1.4 Bypass Platform Configurations

1.5 Switch Mode Power Supply

1.5.1 Control Transformer 2-3

1.6 Disconnects

2-1

2-2

2-3

1.6.1 Main Disconnect 2-3

1.6.2 Mode Selector Switch 2-4

1.6.3 Panel Configurations 2-5

1.6.4 Panel Voltage and Frame Ratings 2-6

1.7 Power Component Functions

1.7.1 Power Fusing 2-6

2 Pre-installation

2.1.1 Receiving Inspection 3-1

2.1.2 Pre-installation Check 3-1

2.1.3 Installation Site Check 3-1

2.2 Harsh Environments

2.2.1 Airborne Liquids 3-2

2.2.2 Airborne Solids 3-2

2.2.3 Corrosive Chemicals 3-2

3 Installation

3.1.1 Tools Required 4-1

2-6

3-1

3-2

4-1

BAS-SVX49A-EN

3.1.2 Drive Fuses 4-1

3.1.3 Internal Main Panel Fuses 4-3

3.2 Mechanical Installation

4-3

Contents

3.2.1 Lifting 4-3

3.2.2 Hoist or Overhead Lift 4-3

3.2.3 Forklift 4-3

3.2.4 Shipping Weights 4-3

3.3 Cooling

3.4 Electrical Installation

3.4.1 Component Identification & Customer Connection 4-7

3.4.2 Wire and Cable Access 4-15

3.4.3 Wire Size 4-19

3.4.4 Wire Type Rating 4-20

3.4.5 Terminal Tightening Torques 4-20

3.4.6 Input Line Connection 4-25

3.4.7 Motor Wiring 4-25

3.4.8 Grounding (Earthing) 4-26

3.4.9 Control Wiring 4-26

3.4.10 Serial Communication Bus Connection 4-27

3.4.11 Drive Control Terminals 4-28

4 Start Up

4.1.1 Inspection Prior to Start Up 5-2

4.1.2 Start Up Procedure 5-2

4-4

4-5

5-1

5 Electromechanical Bypass (EMB2) Operation

5.1.1 Typical Control Connections for Common HVAC Applications 6-1

5.1.2 EMB2 Auto Bypass 6-3

5.1.3 EMB2 Common Run/Stop 6-3

5.1.4 EMB2 Run Permissive 6-4

5.1.5 EMB2 Overload 6-4

5.1.6 EMB2 Safety Interlock 6-5

5.1.7 EMB2 Fire Mode 6-5

5.1.8 EMB2 Fault Reporting 6-5

5.1.9 EMB2 Switches 6-6

6 Electronically Controlled Bypass (ECB) Operation

6.1 Electronically Controlled Bypass (ECB) Operation

6.1.1 Overview 7-1

6.1.2 ECB Control Card 7-2

6.1.3 ECB Drive or Bypass Selection 7-5

6.1.4 ECB Programming 7-7

6-1

7-1

BAS-SVX49A-EN

6.1.5 ECB Hand/OFF/Auto 7-8

6.1.6 ECB Mode of Operation 7-8

6.1.7 Bypass Status Word Bit Examples 7-10

6.1.8 ECB Auto Bypass 7-10

6.1.9 ECB Run Permissive 7-11

6.1.10 ECB Overload 7-11

6.1.11 ECB Safety Interlock 7-12

6.1.12 ECB Common Run/Stop 7-12

6.1.13 ECB Advanced Fire Mode 7-13

6.1.14 ECB Fault Reporting 7-13

Contents

7 Start Up Troubleshooting

7.1.1 Option Panel Alarm and Warnings 8-1

8 Appendix

8.1.1 Dimensions 9-1

8.1.2 Mechanical Diagrams 9-2

8.1.3 Typical Wiring Diagrams 9-6

8-1

9-1

BAS-SVX49A-EN

Contents

BAS-SVX49A-EN

1Introduction

Introduction

1.1.1 Purpose of the Manual

This manual is intended to provide detailed information for the installation and operation of the option panel used in conjunction with a Trane variable frequency drive (VFD or drive). To enable efficient handling of the equipment, requirements are provided for installation of mechanical, electrical, control wiring, proper grounding, and environmental considerations. Pre-start and start up procedures are detailed. Also included is a detailed overview of the option panel bypass function. In addition, identification of other optional components and their operation and start up troubleshooting instructions are included. For the electronically controlled bypass, additional programming and operation information is provided.

1.1.2 Overview

A variable frequency drive regulates the speed and operation of an electric motor. The drive is programmable and offers many features and savings compared to operating a motor from unregulated line voltage. The option panel is a protective enclosure in which the drive and various optional components are assembled and mounted. The vertical non bypass panel is always configured with a disconnect switch and fuses to protect the drive. The vertical bypass panel allows switching between running the motor from the drive (variable speed) or across the line input power (constant speed).

The vertical bypass panel comes with one of two control options:

The electromechanical bypass (EMB2)

•

Electronically controlled bypass (ECB)

•

The EMB2 is operated by a selector switch on the front of the panel. The EMB2 controls a motor by switching between drive control, operation in bypass, or off. In addition, a test selection is available, which disengages the motor from the drive but keeps the drive operational while the motor runs in bypass. The switching function activates contactors to provide power to the motor through the drive or bypass circuitry, as required.

inputs, and status reporting. The VFD’s logic circuitry is backed up by an independent panel-mounted power supply so that, even if the drive loses power, control and communication functions are maintained. Programming and display are provided by the keypad. An important feature of the ECB is the ability to accept commands from a building automation system (BAS) and to report operational status in return.

See more detailed descriptions of the EMB2 in 5 Electrome-

chanical Bypass (EMB2) Operation and ECB in 6 Electronically Controlled Bypass (ECB) Operation of this manual.

1.1.3 Typical Bypass Operation

With contactors M1 and M2 closed and contactor M3 open, the motor is running in drive control. Opening contactor M2 removes power to the motor but allows the drive to remain under power. This is referred to as test mode. With contactors M1 and M2 open and contactor M3 closed, the motor is running in bypass from the line input power.

1.2 Bypass Circuits

1.2.1 Three-contactor Bypass

The bypass circuit consists of a bypass contactor (M3) interlocked with a drive output contactor (M2), a drive input contactor (M1), and an overload relay. For the EMB2, a door mounted Drive/OFF/Bypass/Test Selector switch is used to electrically select whether the motor is powered by the drive, connected to the full speed bypass, or disconnected from both. The test position applies power to the motor through the bypass (M3 closed) contactor but removes power from the drive (M2 open) while keeping the drive powered (M1 closed). A Pilot light indicates when in bypass. For the ECB, control selection is made through the drive keypad by pressing the DRIVE BYPASS key and selecting from the available options shown. Display data indicates when in bypass. The circuitry may be supplied with either an input disconnect switch or an input circuit breaker.

The ECB also uses contactors to provide power to the motor through the drive or bypass circuitry. However, the ECB contains a local processor that interacts with the drive’s control logic for programmable options, remote

BAS-SVX49A-EN 1-1

Introduction

Contactor Drive Mode OFF Bypass

Mode

M1 Closed Open Open Closed

M2 Closed Open Open Open

M3 Open Open Closed Closed

Table 1.1 Contactor Operation

Figure 1.1 Basic Non Bypass Circuit

Test Mode

1.3 Bypass Options

1.3.1 Common Run/Stop with Bypass

Allows a remote signal to initiate operation in either drive control or bypass depending upon the position of the bypass selector switch.

1.3.2 Automatic Bypass

1.3.4 Basic Fire Mode in Bypass

This option switches the panel to bypass whenever a remote fire mode signal is given to the VFD through the input terminals. In either drive or bypass, fire mode is intended to ignore common safety and overload inputs for emergency situations. The motor will continue to run in bypass until fire mode is removed or the drive, panel, or motor fails. External safety signals and motor overload are ignored when in fire mode.

This feature automatically transfers the motor from drive to bypass without operator intervention when a fault condition trips the drive, after a programmable time-out period. The VFD’s internal fault circuitry controls this action. The time delay permits all automatically resettable faults to clear prior to transfer to bypass. Run permissive or safety circuit signals override the auto bypass function and may prevent or delay bypass operation.

1.3.5 Advanced Fire Mode in Bypass

The advanced fire mode allows for a variety of programmable responses to an external fire mode command signal. Bypass options are programmed through the drive’s fire mode parameters. See 6.1.13 ECB Advanced Fire Mode.

1.3.6 Overload Protection

1.3.3 Run Permissive in Bypass

This thermally activated device provides mechanical

With run permissive active, the drive sends a run request and waits for a remote response before commanding the motor to start. The response indicates the system is safe to operate.

1-2 BAS-SVX49A-EN

overload protection for the motor while in bypass operation. It measures motor current and is set to the full load amps (FLA) of the motor. A 1.2 x FLA service factor is built-in and maintained, meaning that should the motor current increase above that value, the overload will calculate the level of increase to activate timing for the trip function. The higher the current draw, the quicker the trip response. The overload provides Class 20 motor protection.

1.4 Bypass Platform Configurations

The two bypass platform configurations are ECB and EMB2. The features available as options with each platform are listed in Table 1.2. The ECB, also listed below, has all option features available. See 5 Electromechanical Bypass (EMB2)

Operation for additional details on the EMB2 and 6 Electronically Controlled Bypass (ECB) Operation for the

ECB.

Introduction

Control Features EMB2 ECB

Safety Interlock X X

Common Start / Stop X X

Automatic Bypass X X

Run Permissive X X

Basic Fire Mode X X

Advanced Fire Mode X

Serial Communication X

Table 1.2 Bypass Configurations

Figure 1.2 Basic Bypass Circuit

1.5 Switch Mode Power Supply

The VFD’s logic circuitry is backed up by an independent panel-mounted switch mode power supply so if the drive loses power, control and communication functions are maintained. The SMPS converts three-phase AC input power to 24 V DC control power. Since the SMPS draws power from all three phases, it offers immunity protection from most phase-loss and brown-out conditions. The SMPS is internally protected from short circuit on its output and three board-mounted fuses provide additional protection. The SMPS is not designed for external use and may take up to 5 sec. to initialize at power-up. The SMPS will maintain a 24 V DC output with a low input line voltage. The 200 Volt SMPS will maintain the 24 V DC output with a line voltage as low as 150 V AC and the 600 V SMPS to 335 V AC. Refer to Figure 1.2.

1.5.1 Control Transformer

A control transformer is included on larger horsepower units where the contactor coils are AC. The control transformer steps down the line input voltage to 120V AC. The coils of AC contactors are isolated from the Switch Mode Power Supply via relays.

1.6 Disconnects

1.6.1 Main Disconnect

The main disconnect removes line input power to the drive and bypass. A main disconnect is available in four options.

Fused disconnect. Two-position (ON/OFF) rotary

•

switch, padlock compatible, with three fuses, one on each phase, built into the switch. For safety, the switch must be in the OFF position before

BAS-SVX49A-EN 1-3

Introduction

the option panel door can be opened. (Bypass panel only.)

Disconnect without fuses. For user-supplied fuses

•

option. (Bypass panel only.)

Main circuit breaker. A thermal/ magnetic current

•

interrupt device using an ON/TRIP/OFF/RESET switch. When in the ON position, a trip fault removes power from the drive/bypass circuit and the switch moves to the TRIP setting. The switch must be moved to the RESET position momentarily after the fault has been cleared to reset the circuit breaker. (Bypass panel only.)

Main Disconnect with drive fuses. Non-bypass

•

panel two-position (ON/OFF) rotary switch that disconnects the main AC line power to the drive only.

1.6.2 Mode Selector Switch

The mode selector switch is used for 3-contactor bypass on EMB2 units. The selector switch allows the operator to select from four modes of operation. Drive mode: When drive mode is selected, the M1 and M2 contactors are closed allowing power to flow in and out of the drive to the motor. Off mode: This mode opens all contactors removing any power to the motor. Bypass mode:When bypass mode is selected, the M3 contactor closes and allows the motor to run directly from the input line power. Test mode:Test mode closes the M1 and M3 contactors and allows the motor to be powered by the input line power. This also allows the drive to power up without being connected to the motor. Refer to Figure 1.2.

1-4 BAS-SVX49A-EN

Introduction

1.6.3 Panel Configurations

The TR 200 Drive Series comes in two panel enclosure types. One is the non bypass and the other is the bypass. See Table 1.3 for descriptions and available options.

Non bypass Bypass

Drive plus both of the following:

1. Fuses

2. Disconnect

Table 1.3 Tier Definitions and Features

BAS-SVX49A-EN 1-5

Drive with bypass:

1. Fuses

2. Disconnect/Circuit Breaker

3. Contactors

4. Power Supply

5. Control Module

Introduction

1.6.4 Panel Voltage and Frame Ratings

Table 1.4Table 1.4 defines the voltage and hp ratings of the frames sizes for the panel. See 8 Appendix for overall and mounting dimensions.

Panel P2

(B3 - Drive)

Volts VAC HP (KW)

208 & 230 7.5 (5.5) - 15 (11) 7.5 (5.5) - 15 (11)

460 & 600 15 (11) - 25 (18.5) 15 (11) - 25 (18.5)

Panel P3

(B4 - Drive)

Volts VAC HP (KW)

208 20 (15)

230 20 (15) - 25 (18.5)

460 & 600 30 (22) - 50 (37) 30 (22) - 50 (37)

Panel P4

(C3 - Drive)

Volts VAC HP (KW)

208 25 (18.5)

230 30 (22) - 40 (30)

460 & 600 60 (45) - 75 (55) 60 (45) - 75 (55)

Panel P5

(C4 - Drive)

Volts VAC HP (KW)

208 & 230 50 (37) - 60 (45) 50 (37) - 60 (45)

460 & 600 100 (75) - 125 (90) 100 (75) - 125 (90)

Bypass Non Bypass

TR200 TR200

Bypass Non Bypass

TR200 TR200

20 (15) - 25 (18.5)

Bypass Non Bypass

TR200 TR200

30 (22) - 40 (30)

Bypass Non Bypass

TR200 TR200

Table 1.4 Panel Voltage and Frame Ratings

1.7 Power Component Functions

1.7.1 Power Fusing

For main panel power fuses, only use the specified fuse or an equivalent replacement. For drive fuses only use the specified fuse. See the fuse ratings label on the inside cover of the unit or Table 3.2Table 3.2, Table 3.3Table 3.3, Table 3.4Table 3.4 and Table 3.5Table 3.5.

Main fusing Main fuses are located ahead of the drive and bypass. Main fuses are designed to protect the circuitry within the bypass panel but is not adequate to protect the drive. Main fuses are dual-element, time-delay types and mount inside the bypass enclosure.

1-6 BAS-SVX49A-EN

Drive fusing Drive fuses are located ahead of the drive and are a fastacting type. Drive fuses are standard in all bypass and nonbypass panels.

5,000 or 100,000 amp SCCR The bypass panel supplied with a non fusible Main Disconnect Switch is 5,000 amps short-circuit current rating (SCCR). The bypass panel supplied with a Fusible disconnect or circuit breaker is 100,000 amp SCCR. The non bypass panel supplied with a non-fusible Main Disconnect is 100,000 amp SCCR. See the panel label for SCCR rating.

NOTE!

The 600 V circuit breaker option is 5,000 amp (SCCR).

2 Pre-installation

Pre-installation

2.1.1 Receiving Inspection

Inspect the packaging and equipment closely when received. Any indication of careless handling by the carrier should be noted on the delivery receipt, especially if the equipment will not be immediately uncrated. Obtain the delivery person’s signed agreement to any noted damages for any future insurance claims. Ensure that the model number and power match the order and intended use for the drive.

IMPORTANT LOST OR DAMAGED GOODS INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL If goods are received short or in damaged condition, insist on a notation of the loss or damage across the face of the freight bill. Otherwise no claim can be enforced against the transportation company. If concealed loss or damage is discovered, notify your carrier at once and request an inspection. This is absolutely necessary. Unless you do this the carrier will not entertain any claim for loss or damage. The agent will make an inspection and can grant a concealed damage notation. If you give the transportation company a clear receipt for equipment that has been damaged or lost in transit, you do so at your own risk and expense. Trane is willing to assist you to collect claims for loss or damage, but willingness on our part does not make us responsible for collection of claims or replacement of material. The actual filing and processing of the claim is your responsibility.

2.1.2 Pre-installation Check

1. Compare panel model number to what was ordered.

2. Ensure each of the following are rated for the same voltage:

Drive

•

Panel

•

Power line

•

Motor

•

3. Ensure that the panel output rating is equal to or greater than motor total full load current for full motor performance.

Motor power size and panel must match

•

for proper overload protection.

If panel rating is less than motor; full

•

motor output cannot be achieved.

4. Check motor wiring:

Any disconnect between drive and

•

motor should be interlocked to drive safety interlock circuit to avoid unwanted drive trips.

Do not connect power factor correction

•

capacitors between the drive and motor.

Two speed motors must be wired

•

permanently for full speed.

Y-start, Δ-run motors must be wired

•

permanently for run.

2.1.3 Installation Site Check

Because the option panel relies on the ambient

•

Figure 2.1 Sample Panel Label

BAS-SVX49A-EN 2-1

air for cooling, it is important to observe the limitations on ambient air temperature. Derating concerns start above 104°F (40°C) and 3300 feet (1000m) elevation above sea level.

It is important with multiple panels to check wall

•

strength. Make sure that the proper mounting screws or bolts are used.

Ensure that the wall or floor area for installation

•

will support the weight of the unit.

If construction work continues after the

•

equipment is mounted, it is important to keep the interior free from concrete dust and similar

Pre-installation

dirt. If the unit does not have power applied to it, supply a protective covering. It is important to ensure that the components stay as clean as possible. It may be necessary to clean the interior once construction is completed.

Keep drawings and manuals accessible for

•

detailed installation and operation instructions. It is important that the manuals be available for equipment operators.

2.2 Harsh Environments

NOTE!

The mechanical and electrical components within the option panel can be adversely affected by the environment. The effects of contaminants in the air, either solid, liquid, or gas, are difficult to quantify and control.

2.2.1 Airborne Liquids

Liquids in the air can condense in components. Water carried in the air is easily measured as relative humidity, but other vapors are often more difficult to measure or control. Steam, oil and salt water vapor may cause corrosion of components. In such environments, use TYPE 12 enclosures to limit the exchange of outside air into the option enclosure. Extremely harsh environments may require a higher level of protection.

2.2.2 Airborne Solids

Particles in the air may cause mechanical, electrical or thermal failure in components. A TYPE 1 enclosure provides a reasonable degree of protection against falling particles, but it will not prevent the fan from pulling dirty air into the enclosure.

2.2.3 Corrosive Chemicals

In environments with high temperatures and humidity, corrosive gases such as sulfur, nitrogen and chlorine compounds cause corrosion to occur in components. Indications of corrosion are blackened copper or rust on steel or oxidized aluminum. In such environments, it is recommended that the equipment be mounted in a cabinet with fresh air ventilation and that corrosive compounds be kept away. A non-ventilated cabinet fitted with an air conditioner as a heat exchanger may be used. Conformal coated circuit boards may be specified to reduce the corrosive effects of a harsh environment.

2-2 BAS-SVX49A-EN

3 Installation

Installation

3.1.1 Tools Required

In addition to the standard tool kit, the tools in Table 3.1 are recommended for installation of the option panel.

Spreader bar capable of lifting up to 750 lbs.

Max diameter 0.5 in.

Forklift, crane, hoist or other lifting device capable of handling

up to 750 lbs. (Qualified device operator available for operating

the equipment.)

Metric Socket Set: 7 - 19mm

Socket Extensions: 4, 6, and 12 inch

Torx driver set: T10 - T40

Torque wrench: 6 - 375 lbs-in

Allen Wrenches:1/8, 3/16, 1/4, & 5/16 inches

Metric or English wrenches: 7 - 19mm

Table 3.1 Tools Required

TOOLS

3.1.2 Drive Fuses

To maintain UL, the drive fuses should be replaced only with the fuses specified in , , , and . If an alternate drive fuse is desired please consult the factory. See the specifications label inside the cover of the unit for acceptable replacement drive fuses. A sample of this data can be seen in Table 3.6

208 V AC

HP (KW)

7.5 (5.5) 24,2

10 (7.5) 30,8 LPJ-50-SP JJN-50

15 (11) 46,2 LPJ-70-SP JJN-60

20 (15) 59,4 P3 LPJ-90-SP JJN-80

25 (18.5) 74,8

30 (22) 88

40 (30) 114 LPJ-175-SP JJN-150

50 (37) 143

60 (45) 169 LPJ-250-SP JJN-250 FNQ-R-1.25

UL Motor

Current

Panel (TR200) Non Bypass

& Bypass

P3 - Non Bypass P4 -

Bypass

Main Fuse (TR200)

Bussman

LPJ-40-SP JJN-50

LPJ-125-SP JJN-125

LPJ-150-SP JJN-125

LPJ-250-SP JJN-200 FNQ-R-1.25

Drive Fuse (TR200)

Bussman

Transformer Fuse (TR200)

Bussman

Table 3.2 Drive Fuses 208 V

BAS-SVX49A-EN 3-1

Installation

230 V AC

HP (KW)

7.5 (5.5) 22

10 (7.5) 28 LPJ-45-SP JJN-50

15 (11) 42 LPJ-70-SP JJN-60

20 (15) 54

25 (18.5) 68 LPJ-100-SP JJN-125

30 (22) 80

40 (30) 104 LPJ-150-SP JJN-150

50 (37) 130

60 (45) 154 LPJ-250-SP JJN-250 FNQ-R-1.25

Table 3.3 Drive Fuses 230 V

HP (KW)

15 (11) 21

20 (15) 27 LPJ-40-SP JJS-40

25 (18.5) 34 LPJ-50-SP JJS-50

30 (22) 40

40 (30) 52 LPJ-80-SP JJS-80

50 (37) 65 LPJ-100-SP JJS-100

60 (45) 77

75 (55) 96 LPJ-150-SP JJS-150

100 (75) 124

125 (90) 156 LPJ-250-SP JJS-250 FNQ-R-0.60

UL Motor

Current

UL Motor

Current

Panel (TR200) Non Bypass

& Bypass

Panel (TR200) Non

Bypass & Bypass

Main Fuse (TR200)

Bussman

LPJ-35-SP JJN-50

LPJ-90-SP JJN-80

LPJ-125-SP JJN-125

LPJ-200-SP JJN-200 FNQ-R-1.25

460 V AC

Main Fuse (TR200)

Bussman

LPJ-35-SP JJS-40

LPJ-60-SP JJS-60

LPJ-125-SP JJS-125

LPJ-200-SP JJS-200 FNQ-R-0.60

Drive Fuse (TR200)

Bussman

Drive Fuse (TR200)

Bussman

Transformer Fuse (TR200)

Bussman

Table 3.4 Drive Fuses 460 V

600 V AC

HP (KW)

15 (11) 17

20 (15) 22 LPJ-35-SP JJS-35

25 (18.5) 27 LPJ-45-SP JJS-45

30 (22) 32

40 (30) 41 LPJ-60-SP JJS-60

50 (37) 52 LPJ-80-SP JJS-80

60 (45) 62

75 (55) 77 LPJ-125-SP JJS-125

100 (75) 99

125 (90) 125 LPJ-200-SP JJS-175 FNQ-R-0.50

Table 3.5 Drive Fuses 600 V

UL Motor

Current

Panel (TR200) Non

Bypass & Bypass

Main Fuse (TR200)

Bussman

LPJ-30-SP JJS-35

LPJ-50-SP JJS-50

LPJ-100-SP JJS-100

LPJ-150-SP JJS-150 FNQ-R-0.50

Drive Fuse (TR200)

Bussman

Transformer Fuse (TR200)

Bussman

3-2 BAS-SVX49A-EN

Installation

3.1.3 Internal Main Panel Fuses

Use only the specified fuse or an equivalent replacement for the internal main fuses. See the specifications label inside the cover of the unit for acceptable replacement main fuses. A sample of this can be seen in Table 3.6.

Fuse Description Manufacturer Part Number/Size

F13A & C Primary Transformer Bussmann FNQ-R-0.50

F15A, B, & C Main Fuses Bussmann LPJ-30-SP

F16A, B, & C Drive Fuses Bussmann JJS-35

F900, F901,F902 SMPS - Power Supply Bussmann FWH-020A6F, 500V

Table 3.6 Sample Fuse Rating Label

3.2 Mechanical Installation

3.2.1 Lifting

WARNING

Heavy Objects! Do not use cables (chains or slings) except as shown. Each of the cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit. Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit lift. Other lifting arrangements may cause equipment or property-only damage. Failure to properly lift unit could result in death or serious injury. See details below.

WARNING

Check the weight of unit to determine the safety of the lifting method. Ensure that the lifting device is suitable for the task. If necessary, plan for a hoist, crane or forklift with appropriate rating to move the units.

Follow recommendations below. failure to do so could result in death or serious injury.

3.2.2 Hoist or Overhead Lift

3.2.3 Forklift

Only a competent lift operator with additional

•

support personnel should attempt moving the unit.

Carefully position forklift and ensure stability prior

•

to lift.

3.2.4 Shipping Weights

Weights listed in Table 3.7 are approximate for base units. Options can add or reduce weight of unit. Weights listed are in lbs.

Frame Non Bypass Panel Bypass Panel

P2 36 84

P3 66 106

P4 106 167

P5 155 248

Table 3.7 Approximate Shipping Weights

Use a solid steel spreader bar for lifting. Slide the

•

spreader bar through the two (2) lifting holes on the panel. Lifting rings are 0.59in (15mm) in diameter (see Figure 3.1). If VFD mounting screws interfere with the spreader bar, lifting hooks can be used instead of the lifting bar.

Connect the spreader bar to a hoist or other

•

lifting device.

Carefully lift the unit and secure it to the wall.

•

Refer to 8 Appendix for dimensional drawings to determine fasteners size and location.

BAS-SVX49A-EN 3-3

Installation

Figure 3.1 Proper Lifting Method

3.3 Cooling

Only mount the drive and panel vertically.

•

Panels rely on the ambient air for cooling. It is

•

important to observe the limitations on ambient air temperature. The maximum ambient temperature for all bypass panels is 40°C and 45°C for non bypass panels. Derating concerns start above 3300 feet elevation above sea level.

Most panels may be mounted side-by-side

•

without additional side clearance. However, the P2 (B3 frame size) units require 1.5 in. minimum clearance between units (see Figure 3.2).

Top and bottom clearance is required for cooling

•

(see Figure 3.3). Generally, 2 to 10 inches (50 to 250mm) minimum clearance is required, depending upon the hp (kW) of the unit. See the dimensional drawings in 8 Appendix for specific requirements.

No additional back plate is required for drives

•

with the bypass and non bypass panels.

Figure 3.2 Side Cooling Clearance

Figure 3.3 Cooling Airflow

3-4 BAS-SVX49A-EN

Installation

3.4 Electrical Installation

WARNING

Hazardous Voltage!

Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.

WARNING

Proper Field Wiring and Grounding Required!

All field wiring MUST be performed by qualified personnel. Improperly installed and grounded field wiring poses FIRE and ELECTROCUTION hazards. To avoid these hazards, you MUST follow requirements for field wiring installation and grounding as described in NEC and your local/state electrical codes. Failure to follow codes could result in death or serious injury.

WARNING

EQUIPMENT HAZARD!

Rotating shafts and electrical equipment can be hazardous. It is strongly recommended that all electrical work conform to all national and local regulations. Installation, start-up and maintenance should be performed only by qualified personnel. Failure to follow local regulations could result in death or serious injury.

Motor control equipment and electronic controls

•

are connected to hazardous line voltages. Extreme care should be taken to protect against electrical hazard.

Correct protective grounding of the equipment

•

must be established. Ground currents are higher than 3mA.

A dedicated ground wire is required.

•

Wear safety glasses whenever working on electric

•

control or rotating equipment.

NOTICE! Make all power connections with a minimum of 60°C/ 140°F rated copper wire.

WARNING

INDUCED VOLTAGE!

Run output motor cables from multiple drives separately. Induced voltage from output motor cables run together can charge equipment capacitors even with the equipment turned off and locked out. Failure to run output motor cables separately could result in death or serious injury.

NOTE!

Run input power, motor wiring and control wiring in three separate metallic conduits or raceways for high frequency noise isolation. Failure to isolate power, motor and control wiring could result in less than optimum drive and associated equipment performance.

NOTE RUN INPUT POWER, MOTOR WIRING AND CONTROL WIRING IN THREE SEPARATE METALLIC CONDUITS OR RACEWAYS FOR HIGH FREQUENCY NOISE ISOLATION. FAILURE TO ISOLATE POWER, MOTOR AND CONTROL WIRING COULD RESULT IN LESS THAN OPTIMUM DRIVE AND ASSOCIATED EQUIPMENT PERFORMANCE.

Because the motor wiring carries high frequency

•

electrical pulses, it is important that no other wires are run together. If the incoming power wiring is run in the same conduit as the motor wiring, these pulses can couple electrical noise back onto the building power grid.

At least three separate conduits must be connected to the panel (Figure 3.4).

Power into the panel (and ground back to the

•

distribution panel)

Power from the panel to the motor and earth

•

insulated motor ground

Control wiring

•

Control wiring should always be isolated from the high voltage power wiring.

Avoid getting metal chips into electronics.

Follow the connection procedures as illustrated in the drawing provided with the unit.

BAS-SVX49A-EN 3-5

Installation

Figure 3.4 Power Connections

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Installation

3.4.1 Component Identification & Customer Connection

Mechanical layout drawings are intended to provide the installer or equipment user with component identification and location for that specific unit. Figure 3.5 represents a typical layout drawing. Table 3.8 provides definitions for drawing reference designators. (Not all reference designators are shown.)

Figure 3.5 P2 Bypass Mechanical Layout Diagram

ID Device Definition ID Device Definition

1 24 V DC Panel 24 V DC SMPS 15 S1 Auto Bypass Selector Switch

2 HPC High Pot Connector 16 TF 120 V AC control transformer

3 F13 T1 primary fuse 17 VFD Variable frequency drive

4 CB1 Main Circuit Breaker 18 EMB2 Control Module

5 DS1 Main or Drive Disconnect 19 ECB Control Module

6 F15 Main fuse 20 TB1-C Terminal block 1 - Control

7 F16 Drive fuse 21 TB1-P Terminal block 1 - Power

8 GND Ground terminal 22 PR1 Control Relay for M1 Contactor

9 keypad keypad 23 PR2 Control Relay for M2 Contactor

10 M1 Drive Input contactor 24 PR3 Control Relay for M3 Contactor

11 M2 Drive Output contactor 25 UVM Under voltage module

12 M3 Bypass contactor 26 TC Top Cover

13 OL1 Overload for Motor 27 DH Disconnect Handle

14 PL1 Bypass indicator light

Table 3.8 Reference Designator Definitions

BAS-SVX49A-EN 3-7