Yaskawa P7B User Manual

P7B Drive/Bypass

Technical Manual

Model: P7B Document Number: TM.P7B.01

Quick Reference for Bypass Parameters

Parameter

Number

Factory Setting

User

Setting

Parameter

Number

Factory Setting

User

Setting

Parameter

Number

Factory Setting

User

Setting

Parameter

Number

Factory Setting

User

Setting

A1-00 0 b5-04 100 E1-05 240V or 480V L1-05 0.2 A1-01 2 b5-06 100 E1-06 60 L2-01 2 A1-03 0 b5-07 0 E1-07 3 L2-02 0.1 A1-04 0 b5-08 0 E1-08 18 L2-03 0.1 A1-05 0 b5-09 0 E1-09 1.5 L2-04 0.3 A2-01 b5-10 1 E1-10 10.8 L2-05 190 A2-02 b5-11 0 E1-11 0 L3-01 1 A2-03 b5-12 0 E1-12 0 L3-02 120 A2-04 b5-13 0 E1-13 0 L3-04 1 A2-05 b5-14 1 E2-01 kVA Dep. L3-05 1 A2-06 b5-15 0 E2-03 kVA Dep. L3-06 120 A2-07 b5-16 0 E2-05 kVA Dep. L4-01 0 A2-08 b5-17 0 F6-01 3 L4-02 2 A2-09 b5-18 0 F6-02 0 L4-05 0 A2-10 b5-19 0 F6-03 1 L4-06 80 A2-11 b5-20 1 F6-05 0 L5-01 10 A2-12 b5-21 1 H1-01 70 L5-02 0 A2-13 b5-22 0 H1-02 L5-03 600 A2-14 b5-23 0 H1-03

See Table 2 of

the bypass

schematic

L6-01 6 A2-15 b5-24 0 L6-02 15 A2-16 b5-25 0 L6-03 10 A2-17 b5-26 0 H1-04 4 L8-01 0 A2-18 b5-27 60 H1-05 6 L8-02 95 A2-19 b5-28 0 H2-01 0 L8-03 4 A2-20 b5-29 1 H2-02 3B L8-06 5 A2-21 b5-30 0 H3-02 See Table 2 of

the bypass

schematic

L8-09 1 A2-22 b8-01 1 L8-10 0 A2-23 b8-04 kVA Dep. L8-11 300 A2-24 b8-05 20 H3-03 0 L8-12 45 A2-25 b8-06 0 H3-08 See Table 2 of

the bypass

schematic

L8-15 1 A2-26 C1-01 60 L8-18 1 A2-27 C1-02 60 L8-19 20 A2-28 C1-03 30 H3-09 See T able 2 of

the bypass

schematic

n1-01 1 A2-29 C1-04 30 n1-02 1 A2-30 C1-09 10 n3-01 5 A2-31 C1-11 0 H3-10 100 n3-02 150 A2-32 C2-01 0.2 H3-11 0 n3-03 1 b1-01 See T able 2 of

the bypass

schematic

C2-02 0.2 H3-12 0.3 n3-04 40 C4-01 1 H3-13 See Table 2 of

the bypass

schematic

o1-01 6

C4-02 200 o1-02 1 b1-02 1 C6-02 kVA Dep. o1-03 0 b1-03 0 C6-03 kVA Dep. H4-01 2 o1-05 3 b1-04 1 C6-04 kVA Dep. H4-02 100 o1-06 0 b1-07 1 C6-05 0 H4-03 0 o1-07 2 b1-08 1 d1-01 10.0 H4-04 8 o1-08 3 b1-11 0 d1-02 6.0 H4-05 50 o2-01 1 b1-12 0 d1-03 0 H4-06 0 o2-02 0 b2-01 0.5 d1-04 40 H4-07 0 o2-03 0 b2-02 50 d1-17 6 H4-08 0 o2-04 kVA Dep. b2-03 5.0 d2-01 100 H5-01 1F o2-05 1 b2-04 0 d2-02 0 H5-02 3 o2-06 1 b2-09 0 d2-03 0 H5-03 0 o2-07 0 b3-01 2 d3-01 0 H5-04 3 o2-08 1 b3-02 120 d3-02 0 H5-05 1 o2-09 1 b3-03 2 d3-03 0 H5-06 5 o2-10 0 b3-05 0.2 d3-04 1 H5-07 1 o2-12 0 b3-14 1 d4-01 0 H5-08 0 o2-14 0 b4-01 0 d4-02 10 H5-09 2 o2-15 0 b4-02 0 E1-01 208, 240V or

480V

L1-01 1 o3-01 0 b5-01 0 L1-02 8 o3-02 1 b5-02 2 E1-03 F L1-03 3 T1-02 kVA Dep. b5-03 5 E1-04 60 L1-04 1 T1-04 kVA Dep.

Warnings and Cautions

This Section provides warnings and cautions perti nent to this product, that if not heeded, may result in personal injury, fatality, or equipment damage. Yaskawa is not responsible for consequences of ignoring these instructions.

WARNING

YASKAWA manufactures component parts that can be used in a wide variety of industrial applications. The selection and application of YASKAWA products remain the responsibility of the equipment designer or end user. YASKAWA accepts no responsibility for the way its products are incorporated into the final system design. Under no circumstances should any YASKAWA product be incorporated into any product or design as the exclusive or sole safety control. Without exception, all controls should be designed to detect faults dynamically and fail safely under all circumstances. All products designed to incorporate a component part manufactured by YASKAWA must be supplied to the end user with appropriate warnings and instructions as to that part’s safe use and operation. Any warnings provided by YASKAWA must be promptly provided to the end user. YASKAWA offers an express warranty only as to the quality of its products in conforming to standards and specifications published in the YA SKAWA manual. NO OTHER WARRANTY, EXPRESS OR IMPLIED, IS OFFERED. YASKAWA assumes no liability for any personal injury, property damage, losses, or claims arising from misapplication of its products.

WARNING

• Read and understand this manual before installing, operating, or servicing this Drive. All warnings, cautions, and

instructions must be followed. All activity must be performed by qualified personnel. The Drive must be installed according to this manual and local codes.

• Do not connect or disconnect wiring while the po we r is on. Do not remov e covers or t ou ch ci rcuit boar ds while the po wer is

on.

• Before servicing, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply

is turned off. Status indicator LEDs and Digital Operator display will be extinguished when the DC bus voltage is below 50 VDC. To prevent electric shock, wait at least five minutes after all indicators are OFF and measure DC bus voltage level to confirm safe level.

• Do not perform a withstand voltage test on any part of the unit. This equipment uses sensitive devices and may be damaged

by high voltage.

• The Drive an d Bypass unit is not s uitable for circuits capable of deliv ering more than the specified RMS symmetrical

amperes. Install adequate branch short circuit protection per applicable codes. Refer to the specification. Failure to do so may result in equipment d amage and/or personal inj ury.

• Do not connect unapproved LC or RC interference suppression filters, capacitors, or overvoltage protection devices to the

output of the Drive. These devices may generate peak currents that exceed Drive specifications.

• To avoid unnecessary fault displays caused by contactors or output switches placed between Drive and motor, auxiliary

contacts must be properly integrated into the control logic circuit.

• YASKAWA is not responsible fo r any modification of the product m ade by the user; doing so will void the warranty. This

product must not be modified.

• Verify that the rated voltage of the Drive and Bypass un it matches the voltag e of the inco ming pow er supply befor e applyin g

power.

• To meet CE directives, proper line filters and proper installation are required.

WARNING

• Some drawin gs in this manual may be shown with protectiv e covers or shields removed, to descr ibe details. These must be

replaced before operation.

• Observe electrostatic discharge procedures when handling circuit cards to prev ent ESD damage.

• The equipment may start unexpectedly upon application of power. Clear all personnel from the Drive, motor, and machine

area before applying power. Secure covers, couplings, shaft keys, and machine loads before energizing the Drive and By pass unit.

• Please do not connect or operate any equipment with visible damage or missing parts. The op erating company is responsible

for any injuries or equipment damage resulting from failure to heed the warnings in this manual.

! Intended Use

Drives and Bypass Units are intended for installation in electrical systems or machinery. For use in the European Union, the installation in machinery and systems must conform to the following product standards of

the Low Voltage Directive: EN 50178, 1997-10, Equipping of Power Systems with Electronic Devices EN 60201-1, 1997-12 Machine Safety and Equipping with Electrical Devices

Part 1: General Requirements (IEC 60204-1:1997)/ EN 61010, 1997-11Safety Requirements for Information Technology Equipment (IEC 950:1991 + A1:1992 + A2:1993 + A3:1995 + A4:1996, modified)

CE certification per EN 50178 can be achieved using the line filters specified in this manual and following the appropriate

installation instructions.

!Other

The Drive and Bypass unit is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 240Vac maximum (240V Class) and 480Vac maximum (480V Class).

This manual is for reference only and subject to change without notice.

Introduction

This Section describes the applicability of the Manual

! Product Description

The P7 Bypass unit provides a means of bypassing the Drive while allowing the motor to operate at full speed, directly from the AC line. It incorporates an AC Drive and three contactor Bypass arrangement in a single UL listed enclosure. The three electrically interlocked IEC rated contactors isolate the Drive when operating in Bypass mode.

Control logic provides industry standard Hand/Off/Auto functions and safety circuit interlocks in both drive and Bypass operating modes.

Bypass components include: a fused 120 VAC control circuit transformer, an input Motor Circuit Protector (MCP) circuit breaker/disconnect, motor overload relay, selector switches and indicating lights.

The P7 Drive, a component of the P7 Bypass package, is a Pulse Width Modulated Drive for 3-Phase AC induction motors. This type of Drive is also known as an Adjustable Frequency Drive, Variable Frequency Drive, AC Drive, AFD, ASD, VFD, and Inverter. In this manual, the P7 Drive will be referred to as the “Drive”.

The Drive is a variable torque AC drive, designed specifically for HVAC applications, including fans, blowers and pumps. A new benchmark for size, cost, performance, benefits, and quality, the Drive includes numerous built-in features such as network communications, H/O/A, PI, parameter storage and copy functions.

The Drive has communications for the popular protocols: DeviceNet, Profibus, Ethernet, etc. An optional L interface card is also available.

The LCD keypad/operat or is equi p ped wit h Hand/ Off/Auto functions, copy feature, 7 language choices, and 5 li nes of di s play with 16 characters per line. User parameter settings can be recovered at any time via “User Initialization”. Optional DriveWizard software allows upload/download, as well as graphing and monitoring of drive parameters from a PC for ease of drive management.

Built-in PI eliminates the need for closed loop output signals from a building automation system. It includes feedback display, inverse, square root and differential control functions, and maintains setpoint for closed loop control of fans and pumps for pressure, flow, or temperature regulation.

This manual is applicable to P7 Drives defined by model numbers of CIMR-P7U_ _ _ _ contained within Bypass units defined by model numbers of P7B_ _ _ _.

This manual is subject to change as product improvements occur. The latest version of the manual can be obtained from the Yaskawa website www.drives.com of Drive software is also shown.

. The date shown on the rear cover is changed when revisions are made. The latest version

ONWORKS®

Introduction iii

This manual may describe trademarked equipment, which is the property of other companies. These trademarks are the property of the registered owner companies and may include the following:

PROFIBUS DeviceNet is a registered trademark of ODVA (Open DeviceNet Vendor Association, Inc.)

Modbus

ONWORKS

Other Documents and Manuals are available to support special use or installation of this product. These documents may be provided with the product or upon request or downloaded from www.drives.com. Documents may include the following:

TM.P7.02.Programming … Manual included on CD ROM with product DriveWizard … Software and Manual…Included on CD ROM with product Option Instructions … Included on CD ROM with product

and PROFIBUS-DP® are registered trademarks of PROFIBUS Nutzerorganization e.v.

, trademark of Schneider Automation, Inc.

, trademark of Echelon Corporation

! Definitions of Acronyms and Abbreviations

AC Alternating Current LRA Locked Rotor Amperes AIC Amps Interrupting Capacity MCP Motor Circuit Protector CB Circuit Breaker MTBF Mean Time Between Failures CIMR Control Induc tion Motor Rotation NC Normally Closed CN Connector NEC National Electrical Code CPT Control Power Transformer NEMA National Electrical Manufacturers Association CPU Central Processing Unit NO Normally Open DIP Dual Inline Package OLR Over Load Relay FLA Full Load Amperes PCB Printed Circuit Board FVFF Forced Ventilated, inlet Filter, outlet Filter PI Proportional plus Integral control action HOA Hand/Off/Auto SFS Soft Start HP Horsepower TB T ermin al Block IEC International Electrotechnical Commission THD Total Harmonic Distortion IGV Inlet Guide Vanes VA Volt Amperes IPM Intelligent Power Module VAC Volts Alternating Current KVA Kilo Volt Amperes VAV Variable Air Volume LED Light Emitting Diode

! Terminology in This Manual

“Standard” or “Configured” options - are available with standard lead times

“Engineered” or “Custom” options - are available only with extended lead times

Introduction iv

! Resources Available

Document Number Description

TM.P7.01 Drive User Manual TM.P7.02 Drive Progr a mming Manual TM.AFD.14 DeviceNet Technical Manual TM.AFD.12 Profibus Technical Manual

Table of Resources

Manuals, Installation Guides, and CD’s

IG.AFD.20 LONWORKS IG.AFD.50 3-15 PSI Pressure Transducer Installation Guide CD.AFD7.01 CD ROM for Drives

Document Description

DriveWizard® Software DriveWizard® Software Version 5.3 o r l a ter

® Option Installation Guide

Software

Introduction v

Notes:

Introduction vi

Table of Contents

Quick Reference Parameter List ........................................................Inside front cover

Warnings and Cautions................................................................................................ i

Introduction..................................................................................................................iii

Chapter 1 - Physical Installation ...............................................................................1-1

Bypass Model Number and Enclosure Style .............................................................. 2

Enclosure Data ........................................................................................................... 4

Confirmations upon Delivery ...................................................................................... 7

Bypass Product Options ............................................................................................. 9

Bypass Component Descriptions ............................................................................. 11

Exterior and Mounting Dimensions .......................................................................... 17

Checking and Controlling Installation Site ................................................................ 24

Chapter 2 - Electrical Installation..............................................................................2-1

Termination Configuration - Power Wiring ................................................................. 2

Control Wiring ............................................................................................................. 9

Wiring Diagram ......................................................................................................... 20

Logic Diagram .......................................................................................................... 22

Chapter 3 - Digital Operator.......................................................................................3-1

Digital Operator and Control Panel Display ...............................................................2

Drive Main Menus ......................................................................................................8

Example of Changing a Parameter ..........................................................................16

Chapter 4 - Start Up and Operation ..........................................................................4-1

Start Up Introduction ..................................................................................................2

Bypass Start Up Preparation.......................................................................................3

Bypass Unit Start Up Procedure .................................................................................4

Bypass Operation Description.....................................................................................8

Chapter 5 - Programming ..........................................................................................5-1

Bypass Basic Programming Parameters ...................................................................2

Table of Contents vii

Chapter 6 - Diagnostics & Troubleshooting ........................................................... 6-1

Bypass Diagnostics ....................................................................................................2

Drive Diagnostics .......................................................................................................3

Drive Troubleshooting ..............................................................................................16

Drive Main Circuit Test Procedure ............................................................................22

Drive Date Stamp Information ..................................................................................26

Chapter 7 - Maintenance............................................................................................7-1

Maintenance ...............................................................................................................2

Removing and Replacing Drive in a Bypass Unit .......................................................9

Appendix A - Parameters..........................................................................................A-1

Parameter List ............................................................................................................2

Monitor List ...............................................................................................................26

Fault Trace List ........................................................................................................28

Fault History List ......................................................................................................29

Appendix B - Capacity Related Parameters............................................................B-1

Drive Capacity ............................................................................................................2

Appendix C - Specifications.....................................................................................C-1

Standard Drive and Bypass Specifications .................................................................2

Appendix D - Communication ..................................................................................D-1

Using Modbus Communication ..................................................................................2

Modbus Function Code Details ..................................................................................7

Modbus Data Tables ..................................................................................................9

Modbus Self-Diagnosis ............................................................................................14

Appendix E - Peripheral Devices ............................................................................. E-1

General Peripheral Devices .......................................................................................2

Table of Contents viii

Appendix F - Replacement Parts ............................................................................. F-1

Primary Parts - 208/230/240VAC ...............................................................................2

Primary Parts - 480VAC .............................................................................................3

Bypass Replacement Parts.........................................................................................4

Table of Contents ix

Notes:

Table of Contents x

Chapter 1

Physical Installation

This chapter describes the checks required upon receiving

and the installation process for a Drive and Bypass unit.

Bypass Model Number and Enclosure Style ..................................2

Enclosure D a ta .................... ... .. .......................................... ............ 4

Confirmations upon Delivery ..........................................................7

Receiving C h e c ks .................. .. .. ............................. ...................7

Bypass Namep la te Information ............................. ..................... 7

Bypass Unit Enc l o s u re s ..... ............................ ............................ 8

Bypass Product Options .................................................................9

Bypass Component Descriptions ................................................. 11

Bypass Unit Front Control Panel ............................................ 11

Exterior and Mounting Dimensions ........................ ......................17

Bypass Unit 30 HP and Below, 480 VAC;

15 HP and Below, 208V/240V .................................................17

Bypass Unit 30 HP and Below, 480 VAC;

15 HP and Below, 208V/240V With Add-On Box ...................18

Bypass Unit 40 HP to 100 HP, 480 V AC;

20 HP to 40 HP, 208V/240V ....................................................19

Bypass Unit 40 HP to 100 HP, 480 V AC;

20 HP to 40 HP, 208V/240V With Add-On Box ........................20

Bypass Unit 125 HP to 250 HP, 480 VAC;

50 HP to 125 HP, 208V ................................................. ...........21

Dimensions and Weights ................................ .........................22

Checking and Controlling Installation Site ....................................24

Installation Site ........................................................................ 24

Controlling the Ambient Temperature ......................................25

Protecting the Bypass Unit fr om Foreign Matter ............... .......25

Installation Orientation and Enclosure Considerations ............26

Physical Installation 1 - 1

Bypass Model Number and Enclosure Style

The Bypass covers two voltage ranges: 208-240 VAC and 480 VAC. Ratings applicable are from 1/2 to 500 HP.

Table 1.1 Bypass

Voltage

208 VAC

240 VAC

Bypass

Base Model Number

NEMA 1

P7BVD002 P7BBD002 0.5 2.4 CIMR-P7U22P2 P7BVD003 P7BBD003 0.75 3.5 CIMR-P7U22P2 P7BVD004 P7BBD004 1 4.6 CIMR-P7U22P2 P7BVD007 P7BBD007 2 7.5 CIMR-P7U22P2 P7BVD010 P7BBD010 3 10.6 CIMR-P7U22P2 P7BVD016 P7BBD016 5 16.7 CIMR-P7U23P7 P7BVD024 P7BBD024 7.5 24.2 CIMR-P7U27P5 P7BVD030 P7BBD030 10 30.8 CIMR-P7U27P5 P7BVD046 P7BBD046 15 46.2 CIMR-P7U2011 P7BVD059 P7BBD059 20 59.4 CIMR-P7U2015 P7BVD074 P7BBD074 25 74.8 CIMR-P7U2018 P7BVD088 P7BBD088 30 88 CIMR-P7U2022 P7BVD114 P7BBD114 40 114 CIMR-P7U2030 P7BVD143 P7BBD143 50 143 CIMR-P7U2037 P7BVD169 P7BBD169 60 169 CIMR-P7U2045 P7BVD211 P7BBD211 75 211 CIMR-P7U2055 P7BVD273 P7BBD273 100 273 CIMR-P7U2075 P7BVD343 P7BBD343 125 343 CIMR-P7U2090 P7BVD396 P7BBD396 150 396 CIMR-P7U2110 P7BVA002 P7BBA002 0.5 2.2 CIMR-P7U22P2 P7BVA003 P7BBA003 0.75 3.2 CIMR-P7U22P2 P7BVA004 P7BBA004 1 4.0 CIMR-P7U22P2 P7BVA006 P7BBA006 2 6.8 CIMR-P7U22P2 P7BVA009 P7BBA009 3 9.6 CIMR-P7U22P2 P7BVA015 P7BBA015 5 15.2 CIMR-P7U23P7 P7BVA022 P7BBA022 7.5 22 CIMR-P7U25P5 P7BVA028 P7BBA028 10 28 CIMR-P7U27P5 P7BVA042 P7BBA042 15 42 CIMR-P7U2011 P7BVA054 P7BBA054 20 54 CIMR-P7U2015 P7BVA068 P7BBA068 25 68 CIMR-P7U2018 P7BVA080 P7BBA080 30 80 CIMR-P7U2022 P7BVA104 P7BBA104 40 104 CIMR-P7U2030

*NEMA 12

FVFF

Bypass

Continuous

Output Current (Amps)

Uses

Basic Drive

Model-Number

Physical Installation 1 - 2

Table 1.1 Bypas s

Bypass

Base Model Number

Voltage

NEMA 1

P7BVA130 P7BBA130 50 130 CIMR-P7U2037 P7BVA154 P7BBA154 50 154 CIMR-P7U2037

230 VAC

480 VAC

* The Nema 12 FVFF Enclosure is ventilated and filtered with gaskets. UL does not recogniz e NE MA 12

ventilated enclosures, therefore, for UL purposes, these units are designated NEMA 1.

P7BVA192 P7BBA192 60 192 CIMR-P7U2045 P7BVA248 P7BBA248 75/100 248 CIMR-P7U2075 P7BVA312 P7BBA312 125 312 CIMR-P7U2075 P7BVA360 P7BBA360 150 360 CIMR-P7U2090 P7BVB001 P7BBB001 0.5 1.1 CIMR-P7U42P2 P7BVB001 P7BBB001 0.75 1.6 CIMR-P7U42P2 P7BVB002 P7BBB002 1 2.1 CIMR-P7U42P2 P7BVB003 P7BBB003 2 3.4 CIMR-P7U42P2 P7BVB004 P7BBB004 3 4.8 CIMR-P7U42P2 P7BVB007 P7BBB007 5 7.6 CIMR-P7U43P7 P7BVB011 P7BBB011 7.5 11 CIMR-P7U45P5 P7BVB014 P7BBB014 10 14 CIMR-P7U47P5 P7BVB021 P7BBB021 15 21 CIMR-P7U4011 P7BVB027 P7BBB027 20 27 CIMR-P7U4011 P7BVB034 P7BBB034 25 34 CIMR-P7U4015 P7BVB040 P7BBB040 30 40 CIMR-P7U4018 P7BVB052 P7BBB052 40 52 CIMR-P7U4030 P7BVB065 P7BBB065 50 65 CIMR-P7U4030 P7BVB077 P7BBB077 60 77 CIMR-P7U4037 P7BVB096 P7BBB096 75 96 CIMR-P7U4045 P7BVB124 P7BBB124 100 124 CIMR-P7U4055 P7BVB156 P7BBB156 125 156 CIMR-P7U4075 P7BVB180 P7BBB180 150 180 CIMR-P7U4090 P7BVB240 P7BBB240 200 240 CIMR-P7U4110 P7BVB302 P7BBB302 250 302 CIMR-P7U4160

*NEMA 12

FVFF

(Continued)

Bypass

Continuous

Output Current (Amps)

Uses

Basic Drive

Model-Number

Physical Installation 1 - 3

Enclosure Data

Table 1.2 208V Enclosure Data

Input

Volts

0.75 P7U22P21A P7B_D003 3.5 3.8 68

208

Drive

Model CIMR-

0.5 P7U22P21A P7B_D002 2.4 2.6 68

1 P7U22P21A P7B_D004 4.6 5.1 78 2 P7U22P21A P7B_D007 7.5 8.2 110 3 P7U22P21A P7B_D010 10.6 11.7 141 5 P7U23P71A P7B_D016 16.7 18.4 202

7.5 P7U27P51A P7B_D024 24.2 26.6 273 10 P7U27P51A P7B_D030 30.8 33.9 365 15 P7U20111A P7B_D046 46.2 50.8 578 20 P7U20151A P7B_D059 59.4 65.3 653 25 P7U20181A P7B_D074 74.8 82.3 746 30 P7U20221A P7B_D088 88.0 96.8 939 40 P7U20301A P7B_D114 114.0 125.4 1340 50 P7U20370A P7B_D143 143.0 157.3 1523 60 P7U20450A P7B_D169 169.0 185.9 1762 75 P7U20550A P7B_D211 211.0 232.1 2244

100 P7U20750A P7B_D273 273.0 300.3 3003 1214 lbs 125 P7U20900A P7B_D343 343.0 377.3 3296 1330 lbs 150 P7U21100A P7B_D396 396.0 435.6 4029 1423 lbs

Bypass

Model

Number

NEC

FLA

OL 110% 1 min

Note 1: Horsepower rating is based on a standard NEMA B 4-pole motor.

Heat

Loss

NEMA 1 & NEMA 12 -FVFF

Watts

H W D

29.48 19.06 13.66

40.48 25.63 14.66

84.00 25.63 26.25

Enclosure Dimensions

inches

Dimension Drawing

S-5542

Dimension Drawing

S-5544

Dimension Drawing

S-5550

Weight

Assembly

115 lbs

127 lbs 164 lbs

208 lbs

221 lbs 307 lbs

847 lbs

943 lbs

Enclosure Dimensions w/Add-on

NEMA 1 & NEMA 12-FVFF

H W D

43.35 19.06 13.66

55.35 25.63 14.66

inches

Dimension Drawing

S-5543

Dimension Drawing

S-5545

NOT REQUIRED

Weight5 of

Assembly

+Add-on

156 lbs

291 lbs

Electrical

Schematic

Box

P7B-00

Note 2: The underscore position in these model numbers codes for the encl osur e type: V = N EMA1, B = NEM A12 FVF F.

Note 3: Heat loss is the amount of heat dissipated by the drive at full load with all standard options availa ble inside the enclosure. Drive heat sink losses are

included in the heat loss data. Heat loss data is for the enclosure without the add-on enclosure. Note 4: Height dimension (H) excludes the mounting screw tabs. Depth dimension (D) excludes MCP disconnect handle. Note 5: This data represents the total weight with all possibl e stan dard options. Weight could be less depending on the options specified.

Note 6: All standard options are available in this size enclosur e exce pt options E (RFI Filter) and K (5% Output Reactor ) . Opt ions E and K require the ad d- on

enclosure.

Note 7: All options are available in this size enclosure except E (RFI Filter), R (3% Line Reactor), and K (5% Output Reactor). Only option E combined with

either option R or option K can be installe d in the add-on enclosure. Options R and K together require an increase in the size of the P7 Bypass Enclosure.

Contact the factory if all three options a re r equ ir ed . Options D (2 Motor “OR”) or A (2 Motor “AND”) for 30 Hp and 40 Hp require the next

size enclo s u re.

Note 8: Heat sink mounted externally varies the depth dimension depending on the drive size. Depth will not exceed dimension shown. Note 9: All options are available in this size enclosure except options D (2 Motor “OR”) or A (2 Motor “AND”) for 75 Hp and 100 Hp require the next

size enclo s u re.

Physical Installation 1 - 4

Table 1.3 240/230V Enclosure Data

Input Volts

240

230

Drive

Model CIMR-

0.5 P7U22P21A P7B_A002 2.2 2.4 68

0.75 P7U22P21A P7B_A003 3.2 3.5 68 1 P7U22P21A P7B_A004 4.0 4.4 78 2 P7U22P21A P7B_A006 6.8 7.5 110 3 P7U22P21A P7B_A009 9.6 10.6 141 5 P7U23P71A P7B_A015 15.2 16.7 202

7.5 P7U25P51A P7B_A022 22.0 24.2 273 10 P7U27P51A P7B_A028 28.0 30.8 365 15 P7U20111A P7B_A042 42.0 46.2 578 20 P7U20151A P7B_A054 54.0 59.4 653 25 P7U20181A P7B_A068 68.0 74.8 746 30 P7U20221A P7B_A080 80.0 88.0 939 40 P7U20301A P7B_A104 104.0 114.4 1340 50 P7U20370A P7B_A130 130.0 143.0 1523 60 P7U20370A P7B_A154 154.0 169.4 1544

75 P7U20450A P7B_A192 192.0 211.2 1860 100 P7U20750A P7B_A248 248.0 272.8 3003 1214 lbs 125 P7U20750A P7B_A312 312.0 343.2 3045 1330 lbs 150 P7U20900A P7B_A360 360.0 396.0 3440 1423 lbs

Bypass

Model

Number

NEC FLA

110%

1 min

Note 1: Horsepower rating is ba sed on a standard NEMA B 4-pole motor.

Heat

Loss Watts

Enclosure Dimensions

NEMA 1 & NEMA 12 -FVFF

H W D

29.48 19.06 13.66

Dimension Drawing

40.48 25.63 14.66

Dimension Drawing

84.00 25.63 26.25

Dimension Drawing

inches

S-5542

S-5544

S-5550

Weight

Assembly

Enclosure Dimensions w/Add-on

115 lbs

127 lbs 164 lbs

208 lbs

221 lbs 307 lbs

847 lbs

943 lbs

NEMA 1 & NEMA 12-FVFF

H W D

43.35 19.06 13.66

55.35 25.63 14.66

inches

Dimension Drawing

S-5543

Dimension Drawing

S-5545

NOT REQUIRED

Weight5 of

Assembly

+Add-on

156 lbs

291 lbs

Electrical

Schematic

Box

P7B-00

Note 2: Th e und erscor e position in these model numbers codes for the encl osure type: V = NEMA1, B = NEMA12 FVFF.

Note 3: Heat loss is the amount of heat dissipated by the drive at full load with all standard options available inside the enclosure. Drive heat sink losses are

included in the heat loss data. Heat loss data is for the enclosure without the add-on enc los ur e. Note 4: Height dimension (H) excludes the mounti ng screw tabs. Depth dimension (D) excludes MCP disconnect handle. Note 5: Th is da ta repr e se nts the total weight with all possible sta nda r d op ti ons. Weight could be less depending on the options specified.

Note 6: Al l sta nda r d opt ions are available in this size enclosu re ex cept options E (RFI Filter) and K (5% Output R eac tor ) . Options E and K require the add-on

enclosure.

Note 7: All options are available in this size enclosur e exce pt E ( RF I Filte r), R ( 3% Line Re a ct or ), and K (5% Output Reactor). Only option E combined with

either option R or option K can be installe d in the add-on enclosure. Options R and K together r eq uir e an incr e as e in the size of the P7 Bypass Enclosure.

Contact the factory if all three options are req uire d. Options D (2 Motor “OR”) or A (2 Motor “AND”) for 30 Hp and 40 Hp require the next size

enclosure.

Note 8: Hea t sink mounted externally varies the dep th dim e nsion depending on the drive size. Depth will not e xcee d dimension shown. Note 9: All options are available in this size enclosure exc e pt options D (2 Motor “OR”) or A (2 Motor “AND”) for 75 Hp and 100 Hp require the next size

enclosure.

Physical Installation 1 - 5

Table 1.4 480V Enclosure Data

Input

Volts

0.75 P7U42P21A P7B_B001 1.6 1.8 57

480

Drive

Model CIMR-

0.5 P7U42P21A P7B_B001 1.1 1.2 57

1 P7U42P21A P7B_B002 2.1 2.3 62 2 P7U42P21A P7B_B003 3.4 3.7 89 3 P7U42P21A P7B_B004 4.8 5.3 121 5 P7U43P71A P7B_B007 7.6 8.4 155

7.5 P7U45P51A P7B_B011 11.0 12.1 217 10 P7U47P51A P7B_B014 14.0 15.4 318 15 P7U40111A P7B_B021 21.0 23.1 404 20 P7U40111A P7B_B027 27.0 29.7 408 25 P7U40151A P7B_B034 34.0 37.4 485 30 P7U40181A P7B_B040 40.0 44.0 618 40 P7U40301A P7B_B052 52.0 57.2 1040 50 P7U40301A P7B_B065 65.0 71.5 1045 60 P7U40371A P7B_B077 77.0 84.7 1197 75 P7U40451A P7B_B096 96.0 105.6 1357

100 P7U40551A P7B_B124 124.0 136.4 1749 125 P7U40750A P7B_B156 156.0 171.6 2032 150 P7U40900A P7B_B180 180.0 198.0 2486 200 P7U41100A P7B_B240 240.0 264.0 2955 1240 lbs 250 P7U41600A P7B_B302 302.0 332.2 4225 1352 lbs 300 P7U41850A P7B_B361 361.0 397.1 4425 350 P7U41850A P7B_B414 414.0 455.4 4451 400 P7U42200A P7B_B477 477.0 524.7 5099 450 P7U42200A P7B_B515 515.0 566.5 5154 500 P7U43000A P7B_B590 590.0 649.0 7329

Bypass

Model

Number

NEC

FLA

110%

1 min

Note 1: Horsepower rating is based on a sta nda rd NEMA B 4-pole motor.

Heat

Loss

NEMA 1 & NEMA 12 -FVFF

Watts

H W D

29.48 19.06 13.66

40.48 25.63 14.66

84.00 25.63 26.25

Enclosure Dimensions

inches

Dimension Drawing

S-5542

Dimension Drawing

S-5544

Dimension Drawing

S-5550

TBD

Weight

Assembly

115 lbs

127 lbs 164 lbs

142 lbs

203 lbs

232 lbs

241 lbs

943 lbs

Enclosure Dimensions w/Add-on

TBD

NEMA 1 & NEMA 12-FVFF

H W D

43.35 19.06 13.66

Dimension Drawing

55.35 25.63 14.66

Dimension Drawing

inches

S-5543

S-5545

NOT REQUIRED

Weight5 of

Assembly

+Add-on

156 lbs

189 lbs

281 lbs

319 lbs

332 lbs

Electrical

Schematic

Box

P7B-00

Note 2: The underscore position in thes e mode l numbers codes for the enclosure type: V = NEMA1, B = NEMA12 FVFF.

Note 3: Heat loss is the amount of heat dissipated by the drive at full load with all standard options available inside the enclosure. Drive heat sink losses are

included in the heat loss data. Heat los s dat a is for the en cl osur e without the add-on enclosure. Note 4: Height dimension (H) excludes the mounting screw tabs. Depth dim ension (D) excludes MCP disconnect ha ndle. Note 5: This data represents the tot al wei ght wit h al l possible standard options. Weight could be less depending on the options specified.

Note 6: All standard options are available in this size enclosure except options E (RFI Filter) and K (5% Output Reactor). Options E and K require the

add-on enclosure.

Note 7: All options are available in this size enclosure except E (RFI Filter), R (3% Line Reactor), and K (5% Output Reactor). Only option E combined with

either option R or option K can be installed in the ad d- on en closur e . Options R and K together require an increase in the size of the P7 Bypass Enclosure.

Contact the factory if all three options are required. Options D (2 Motor “OR”) or A (2 Motor “AND”) for 75 Hp and 100 Hp require the next

size enclo s u re.

Physical Installation 1 - 6

Confirmations upon Delivery

! Receiving Checks

Check the following items as soon as the Drive and Bypass unit is delivered.

Table 1.5 Checks

Item Method

Has the correct model of Bypass unit been

delivered?

Is the Bypass unit damag e d in an y w ay?

Are any screws or other comp onents loose? Use a screwdriver or the appr opriate tool to check for tightness.

If you find any irregularities in the above items, contact the shipping company, the distributor or representative you purchased the Bypass unit from or your Yaskawa office immediately.

The Bypass unit is thoroughly tested at the factory. Any damages or shortages evident when the equipment is received must be reported immediately to the commercial carrier that transported the material. Shipping damage is not covered by the Yaskawa warranty. After unpacking and inspecting for damage, verify that internal wire connections have not come loose during shipment by spot checking wire terminations with a screwdriver or the appropriate tool .

Check the mo del numb er on the nam epla te o n the rig ht s ide o f the Byp ass unit. Reconcile with packi ng slip and/or order information.

Inspect the entire exterior of the Bypass unit to see if there are any dents, scratches or other damage resulting from shipping.

Bypass unit storage must be in a clean and d ry location. Main tain the factory packaging an d provid e cove ring as needed to protect the Bypass unit from construction site dirt, water, debris and traffic prior to and during construction.

! Bypass Nameplate Information

A nameplate is attached to the right side of the enclosure and the inside of the door of each Bypass unit. The nameplate shown below is an example for a standard Bypass unit.

A.C. INPUT

Volts: 480

Phase: 3

A.C. OUTPUT

Volts: 0-480

Phase: 3

Serial No: 4W033727440-0002 Model No: P7BVB065R Type: P7 BYPASS W.D.: P7B-00 Inst. Manual: TM.P7B.01,CD.AFD7.01

Hz: 50/60

Amps: 71.6

Hz: 0-60

Amps: 65

UNPN0001

Fig 1.1 Bypass Nameplate

(Example)

Physical Installation 1 - 7

" Drive Nameplate Informa tion

A nameplate is also attached to the right side of the Drive inside the Bypass enclosur e. The f ollowing namep late is an ex ample for a standard Drive.

Drive Model Number

Input Power Specifications

Output Power Specifications

Serial Number

UL File Number

CIMR-P7U2011

Fig 1.2 Drive Nameplate

(Example)

Drive Enclosure and Revision Code

Weight

" Bypass Unit Model Numbers

The model number on the nameplate of the Bypass unit indicates the enclosure, voltage, Drive rated current and options of the Bypass unit in alphanumeric codes.

BASE NUMBER OPTIONS

P 7 B 0 9 6

B - - - R - - S - - L

P7 B

ypass Configuraton

Enclosure

NEMA 1

NEMA 12

Voltage

208V 230/240V

480V

Current

NEC Rated Amps (Ex.: "096" = 96A)

Motor Control

1 Motor (Standard)

otor "OR"

2 M 2 Motor "AND"

Input Filter

None (Leave Blank)

Cap Filter

RFI Filte

Input Fuses

None (Leave Blank) Fuses

(1)3% and 5% Bus Reactors are only available as an option on Drives up to

25HP at 208V and 30HP at 480V; larger Drives have a Bus Reactor as standard

(2)3% Input Reactor, when combined with the standard Bus Reactor (available on

drives above 25HP at 208V and 30HP at 480V), yields a total of 5% input impedance

Fig 1.3 Bypass Unit Model Number

Communications

Not Enabled (Leave Blank)

DeviceNet

Profibus

LonWorks

Ethernet

Modbus (Internal)

4-20mA Outp ut

None (Leave Blank)

4-20mA Output

3-15 PSI Transducer

None (Leave Blank)

3-15 PSI Tr ansducer

Speed Pot

None (Leave Blank)

Speed Pot

Custom Nameplates

None (Leave Blank)

Custom Nameplates

Load Reactor

None (Leave Blank)

5% Load Reactor

Line Impedance

None (Leave Blank)

3% Bus Re actor

5% Bus Re actor

3% Input Reactor

(1)

(2)

! Bypass Unit Enclosures

All Bypass units are intended for non-hazardous locations. Various enclosure types are provided to protect against the application environmental conditions:

Nema Type 1 Enclosures are constructed for indoor use to provide a degree of protection against incidental contact with enclosed electrical equipment and falling dust or dirt.

NEMA Type 12 FVFF Enclosures. NEMA provides for both non-ventilated and ventilated NEMA 12 enclosures. When ventilated, a suffix to the type number d efines the ventilation method. A NEMA 12 FVFF enclosure has Forced Ventilation with inlet air Filter and outlet air Filter. The internal pressure is positive with respect to the ambient pressure. UL does not recognize NEMA 12 ventilated enclosures, therefore, these enclosures are designated NEMA 1 for UL purposes.

Physical Installation 1 - 8

Bypass Product Options

Option A - Two motor “AND” control: Allows the operation of two motors from one Drive or Bypass. Pump #1 “AND” pump #2 are operated at the same speed via the output from one Drive or Bypass. The motors are always operated simultaneously therefore, no transfer switch is involved. With the 2 motor “AND” option, motor OverLoad Relays and fuses are provided for each motor and the Drive’s internal motor overload function is disabled. The two motors can be of different capacity if this capacity difference was considered in the ordering process. The factory needs to know the FLA value of each motor controlled in order to select the correct motor overload devices and fuses. (Specifying different capacity motors results in longer, non-standard lead times).

Option D - Two motor “OR” control: A MTR #1/AUTO/MTR #2 selector switch is provided to allow local or remote motor operation selection, between two identical motors, for control by either the Drive or the Bypass (for example, Pump #1 “OR” AUTO “OR” Pump #2). In the AUTO position, a customer supplied contact closure at TB1 terminals 23 and 24 can switch between the two motors. The two motors must be the same horsepower and current draw.

Option E - RFI/EMI Filter: Filters to further attenuate possible VFD generated noise. Radio frequency interference/electro magnetic interference filters reduce conducted noise on the Drive input power leads and therefore, radiated noise from those leads. This option is installed on the input power side of the Drive, between the input contactor and the Drive.

Option F - Drive Input Fuses: Fuses capable of protecting semiconductor devices, r ated at 200 kAIC ar e connected to th e line side of the Drive, between the input contactor and the Drive, to protect the Drive semiconductors when motor or output conductor short circuit faults occur.

Option G - Serial Communication, DeviceNet: An option card that provides DeviceNet protocol for network communication.

Option H - Serial Communication, Profibus: An option card that provides Profibus protocol for network communication.

Option K - 5% Output Reactor: Employed on the output side of the Drive for reduction of peak voltages a pplied to the dr iven

motor . In long Drive to motor lead length si tuat ions , hi g h carrier frequency and reflected waves can cause high voltage spikes at the motor . An ou tput reactor provides motor p rotection in these long motor lead leng th situations. Th is option is installed on the output power side of the Drive, between the output contactor and the Drive.

Option L - Serial Communication, Echelon LonWorks: An isolated RS-422/485 circuit board provides LonTalk protocol for network communication. This option plugs into the CN2 connection on the Drive control circuit board.

Option M - 4 to 20 mA Output: Provides two programmable 0 to 10 VDC analog outputs or two programmable 4 to 20 mA analog outputs.

Option N

of voltage distortion and electrical noise. This passive wye-delta capacitve filter is intended for installation on the VFD input in order to protect other sensitive electronic loads, it provides attenuation of conducted RFI and EMI.

Option P - Pressure to Electrical Transducer: This tran sducer is employed when converting a pneumatic signal to an electrical signal for use as the Drive speed command input. The need for this option comes up on retrofit applications when the pneumatic signal that formerly controlled the pneumatic actuator on Inlet Guide Vanes (IGV), for example, is now to be used to control the fan speed via the Drive. This option is wired to Drive terminals +V, A2 and AC, parameters H3-10 and H3-11 are used for final field calibration of this input if there is jobsite variation from the typical 3 to 15 PSIG pneumatic signal input range.

- Input Capacitive Network Radio Frequency Interference Filter: Electronic equipment can be sensitive to low le vels

Physical Installation 1 - 9

Option Q - Serial Communication , Et her net : An op t ion car d t hat provides Modbus TCP proto col fo r netw or k com munication.

Option R - 3% Input Line Reactor: Employed on the input side of the Drive for Total Harmonic Distortion (THD) suppres-

sion. A line reactor also minimizes the potential for Drive input diode damage from line transients and reduces voltage peaks on the DC bus capacitors. This option is installed on the input power side of the Drive, between the input contactor and the Drive.

Option S - Speed Potentiometer: A door mounted single turn potentiometer for manual control of Drive output and motor speed. This option is wired to Drive terminals +V, A1 and AC and is used as the local speed command input to the Drive instead of the keypad up and down arrows. Parameters for use of this option in conjunction with other input signals are detailed in Table 5.2.

Option V - Embedded Serial Communication, Modbus: A no cost option. The Drive in a Bypass unit is capable of Modbus network communication via the standard RS-422/485 terminals.

Option W - Engraved Plastic Nameplate: An enclosure identification namep late to carry the controlled equipment “tag number”.

Option X - 3% DC Bus Reactor: Attenuates harmonic distortion by limiting the rate of rise of the input current. The bus reactor is wired to the Drive (+1) and (+2) DC bus terminals to provide the equivalent impedance of a 3% input reactor. This option is only used on the low end of the horsepo wer range where DC bu s reactors are not a s tandard Drive co mponent (25 HP and below @ 208 VAC, 25 HP and below @ 240 VAC, and 30 HP and below @ 480 VAC.)

Option Z - 5% DC Bus Reactor: Attenuates harmonic distortion by limiting the rate of rise of the input current. The bus reactor is wired to the Drive (+) and (-) DC bus terminals to provide the equivalent impedance of a 5% input reactor. This option is only used on the low end of the horsepower range where DC bus reactors are not a standard Drive component (25 HP and below @ 208 VAC, 25 HP and below @ 240 VAC, and 30 HP and below @ 480 VAC.)

Physical Installation 1 - 10

Bypass Component Descriptions

! Bypass Unit Front Control Panel

The external appearance, component names, an d term inal arr angem ent o f t he By pas s uni t i s s hown i n Fi gu res 1.4 through 1.8.

MCP

Disconnect

Keypad

Operator

Indicating Lights

Selector Switches

Fig 1.4 E7 Bypass Unit Appearance

" Keyp ad Operator

In a Bypass unit the keypad operator is mounted flush with the hinged door of the enclosure. The addition of a HAND/ OFF/AUTO selector switch for the Bypass logic circuit makes the Hand, Off and Auto keys on the standard Drive keypad

operator redundant. In thi s Bypas s config uration the keypad Hand, Off and Auto keys are disabled in the Drive firm ware and a mask (membrane) is placed over the keypad operator to cover these key s, avo i ding the potential for confusion. The mem brane over the Drive keypad is non-removable order a separate keypad.

" Indicating Lights

On the enclosure door just below the digital operator are six 22 mm, 24 VAC LED indicating li ghts f o r: “Contro l Po wer”, “Drive Run”, “Bypass Run”, “Motor OL/Safeties Fault “Drive Fau lt” and “Smoke Purge”. LED type indicating light s are provided to improve the reliability well beyond that of incandescent bulbs. LED’s have a MTBF of 100K hours, eliminating any need for “push to test” type pilot lights.

on these Bypass units (In order to use the keypad copy function on a Bypass unit -

Physical Installation 1 - 11

" HAND/OFF/AUTO Selector Swit ch

A three position rotary switch employed to control the source of the motor start and speed commands in either the Drive or Bypass operating modes.

Hand Position – Drive Mode: The Drive input and output contactors are energized and the Drive is given a run command. Operation is via the local speed input from the keypad or optional speed potentiometer.

Hand Position – Bypass Mode:

line. Off Position: No power is applied to the Bypass circuit. The Drive input and output contactors are energized and the Drive is

stopped (run command removed). The Off position takes precedence over a serial communication run command. Auto Position – Drive Mode: The Drive input and output contactors are energized. The Drive is enabled to receive a run

command contact closure and speed input analog signal from a separate source. Auto Position – Bypass Mode: The motor full speed across-the-line run/stop is controlled by a customer supplied contact

closure, energizing the Bypass contactor. The H/O/A switch must be in the AUTO position if serial communication is to be used for Drive run, stop and speed control.

The Bypass contactor is energized causing the motor to run at full speed directly across-the-

" DRIVE/BYPASS Selector Switch

A two position rotary switch selecting motor operation from the Drive or directly across-the-line. When transferring from Drive operation to Bypass operation, the logic circuit will require the Bypass unit to stop the motor before completing the transfer to full speed across-the-line operation.

" NORMAL/TEST Selector Switch

A two position rotary switch, test position is used to energize the Drive input contactor while operating in the Bypass mo de (via the HAND or AUTO switch position). In Drive mode switching from NORMAL to TEST position will remove the power from the Drive and the motor will stop. In Bypass mode the test position powers the Drive for programming or other “tests” while keeping it isolated from the motor.

" MCP Motor Circuit Protector Circuit Breaker/Disconnect

Electrically located on the input power side of the Bypass unit, the MCP adjustable, instantaneous trip circuit breaker provides protection from short circuits for the motor power cables. The Bypass three phase input power connection is made to the input terminals of the MCP. The door mounted rotary operating mechanism is a convenient means of disconnecting the Bypass unit from line power for equipment maintenance. The MCP must be in the OFF position in order to open the enclosure door. Service and troubleshooting personnel are prov ided w ith a mean s to defeat this door interlock. The rotary handle provides trip indication and can be padlocked in the OFF position.

CAUTION

Only qualified service personnel should use the defeator feature.

Defeator

Fig 1.5 MCP Handle Positions – RESET/LOCK, OFF, TRIP, ON Shown in the “ON” position

Physical Installation 1 - 12

" Internal Bypass Panel

Fig 1.6 MCP Handle Positions – Shown OFF, With Padlock

Digital Operator

PCB A3

Customer Wiring

Terminal Strip (TB1)

PCB A2

Drive

Line

Connections

Motor Circuit

Protector

Load

Connections

Overload

Relay

Control Power

Transformer

Fig 1.7 Internal Bypass Panel

Input

Contactor

(K1)

Physical Installation 1 - 13

Bypass

Contactor

(K3)

Output

Contactor

(K2)

TB1 Label Defining Customer Control Circuit Connection Points

Fig 1.8 Control Terminal Strip

TB1 with Terminal Numbers Printed on the PCB

Slide Switches for switch selectable functions (Auto Transfer, Remote Transfer and Smoke Purge) are behind this ribbon cable connector. See Fig. 1.9 for details.

" Contactors

The Bypass is a “3 contactor Bypass” circuit employing IEC rated contactors in an electrically interlocked arrangement to allow mutually exclusive operation in Drive or Bypass modes. To minimize enclosure space requirements, they are mounted in a 3 contactor assembly. The control logic and “soft start” characteristic of the Drive limit the Drive input and output contactors to motor FLA current or less. For this reason, the Drive input and output contactors have lower current ratings than the Bypass contactor . The Bypas s contactor is exposed to motor inrush current (LRA) when starting the motor across-the-line and therefore requires a higher current rating.

" OverLoad Relay

The OverLoad Relay (OLR) is mounted to the contactor assembly or back panel (depending on rating), just above the Bypass contactor (see Figure 1.7). Electrically on the output power side of the Bypass unit, the adjustable thermal OLR provides overload protection for the motor in both the Drive and Bypass operating modes. The Bypass three phase output power connection to the motor is made to the output terminals of the overload relay. The OLR is set up in the factory to be a manual reset device, requiring operator attention if an overload trip-out is experienced.

" Control Power Transformer

A Control Power T ransf orme r (CPT) is provided to power the Bypass 120 VAC control circuit. The VA capacity is determ ined by the control circuit and optional functions specified for the unit. 100 VA of extra transformer capacity for customer control logic is provided in the standard unit and additional capacity is available as an “engineered” or “custom” option. The CPT primary is fused in both legs, the secondary is fused when requi red by NEC (a bove 350 VA). One side of the transformer secondary is grounded to the Bypass enclosure.

" Relay and Selector Switch Logic

Operating elements such as indicating lights and selector switches, as well as the control relay logic, have been incorporated into a PCB assembly to eliminate the potential for loose wires after shipment and to control factory costs. The operating elements are located on PCB A3, mounted to the insid e of th e enclosure door and ribbon cable connected to the control relay logic PCB A2. The control relay logic PCB A2 is mounted to the left hand side of the enclosure and contains the control circuit field wiring terminal strip (TB1).

" Drive/Bypass logic interlocks explained

The Bypass 120 VAC relay logic circuit is in terconnected with the Drive multi-function digital input terminals and multifunction digital output terminals to allow a single customer interface to control both Drive and Bypass circuits. Some of these terminals are therefore not available for other field use.

Physical Installation 1 - 14

Drive Multi-function input terminals:

Ter minal S

receives the Drive run command from the 120 VAC relay logic circuit.

receives the Drive run enable signal from the 120 VAC relay logic circuit.

receives the Drive local/remote command from the 120 VAC relay logic circuit via the HAND/OFF/

AUTO and NORMAL/TEST selector switch.

Drive Multi-function output terminals:

Terminals M

and M2 are a normally open Drive run relay contact used to communicate the Drive operational mode

to the 120 VAC relay logic circuit. Terminals M

and M4 are a normally open serial com. run status relay contact used to communicate the Drive

operational state to the 120 VAC relay logic circuit. Terminals M

and MC are a normally open Drive fault relay co ntact used to commu nicate the Drive fault status to the

120 VAC relay logic circuit.

" PCB Jumpers explained

The S101 “Berg pin” jump er on the co ntrol relay logic PC B A2 is not for field use. It is employed only in the factory to enable the 2 motor “OR” configured option. It is removed when this option is present and must be in place when this option is not part of the unit specification (See Figure 1.9). The S102 “Berg pin” jump er on the co ntrol relay logic PC B A2 is not for field use. It is employed only in the factory to enable the Run/Stop Push Button (3 wire control) configured option. It is removed when this option is present and must be in place when this option is not part of the unit specification (See Figure 1.9). TB1 terminals 1 and 2 are jumpered (J1) as the unit is shipped from the factory. If a customer supplied series circuit of NC safety devices is to be used, this jumper is removed and the safety circuit connected between terminals 1 and 2. TB1 terminals 5 and 6 are jumpered (J2) as the unit is shipped from the factory. If a customer supplied Drive NO enabling contacts are to be used (such as a damper end switch or occupied cycle timer), this jumper is removed and the enabling contacts wired between terminals 5 and 6.

Physical Installation 1 - 15

" Switch Selectable Functions:

The slide switches used to select these functions are located on the relay controller Printed Circuit Board (PCB) A2 (See Figure 1.9). The factory default is for these functions to be de-selected.

Smoke Purge: When enabled (switch S105) this function allows a contact closure, between terminals 17 and 18 o f TB1, to transfer motor operation to bypass for a maximum capacity smoke control function. When in smoke purge mode, during emergency fire/smoke situations, the motor overloads and safety interlock circuit are overridden to shift the priority to protecting people rather than equipment.

Auto T ran sfer to B ypass: If enabled (switch S103), the P7 Bypass unit will automatically transfer the motor operation from Drive to Bypass in the event of a Drive fault. When the Drive fault condition has cleared, this function is reset by moving the H/O/A switch to the OFF position, waiting for the keypad to go blank, then switching back to the

DRIVE position.

Before selecting this function in fan applications, care must be taken to ensure that the duct-work is

IMPORTANT

Remote Transfer to Bypass: When selected (switch S104) this function allows a contact closure from a separate source, between terminals 25 and 26 of TB1, to transfer motor operation from Drive mode to Bypass mode. This remote tranfer to Bypass function overrides the DRIVE/BYPASS manual switch.

designed to handle the pressure resulting from full speed operation with the VAV terminal unit dampers at minimum position or closed.

Slide Switches

PCB Jumpers

Fig 1.9 Printed Circuit Board A2

Physical Installation 1 - 16

Exterior and Mounting Dimensions

! Bypass Unit 30 HP and Below, 480 VAC; 15 HP and Below, 208V/240V

Ø0.50(4PLS)

0.75 (19)

(Ø12.7)

FWD

SEQ

REV

REF

ALARM

AUTO

ESC

DATA

Monitor

ENTER

RESET

STOP

RUN

MIN. 6

(152.4)

32.00

(812.8)

1.29

(32.8)

0.75 (19)

MIN. 1.50

(3.81)

BYPASS RUN

MOTOR OL/

SAFETIES FAULT

TEST

CONTROL

DRIVE

POWER ON

RUN

SMOKE

DRIVE

PURGE

FAULT

NORMAL

OFF

AUTO

DRIVE

BYPASS

HAND

16.50

(419.1)

19.06

(484.1)

29.48

(748.8)

2.37

(60.2)

13.66 (347)

RECOMMENDED CONDUIT ENTRANCE AREA TOP, BOTTOM AND SIDE

MIN. 6 (152.4)

DIMENSIONS IN INCHES (MM), FOR REFERENCE ONLY

2.50

(63.5)

Fig 1.10 Enclosure 1 for up to 30HP, 480 VAC

NEMA 1 and NEMA 12 FVFF Enclosures

Physical Installation 1 - 17

TOP VIEW

! Bypass Unit 30 HP and Below, 480 VAC; 15 HP and Below, 208V/240V

With Add-On Box

19.06

FWD

Monitor

BYPASS

(419.1)

REV

CONTROL POWER ON

SMOKE

PURGE

16.50

SEQ

REF

AUTO

STOP

DRIVE

(484.1)

Ø0.50(4PLS)

(Ø12.7)

ALARM

ESC

DATA ENTER

RESET

DRIVE

RUN

DRIVE FAULT

OFF

AUTO

HAND

29.48

(748.8)

43.35

(1,101.2)

MIN. 6 (152.4)

44.60

(1132.8)

32.00

(812.8)

(32.8)

0.75

(19)

1.29

SAFETIES FAULT

TEST

RUN

BYPASS

RUN

MOTOR OL/

NORMAL

12.60

(317.5)

(19)

0.75

MIN. 1.50

(3.81)

13.50

(342.9)

5.37

(136.4)

13.87 (3.81)

2.50

(63.5)

2.37

(60.2)

13.66 (347)

RECOMMENDED

CONDUIT

ENTRANCE AREA

TOP, BOTTOM AND SIDE

9.1 3.375

(231.1)

TOP VIEW

(85.7)

DIMENSIONS IN INCHES (MM), FOR REFERENCE ONLY

Fig 1.11 Enclosure 1, with Options Extension, for up to 30HP, 480 VAC

NEMA 1 and NEMA 12 FVFF Enclosures

Physical Installation 1 - 18

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