Yaskawa P7B User Manual

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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

! Bypass Unit 40 HP to 100 HP, 480 VAC; 20 HP to 40 HP, 208V/240V

Ø0.50 (4PLS)

43.00

(1092.2)

0.75 (19)

MOTOR OL/

SAFETIES FAULT

TEST

(Ø12.7)

FWD

SEQ

REV

REF

ALARM

AUTO

ESC

DATA

Monitor

ENTER

RESET

STOP

RUN

CONTROL

BYPASS

RUN

DRIVE

POWER ON

RUN

SMOKE

DRIVE

PURGE

FAULT

OFF

NORMAL

AUTO

DRIVE

BYPASS

HAND

40.48

(1028.2)

MIN. 6

(152.4)

0.75 (19)

1.32

(33.5)

MIN. 1.50

(3.81)

(584.2)

DIMENSIONS IN INCHES (MM), FOR REFERENCE ONLY

23.00

(584.2)

3.50

(88.9)

2.37

(60.2)

14.66

(372.4)

RECOMMENDED CONDUIT ENTRANCE AREA TOP, BOTTOM AND SIDE

Fig 1.12 Enclosure 2, for 40HP to 100HP, 480 VAC

NEMA 1 and NEMA 12 FVFF Enclosures

MIN. 6 (152.4)

TOP VIEW

Physical Installation 1 - 19

! Bypass Unit 40 HP to 100 HP, 480 VAC; 20 HP to 40 HP, 208V/240V

With Add-On Box

25.63 (651)

MOTOR OL/

SAFETIES FAULT

TEST

23.00

(584.2)

FWD

SEQ

REV

REF

ALARM

AUTO

ESC

DATA

Monitor

ENTER

RESET

STOP

RUN

CONTROL

BYPASS

DRIVE

POWER ON

RUN

SMOKE

DRIVE

PURGE

FAULT

OFF

NORMAL

AUTO

DRIVE

BYPASS

HAND

Ø0.50 (4PLS) (Ø12.7)

40.48

(1028.2)

55.35

(1431.3)

MIN. 6

(152.4)

56.60

(1437.6)

1.32

(33.5)

43.00

(1092.2)

0.75 (19)

13.60

(345.4)

MIN. 1.50

(3.81)

DIMENSIONS IN INCHES (MM), FOR REFERENCE ONLY

Fig 1.13 Enclosure 2, with Options Extension, for up to 40HP to 75HP, 480 VAC

14.87

(377.7)

18.00

(457.2)

7.44

(189)

(60.2)

14.66

(372.4)

3.50

(88.9)

NEMA 1 and NEMA 12 FVFF Enclosures

2.37

RECOMMENDED CONDUIT ENTRANCE AREA TOP, BOTTOM AND SIDE

9.1 4.375

(231.1)

TOP VIEW

(111.1)

Physical Installation 1 - 20

! Bypass Unit 125 HP to 250 HP, 480 VAC; 50 HP to 125 HP, 208V

THIS DIMENSION IS 23.50 IF A MA FRAME CIRCUIT BREAKER IS USED

EYEBOLTS ARE REMOVABLE

15.00 (381)

CIRCUIT

BREAKER HANDLE LOCATION

42.00

(1066.8)

1.70

(43.2)

DRIVE

HEATSINK

MIN. 10.00 (254)

84.00

(2133.6)

37.75

(958.8)

MIN. SPACE REQ'D TO OPEN DOOR

3.00

(76.2)

1.00

(25.4)

13.00

(330.2)

.62

(15.8)

(4 PLS)

1.00

(25.4)

1.38

(35.1)

FOR BOTTOM CONDUIT ENTRY, DUE TO POSSIBLE INTERFERENCE WITH OPTIONAL EQUIPMENT MOUNTED INTERNALLY, VERIFY SPECIFIC REQUIREMENTS WITH THE FACTORY.

DIMENSIONS IN INCHES (MM), FOR REFERENCE ONLY

35.00 (889)

RECOMMENDED CONDUIT ENTRANCE AREA TOP AND BOTTOM

35.50

(901.7)

20.00 (508)

Fig 1.14 Enclosure F1, for 125HP to 250HP, 480 VAC

NEMA 1 and NEMA FVFF 12 Enclosures

20.00 (508)

10.00 (254)

TOP VIEW

5.00

(127)

12.00

(304.8)

3.00

(76.2)

COVER PLATE

Physical Installation 1 - 21

! Dimensions and Weights

Rated

Input

Voltage

208V

240V

230V

Continuous

Output

Current (Amps)

2.4 1/2 D002

3.5 3/4 D003

4.6 1 D004

7.5 2 D007

10.6 3 D010

16.7 5 D016

24.2 7.5 D024

30.8 10 D030

46.2 15 D046

59.4 20 D059

74.8 25 D074 88 30 D088

114 40 D114 143 50 D143 169 60 D169 211 75 D211 273 100 D273 1214 343 125 D343 1330 396 150 D396 1423

2.2 1/2 A002

3.2 3/4 A003

4.0 1 A004

6.8 2 A006

9.6 3 A009

15.2 5 A015 22 7.5 A022 28 10 A028 42 15 A042 54 20 A054 68 25 A068 80 30 A080

104 40 A104 130 50 A130 154 60 A154 192 75 A192 248 100 A248 1214 312 125 A312 1330 360 150 A360 1376

Nominal

(1)

Bypass

_ _ _

Table 1.6 Bypass Dimensions and Weights

NEMA 1 and NEMA 12

Dimensions inches (mm)

Height

32.00

(812.8)

43.00

(1092.2)

84.00

(2133.6)

32.00

(812.8)

43.00

(1092.2)

84.00

(2133.6)

(2)

Width Depth

19.06

(484.1)

25.63

(651.0)

37.75

(958.9)

19.06

(484.1)

25.63

(651.0)

37.75

(958.9)

16.03

(407.2)

17.03

(432.6)

21.7

(551.2)

16.03

(407.2)

17.03

(432.6)

21.7

(551.2)

Mounting

Dimensions

30.5 x 16.5 (774.7) x

41.5 x 23.0

(1054.1 x

Floor Mount

35.0 x 13.0

(889 x 330.0)

30.5 x 16.5 (774.7) x

41.5 x 23.0

(1054.1 x

Floor Mount

35.0 x 13.0

(889 x 330.0)

Wall

H x W

(419.1)

584.2)

W x D

(419.1)

584.2)

W x D

Drawing

Number

S-5542 S-5543

S-5544 S-5545

S-5550 N/A

S-5542 S-5543

S-5544 S-5545

S-5550 N/A

Number

(w/ Add-on

Box)

Weight

(4)

(3)

(lbs)

115

127

208

221 847 943

115

127

208

221 847 943

(1) Horsepower rating is based on standard NEMA B 4-pole motor design (2) Height dimension includes the mounting screw tabs. (3) Add-on box adds 13.6 inches to Height dimen sion and 91 lbs. Max. to total (4) Data represents the total weight of the Drive with all possible standard options, not shipping weigh t.

Physical Installation 1 - 22

Rated

Input

Voltage

480V

Table 1.6 Bypass Dimensions and Weights (Continued)

Continuous

Output

Current (Amps)

Nominal

(1)

Bypass

_ _ _

NEMA 1 and NEMA 12

Dimensions inches (mm)

Height

(2)

Width Depth

Wall

Mounting

Dimensions

H x W

Drawing

Number

1.1 1/2 B001

1.6 3/4

2.1 1 B002

3.4 2 B003

4.8 3 B004

7.6 5 B007 11 7.5 B011

32.00

(812.8)

19.06

(484.1)

16.03

(407.2)

30.5 x 16.5 (774.7) x

(419.1)

S-5542 S-5543

14 10 B014 21 15 B021 27 20 B027

40 30 B040 52 40 B052 65 50 B065 77 60 B077 96 75 B096

43.00

(1092.2)

25.63

(651.0)

17.03

(432.6)

41.5 x 23.0

(1054.1 x

584.2)

S-5544 S-5545

124 100 B124 156 125 B156 180 150 B180 240 200 B240 1240

84.00

(2133.6)

37.75

(958.9)

21.7

(551.2)

302 250 B302 1352

Floor Mount

W x D

35.0 x 13.0

(889 x 330.0)

S-5550 N/A

Drawing

Number

(w/ Add-on

Box)

Weight

(4)

(3)

(lbs)

115

127

14234 25 B034

203 232

241

943

(1) Horsepower r ating is based on standar d NEMA B 4-pole motor design (2) Height dimension includes the mounting screw tabs. (3) Add-on box adds 13.6 inches to Height dimension and 91 lbs. Max. to total (4) Data represents the total weight of the drive with all possible standard options, not shipping weight.

Physical Installation 1 - 23

Checking and Controlling Installation Site

Install the Bypass unit as described below and maintain the specified operating condition s.

! Installation Site

Location of the Bypass unit is important to achieving proper performance and design operating life. Install the Bypass unit as close as possible to the motor. The NEMA type 1 & 12 enclosed units should be installed in an area where it will be protected from: Direct sunlight, rain or moisture, corrosive gasses or liquids, vibration and dust or metallic particles. The ambient air available for cooling the unit should be 104° F (40° C) or less.

Wall mount units require a minimum 6 inch clearance above and below, to achieve adequate heat sink cooling. When the addon box is employed for optional equipment, no additional bottom clearance is required.

No side clearance is required for cooling because the cooling air flow is in and out of th e enclo sure d oor at the front surface of the unit (do not block the air flow louver s). Clearance fo r the open in g swi ng of the encl os ur e door should be con sider ed when placing these units. The door is hinged on the left and must open through at least a 90 degree swing with a 120 to 180 degree swing being preferable (minimum clearance is 1.5”).

Floor mounted units require a minimum clearance of 10 inches above the enclosure to allow for air flow over the heat sink fins.

Install the Bypass unit under the following conditions in UL pollution degree 1 & 2 environments. This excludes wet locations where surfaces may become conductive due to moisture and contaminant loading.

Table 1.7 Installation Site

Type Ambient Operating Temperature Humidity Plenum Rated

NEMA Type 1 & 12 14 to 104°F (-10-to-+ 40°C) 95%-RH-or-less-(no-condensation) Yes

Observe the following precautions when mounting the Bypass unit.

• Install the Bypass unit in a clean location that is free from oil mist and dust.

• Install the Bypass unit in an environment w here metal shavings, oil, water, or other foreign matter will not get into th e

Bypass enclosure.

• Install the Bypass unit in a location free from radioactive materials.

• Install the Bypass unit in a location free from harmful gasses and liquids.

• Install the Bypass unit in a location without excessive vibration.

• Install the Bypass unit in a location free from chlorides.

• Install the Bypass unit in a location not in direct sunlight.

• Install the Bypass unit on a non-combustible surface.

Physical Installation 1 - 24

! Controlling the Ambient Temperature

To enhance the reliability of operation, the By pass unit should be installed in an environment free from extreme temperature variations. Do not store this Technical Manual or any other documents on the top surface of the Bypass unit, they may cover the heat sink cooling air discharge opening and cause the unit to overheat.

If the Bypass unit is installed in an enclosure (such as an electrical control box in an air handling unit), use a cooling fan or air conditioner to maintain the Bypass unit internal air temperature below 113°F (45°C).

! Protecting the Bypass Unit from Foreign Matter

During Bypass unit installation an d project construction, it is possible to hav e foreign matter, such as metal shavings or wir e clippings, fall inside the Bypass unit. T o preven t foreign matter from falling into the Bypass unit, place a temporary cover over the unit.

Always remove the temporary cover from the Bypass u nit before star t-up. Ot herwise, ventilat ion will b e reduced, causi ng the Bypass unit to overheat.

Physical Installation 1 - 25

! Installation Orientation and Enclosure Considerations

Install the Bypass unit vertically so as not to reduce the cooling efficiency . When installing the Bypas s unit, always provide the recommended installation clearances to allow normal heat dissipation.

When preparing to mount the unit, lift it by the base (or lifting rings when provided), never by th e e nclosure door. For effective cooling and proper maintena nce, the wall mounte d units must be installed on a flat non-fla mmable vertica l surface using four mounting screws.

To mount units employing the add-on box, a hex head mounting screw and socket wrench will be required for the lower left mounting hole location. See Figure 1.15.

For all units, the MCP handle should be in the OFF position to open the enclosure door. The wall mount units have two full turn fasteners, CCW to open, that require a flat blade screwdriver to open the enclosure door.

Mounting Holes

Fig 1.15 Add-on Options Box

Physical Installation 1 - 26

Chapter 2

Electrical Installation

This chapter describes wiring and the electrical installation process for a Drive and Bypass unit.

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

Field Wiring, Pressure Wire Connector, Wire Type, Range

and Tightnening Torque Specifications .......................... ...........3

Cable Length between Drive and Motor ....................................4

Grounding ................................................................................. 5

Wire Routing ........................... ............................. ............... ......6

Drive Main Circuit Configurations 208-240 VAC .......................7

Drive Main Circuit Configurations 480 VAC ..............................8

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

Bypass Field Control Wire Landing .................................. .. .......9

Annunciation Contacts ..............................................................9

Damper Control Circuit ............................................................ 10

Customer Supplied Run/Stop circuit: ......................................10

Safety Interlock Circuit: ........................................................... 10

Customer Supplied Interlock Circuit

(Drive and Bypass enable input): ............................................10

Switch Selectable Functions: ..................................................10

Bypass Relay Controller PCB ........... ...................... ................ 11

Drive Speed Control Circuit Wiring .......................................... 12

Drive Terminal Block Configuration ......................................... 13

Wiring Chec ks ......................................... ............................ ....14

Control Circuit Wiring Precautions ..........................................14

Bypass Control Circuit Terminal Functions .............................15

DIP Switch S1 ......................................................................... 16

Shunt Connector CN15 ...........................................................17

Field Wiring D ia g ra m ........................ ................ ............... ........ 18

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

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

Electrical Installation 2 - 1

Termination Configuration - Power Wiring

The Circuit Breaker/MCP is located in the upper right hand side of the Bypass unit. The Bypass three phase input power connection is made to the input terminals of the MCP. See Figure 2.1 and 2.2 for representative examples.

Motor

Input Power

Ground Lug

Fig 2.1 Typical Input Power Connection, Fig. 2.2 Typical Input and Output Power

Wall Mount Unit Connections, Floor Mount Unit

The OverLoad Relay (OLR) is mounted to the contactor assembly or back panel (depending on rating), just above the bypass contactor. The Bypass three phase output power connection to the motor is made to the output terminals of the OverLoad Relay. See Figure 2.3 for representative examples.

Motor Connections

Connections

Ground Lug

Motor Connections

Input Power

Overload Relay

Fig 2.3 Typical Output Power Connection, Wall Mount Units

Electrical Installation 2 - 2

! Field Wiring, Pressure Wire Connector, Wire Type, Range and Tightnening

Torque Specifications

BYPASS MODEL NO.

BASE NUMBER

_ _ _ _ -XXXX

208V

A002

D002

A003

D003

A004

D004

D007

A006

D010

A009

D016

A015

D024

A022

D030

A028

D046

A042

D059

A054

A068

D074

A080

D088

A104

D114

A130

D143

A154

D169

A192

D211

A248

D273

D343

A312

D396

A360

BYPASS MODEL NO.

BASE NUMBER

_ _ _ _ -XXXX

208V 480V

240V

A002

D002

A003

D003

A004

D004

A006

D007

A009

D010

A015

D016

A022

D024

A028

D030

A042

D046

A054

D059

A068

D074

A080

D088

A104

A130

D114

D143

A154

D169

A192

D211

A248

D273

A312

A360

D343

D396

The fourth underscore position in these model numbers codes for the enclosure type: V = NEMA1, B = NEMA12 FVFF.

FOR 0 TO 100 AMPS, USE 60 -75 C COPPER WIRE, AND ABOVE 100 AMPS, USE 75 C COPPER WIRE.

MFG.

* *

PART

NUMBER

480V240V

B001

FAL36003

B002

FAL36007

B003

B004

B007

FAL36015

B011

B014

FAL36030

B021

FAL36050

B027

B034

B040

FAL36100

B052

B065

B077

B096

KAL36150

B124

KAL36250

B156

B180

B240

LAL36400

B302

B361

MAL36600

B414

MAL36800

B477

B515

B590

MFG. PART

NUMBER

LR2 D13

B001

B002

LR2 D15

B003

B004

LR2 D15

B007

B011

B014

LR2 D15

B021

LR2 D25

B027

LR2 D35

B034

B040

LR2 D35

B052

LR2 D35

B065

LR2 D35

B077

LR2 D3563

B096

LR9 F5567

LR9 F5569

B124

LR9 F5569

B156

LR9 F5571

B180

B240

LR9 F7575

B302

LR9 F7579

B361

LR9 F7579

B414

LR9 F7581

B477

LR9 F7581

B515

LR9 F7581

B590

CUSTOMER A.C. LINE WIRING

CIRCUIT BREAKER

CURRENT

RATING

(AMPS)

100

150

250

400

600

800

STANDARD BYPASS OVERLOAD RELAY OR, WITH OPTION D A.C. CONTACTORSOR, WITH OPTION A OVERLOAD RELAYS

WIRE SIZE

6 - 300 kcmil

6 - 300 kcmil 275

2 x (6-300 kcmil)

2 x (6-300 kcmil) 2 x 500

2 x (6-300 kcmil)

3 x (6-300 kcmil)

3 x (6-300 kcmil) 3 x 500

3 x (6-300 kcmil)

WIRE SIZE

RANGE

(AWG)

14 - 4

12 - 4

12 - 1/0

4 - 350 kcmil

1 x (1-600 kcmil)

2 x (1-250 kcmil) 2 x 375

(1-3) x (3/0-500 kcmil)

RANGE

(AWG)

18 - 10

14 - 6

10 - 1/0

10 - 1/0 75

10 - 1/0

10 - 1/0 75

10 - 1/0

6 - 3/0

6 - 3/0 200

6 - 3/0

TIGHTENING

TORQUE

(LB.-IN.)

100

200

275

2 x 500

2 x 5002 x (6-300 kcmil)

2 x 500

3 x 500

TIGHTENING

TORQUE

(LB.-IN.)

250

375

(1-3) x 300

CUSTOMER A.C. MOTOR WIRING

MFG. PART

NUMBER

LR2 D13

LR2 D15

LR2 D25

LR2 D35

LR9 F5567

LR9 F5569

LR9 F5571

LR9 F7575

WIRE SIZE

RANGE

(AWG)

18 - 10

18 - 10 15

18 - 10

18 - 10 15

14 - 6

14 - 6 15

10 - 1/0

10 - 1/0 75

10 - 1/0

10 - 1/0 75

10 - 1/0

6 - 3/0

6 - 300 kcmil

2 x (6-300 kcmil)

2 x (6-300 kcmil) 2 x 500

BYPASS MODEL NO.

BASE NUMBER

_ _ _ _ -XXXX

240V 480V208V

D002

A002

D003

A003

D004

A004

D007

A006

D010

A009

D016

A015

D024

A022

D030

A028

D046

A042

D059

A054

A068

D074

A080

D088

A104

D114

D143

A130

D169

A154

D211

A192

D273

A248

D343

A312

D396

A360

TIGHTENING

B001

B002

B003

B004

B007

B011

B014

B021

B027

B034

B040

B052

B065

B077

B096

B124

B156

B180

B240

B302

B361

B414

B477

B515

B590

TORQUE

(LB.-IN.)

200

275

2 x 500

CUSTOMER EARTH GROUND WIRING

MFG. PART

NUMBER

LC1 D09

LC1 D18

LC1 D25

LC1 D32

LC1 D40

LC1 D50

LC1 D65

LC1 D80

LC1 D115

LC1 D150

LC1 F185

LC1 F265

LC1 F330

LC1 F400

LC1 F500

LC1 F630

GROUND LUG

WIRE SIZE

RANGE

(AWG)

14 - 10 35

840

6 - 4 45

WIRE SIZE

RANGE

(AWG)

18 - 10

18 - 8

14 - 6

10 - 3

10 - 2

8 - 250 kcmil

6 - 3/0

6 - 300 kcmil

4 - 500 kcmil

2 x (2-600 kcmil)

3 x (2-600 kcmil)

TIGHTENING

TORQUE

(LB.-IN.)

1204 - 2/0

TIGHTENING

TORQUE

(LB.-IN.)

100

200

275

500

2 x 500

3 x 500

IMPORTANT

WARNING

Determine the wire size for the main circuit so that line voltage drop is within 2% of the rated voltage. Line voltage drop is calculated as follows:

Line voltage drop(V) = √3 x wire resistance (Ω/km) x wire length (m) x current (A) x 10

-3

Prior to removing any protective cover or wiring any part of the Drive, remove all power sources, including main input power and control circuit power. Wait a minimum of 5 minutes after power removal, before removing any cover. The charge lamp located within the Drive should be off prior to working inside. Even if the charge lamp is off, one must measure the AC input, output, and DC Bus potential to insure safe levels prior to resuming work. Failure to adhere to this warning may result in personal injury or death.

Electrical Installation 2 - 3

! Cable Length between Drive and Motor

The Bypass unit should be installed as close as possible to the motor to minimize the len gth of load si de power cable needed between the Drive and the motor. If the cable between the Drive and the motor is long, the high-frequency leakage current will increase, causing the Drive output current to increase as well. This may affect peripheral devices. To prevent this, reduce cable length, or if necessary, adjust the carrier frequency (set in C6-02) as shown in Table 2.1.

The line side power cables, load side power cables and the control wiring should all be run in a separate conduit. C areful attention to this recommended design practice will avoid many potential motor and Drive related pro blems.

Table 2.1 Motor Cable Length vs. Carrier Frequency (C6-02)

Motor Cable Length 164 ft. (50m) maximum 328 ft. (100m) maximum More than 328 ft.(100m)

Carrier Frequency 15kHz maximum 10kHz maximum 5kHz maximum

(See the limitations on carrier frequency, based on Drive capacity and model number in Appendix B).

Electrical Installation 2 - 4

! Grounding

" Drive and Motor Ground Wire Landing

The Drive ground lug (terminal ) is connected to the enclosure. The enclosure ground lug must be connected to earth

ground. See Figures 2.1 and 2.2.

The Drive has a second ground lug to accept the motor ground lead. See Figure 2.9.

" Ground Wiring Precautions

Observe the following precautions when connecting the ground wire:

1. 208-240 VAC Drives should have a ground connection with resistance of less than 100 Ω..

2. 480 VAC Drives should have a ground connection with resistance of less than 10 Ω..

3. Do not share the ground wire with other devices, such as large-current electrical equipment.

4. Always use a ground wire that complies with technical standards on electrical equipment and minimize the length of the ground wire. Leakage current flows through the Drive. Therefore, if the distance between the ground rod and the ground terminal is too long, potential on the ground terminal of the Drive will become unstable.

5. When using more than one Drive, be careful not to loop the ground wire.

For grounding connection to earth ground see Figures 2.1 and 2.2.

Fig 2.4 Ground Wiring Examples

" Control Circuit Ground Terminals

The removable Drive control terminal card provides two ground terminals (marked TB3 and TB4) to accept the control wire shield connection. The control wire shield should be connected on this end only, the opposite end should be isolated with electrical tape.

IMPORT ANT

Grounding of the Bypass enclosure and motor is required for proper system operation.

Electrical Installation 2 - 5

! Wire Routing

The following Figures indicate suggested wire entry and bending areas for representative wall mount enclosures.

Control

circuit wiring

Motor

connection

Input

power

Control

circuit wiring

Motor

connection

Typical Enclosure 2 Typical Enclosure 2

Fig 2.5 Wall Mount Enclosures

Input

power

Electrical Installation 2 - 6

! Drive Main Circuit Configurations 208-240 VAC

The main circuit configurations of the Drive are shown in Tables 2.2 and 2.3.

Table 2.2 Drive Main Circuit Configurations

208-240 VAC

Note

CIMR-_ _ _ 20P4 to 2018

{

(1/2 Hp to 25 Hp)

Notes 1 & 3

{

CIMR-_ _ _ 2022 and 2030

(30 Hp to 40 Hp)

Power supply

Control circuits

---

Power supply

Control circuits

Power supply

CIMR-_ _ _ 2037 to 2110

(50 Hp to 150 Hp)

Notes 1 & 3

{

Note1. Input fuses or molded case circuit breakers are required for proper branch circuit protection for all Drives. Failure

to use recommended fuses/circuit breakers (See Appendix E) may result in damag e to the wiring, Drive and/or personal injury.

2. Control power is supplied internally from the main circuit DC power supply for all Drives.

3. Consult your Yaska wa repres enta tive befo re using 12 -pu lse rectifica tio n.

Electrical Installation 2 - 7

! P7 Drive Main Circuit Configurations 480 VAC

CIMR

4030

Table 2.3 Drive Main Circuit Configurations

480 VAC

Note

CIMR-_ _ _ 40P4 to 4018

{

(1/2 Hp to 30 Hp)

Notes 1 & 3

{

-_ _ _

(40 Hp to 100 Hp)

to 4055

Power supply

Control circuits

---

Power supply

Control circuits

Power supply

CIMR-_ _ _ 4075 to 4160 and CIMR-_ _ _ 4185 to 4300

Notes

1 & 3

{

Note1. Input fuses or molded case circuit breakers are required for proper branch circuit protection for all Drives. Failure

to use recommended fuses/circuit breakers (See Appendix E) may result in damag e to th e wiring, Drive and/or personal injury.

2. Control power is supplied internally from the main circuit DC power supply for all Drives.

3. Consult your Yaska wa repres enta tive befo re using 12 -pu lse rectifica tio n.

(125 Hp to 500 Hp)

Electrical Installation 2 - 8

Control Wiring

! Bypass Field Control Wire Landing

The Bypass field control wiring is terminated on the relay control PCB A2, Terminal block TB1. The terminal designations are labeled on the door, adjacent to PCB A2 (see Figure 2.6). Route the control wiring as shown in Figure 2.5.

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 customer supplied Drive NO enabling contacts (open = Drive disabled, closed = Drive enabled) 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.

Fig 2.6 TB1 Control Terminal Locations, All Models

! Annunciation Contacts

Contacts for customer use are provided and wired to TB1 as follows for use as annunciators of Bypass unit operation. All are 1 amp at 120 VAC contacts.

Table 2.4 Annunciation Contacts

Function Type TB1 Terminals

Motor OL/Safeties Fault Form C 14-15-16

Bypass Run Form A 9-10

Drive Run Form A 7-8

Drive Fault Form C 11-12-13

Electrical Installation 2 - 9

! Damper Control Circuit

TB1 terminals 19 and 20 are provided to power a customer supplied 120 VAC relay, electric actuator or electro-pneumatic solenoid air valve employed to control a pneumatic damper actuator, typically for outdoor air intake damper interlock. The power rating of the conn ected dev i ce sh ou ld be no m ore th an 4 0 VA continuou s and 70 VA inrush. An off command (f rom the H/O/A switch) or a safety device trip-out will immediately de-energize these terminals. At the same time the Drive will begin the ramp to stop process (in Drive mode with the default stopping method). In some air handling unit applications operation during the ramp to stop time with the dampers closed may be problem a tic. Over p ress urization of ducts or tri p-o ut o n high DC bus voltage, due to overhauling of the load by other fans in the system, are possible outcomes. One solution is to reprogram the stopping method in parameter b1-03 to “coast to stop” elimin ating the potential for both of these problems.

! Customer Supplied Run/Stop circuit:

A control terminal block position (TB1, terminals 3 and 4) is provided to connect the Normally Open (NO) Run/Stop contact from a separate source or other remote controller for auto mode control.

There must be continuity between these terminals in order for the motor to run.

! Safety Interlock Circuit:

A control terminal block position (TB1, terminals 1 and 2) is provided to connect the series circuit of Normally Closed (NC) safety devices such as: freeze up thermostats, smoke/fire sensors, high pressure limits, temperature limits or vibration detectors.

There must be continuity between these terminals in order for the motor to run.

! Customer Supplied Interlock Circuit (Drive and Bypass enable input):

A control terminal block position (TB1, terminals 5 and 6) is provided to connect Normally Open (NO) enabling contacts such as: damper end switches or occupied cycle timers.

There must be continuity between these terminals in order for the motor to run.

! 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 of 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 overridde n to sh ift the priority to protecting people rather than equipment.

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.

Electrical Installation 2 - 10

! Bypass Relay Controller PCB

TB1

ON PCB A2

(L1)

Fig 2.7 Bypass Control Circuit Inputs and Outputs

Customer provided contact closure inputs must have a minimum rating of 0.1 amp at 120 VAC.

Electrical Installation 2 - 11

! Drive Speed Control Circuit Wiring

The auto mode speed reference (speed command) field wiring connection is made directly to Drive terminals A2 (signal positive), AC (signal common) and G (shield). Keep this lead length as short as possible to maint a in signal q uality. Insulated twisted shielded pair wire (2 conductor # 18 ga, Belden 8760 or equivalent) is required. Do not run these wires in the same conduits as other AC power or con trol wires . The shield mu st be connect ed on this end on ly, stub and isolate the other end. The signal employed is 4 to 20 mA with parameter H3-08 set for “2: 4 - 20 mA”. For 0 to 10 VDC, parameter H3-08 is set for “0: 0 - 10 VDC” and the P7 control board DIP switch S1-2 must be in the OFF position. (See Figure 2.11)

For remote operation, keep the length of the control wiring to 50 m or less. Separate the control wiring from high-power lines

(input power, motor leads or relay sequence circuits) to reduce induction from peripheral devices.

When setting speed commands from an external speed potentiometer (and not from a Digital Operator), use shielded twisted-

pair wires and ground the shield to terminal E(G), as shown in Figure 2.8. Terminal numbers and wire sizes are shown in T able 2.5.

Shield terminal

E (G)

External frequency reference

0 to +10 V

Fig 2.8 Analog Input Terminal Configuration on Drive

Speed setting power supply, +15 V 20 mA Master speed reference, 0 to +10 V (20 kΩ)

Master speed reference, 4 to 20 mA (250 Ω)/0 to +10 V (20 kΩ)

P = Wire Pair

Electrical Installation 2 - 12

! Drive Terminal Block Configuration

The wiring terminals are shown in Figure 2.9.

AC MP

-V

SCS+A2

Control circuit terminals

SN M6

E(G) E(G)

S4SPS7 M4

R- M5

R+RP

AC MA

AMS6

M3S2 S-

MCMB

Main circuit terminals

Charge indicator

Control circuit terminals

Main circuit terminals

Ground terminal

Models CIMR-_ _ _2018 (25 HP, 208V)/ 4018 (30 HP, 480V) and smaller

AC MP

-VIGR- M5FMR+RP

SCS+A2M2SN M6

E(G) E(G)

AC MA

AMS6

S4SPS7 M4

MCMB

M3S2 S-

Ground terminal

Charge indicator

Ground terminal

Models CIMR-_ _ _2022 (30 HP, 208V)/ 4030 (40 HP, 480V) and larger

Fig 2.9 Drive Terminal Configurati on

Electrical Installation 2 - 13

Terminals

DRIVE

TERMINALS:

FM, AC, AM, SC, SN,

SP, A1, A2, +V, S1, S2, S3, S4, S5, S6, S7, MA, MB, MC, M1, M2 , M3,

M4, MP, R+, R-, S+,

S-, IG

TB1 ON PCB A2

TERMINALS:

TB1-1 through TB1-26

Table 2.5 Te rminal Numbers and Wire Sizes (Same for all Bypass Units)

Terminal

Screws

Phoenix

type *3

Tightening

Torque

lb.-in.

(N•m)

4.2 to 5.3

(0.5 to 0.6)

Possible

Wire Sizes

AWG

(mm

Stranded

wire:

26 to 16

(0.14 to 1.5)

)

Recommended

Wire Size

AWG

(mm

)

(0.75)

• Shielded, twisted-pair wire

• Shielded, polyethylene -c ov er e d , vinyl sheath cable

Wire Type

E(G) M3.5

*1.Us e shielded twisted-p air cables to input an external speed command. *2. We recommend using straight solderless te rminals on digital inputs to simplify wiring and improve reliability. *3.We recommend using a thin-slot screwdriver with a 3.5 mm blade width.

7.0 to 8.8

(0.8 to 1.0)

20 to 14

(0.5 to 2

)

(1.25)

! Wiring Checks

After all wiring is completed, perform the following checks:

1. Is all wiring correct?

2. Have all wire clippings, screws or other foreign material been removed from the Drive and Bypass enclosure?

3. Are all terminal screws tight?

! Control Circuit Wiring Precautions

Observe the following precautions when wiring control circuits:

1. Separate control wiring from power/motor wiring and other high-power lines.

2. Separate wiring for control circuit terminals for digital outputs from wiring to other control circuit terminals.

3. If using an optional external power supply, it should be a UL Listed Class 2 power supply source.

4. Use twisted-pair or shielded twisted-pair cables for control circuits to prevent operating faults. Prepare cable ends as shown in Figure 2.10.

5. Connect the shield wire to terminal E(G).

6. Insulate the shield with tape to prevent contact with other signal lines and equipment.

Shield sheath

Connect to shield sheath terminal E(G) at Drive

Fig 2.10 Preparing the Ends of Shielded Twisted-Pair Cables

Insulate with tape

Insulation

Do not connect here.

Electrical Installation 2 - 14

! Bypass Control Circuit Terminal Functions

The functions of the control circuit terminals are shown in Table 2.6.

Table 2.6 Bypass Control Circuit Terminals

Type No. Signal Name Function S ign al Lev el

Digital

input

signals

Analog

input signals (Drive)

TB1-3 TB1-4 TB1-1 TB1-2 TB1-5

TB1-6 TB1-17 TB1-18 TB1-23 TB1-24 TB1-25 TB1-26

+V +15 VDC power output +15 VDC power supply for analog Transmitters A1 Analog Input or Speed Command 0 to +10 VDC/100% 0 to +10 V(20 kΩ) A2 Multi-function analog input

AC Analog input common – –

E(G)

Auto Mode run/stop command Run when CLOSED; stopped when OPEN.

NC Safety Circuit Fault when OPEN

Customer Supplied Interlock Enable Drive when Closed

Smoke Purge *Transfer to Bypass when Closed

2 Motor “OR” *Transfer to Motor 2 When Closed

Remote Transfer *Transfer to Bypass when Closed

Shield wire, optional g round line

connection point

4 to 20 mA/100%

0 to +10 VDC/100% (H3-08)

––

Function set by

H3-09.

Contacts

+15 VDC

(Max. current: 20 mA)

4 to 20 mA(250Ω)

0 to +10 V(20kΩ)

Dry

TB1-7

TB1-8

TB1-9

Digital

output

signals

Analog output signals (Drive)

* Switch Selectable Options

TB1-10 TB1-11

TB1-12 TB1-13 TB1-14 TB1-15 TB1-16

FM Multi-function analog output

AC Analog output common –

AM Multi-function analog output

Running on Drive

Running on Bypass

Drive Fault

Motor Overload or

Safety Circuit Fault

CLOSED During Operation

11/12 CLOSED During Fault Condition

12/13 OPEN During Fault Condition

14/15 CLOSED During Fault Condition

15/16 OPEN During Fault Condition

Frequency Output

0 to +10 VDC/100% frequency

Current Monitor 0 to +10 VAC/100% Drive's rated current

Dry contacts

Contact capacity:

1 A max. at 250 VAC

1 A max. at 30 VDC

Multi-function

analog monitor 1

Function set by

H4-01

0 to +10 VDC max. ±5%

2 mA max.

Multi-function

analog monitor 2

Function set by

H4-04

Electrical Installation 2 - 15

Table 2.6 Bypass Control Circuit Terminals (Continued)

Type No. Signal Name Function S ign al Lev el

RS-485/

422

(Drive)

R+

R-

S+

S-

Communication input

For 2-wire RS-485, short R+ to S+

and R- to S-.

Communication output

Differential input,

optical isolation

Differential input,

optical isolation

IG Signal common - -

Control

Power

Output

TB1-19 TB1-20 TB1-21 TB1-22

Damper Control Pneumatic Control Interface 40VA@120V

Customer Use Power Customer control Devices 100VA@120V

! DIP Switch S1

DIP Switch S1 is described in this section. The functions of DIP switch S1 are shown in Table 2.7.

1 2

DIP Switch S1-1 located on terminal board.

Terminating resistance

Fig 2.11 DIP Switch S1 Location

Table 2.7 DIP Switch S1

Name Function Setting

S1-1 RS-485 and RS-422 terminating resistance

S1-2 Input signal for analog input A2

OFF: No terminating resistance (Factory default) ON: Terminating resistance of 1 10Ω

OFF: 0-10 VDC (interna l resi stance: 20 KΩ) ON: 4-20 mA (internal resistance: 250 Ω) (Factory default)

Electrical Installation 2 - 16

!Shunt Connector CN15

The shunt connector CN15 is described in this section. Shunt connector along with parameters H4-07 and H4-08 select the signal range of the analog output terminals FM and AM.

Shunt connector CN15 is only available when the optional Terminal Card with the 4-20mA Analog Output Monitor is installed. See Chapter 7 for installation of the optional Terminal Card.

The function of various shunt connector CN15 configurations is shown in Table 2.8.

Fig 2.12 Shunt Connector CN15 Location

Table 2.8 Shunt Connector CN15 Configuration Options

CN15 Analog Output Monitor Configurations

Voltage Output (0-10 VDC) f or te rminals FM- AC (C H1) and A M-AC ( CH 2)

Current Output (4-20mA) for terminals FM-AC (CH1) and AM-AC (CH2)

Voltage Output (0-10 VDC) for terminals FM-AC (CH1) Current Output (4-20mA) for terminals AM-AC (CH2)

Current Output (4-20mA) for terminals FM-AC (CH1) Voltage Output (0-10 VDC) for terminals AM-AC (CH2)

The software configuration for the analog output monitor signal type is listed below:

Parameter

No.

H4-07

H4-08

Parameter Name

Digital Operator Display

Terminal FM Signal Level Selection

AO Level Select1

Terminal AM Signal Level Selection

AO Level Select2

Description

0: 0 - 10 V 2: 4-20 mA

Setting

Range

0 or 2 0 Programming

Factory Setting

Location

Electrical Installation 2 - 17

! Field Wiring Diagram

Use these diagrams to document your field wiring. We suggest copying this page based on your installation needs.

Fig 2.13 Field Wiring Diagram

Electrical Installation 2 - 18

Notes:

Electrical Installation 2 - 19

Wiring Diagram

CB1

FROM

CUSTOMER'S

A.C. LINES

GND LUG

EARTH

GROUND

NOTE 1

(1)

(2)

(3)

(SEE

TABLE 3

FOR CB1

AMPERE

SEE

RATINGS)

CG1

OPTION N

INPUT FILTER

OPTION X

OPTION Z

DC BUS CHOKE

TO CABINET DOOR MOUNTED DRIVE KEYPAD

MANUAL SPEED POT OPTION S

TO A2

L12/1.22

L11/1.23

L13/1.24

STD. AUTO MODE SPEED REFERENCE

ISOLATED AUTO MODE SPEED REFERENCE

4-20MADC

0-10VDC

(SEE

TABLE 2)

3-15 PSI PRESSURE TRANSDUCER OPTION P

3-14.5 PSI PNEUMATIC SIGNAL

WITH OPTION S

L14/1.21 L15/1.20

2 MOTOR OPTION A

(1)

(2)

SEE

NOTE 2

(2) (4) (6)

S11

(1) (3) (5)

"AND"

4T1

3-15 PSI

FOLLOWER

PART NO.

UTC000038

(B)

(R)

(1)

(2)

4T2

JUMPER

4T3

(96)

(95)

(T2)

(4)

(5)

(6)

OPTION R 3% INPUT

REACTOR

DELTA-WYE CAPACITIVE

TO DRIVE

TERMINAL

L1+2+1

WITHOUT OPTION P

WITH OPTION P

SHIELD

NOTE 5

4-20MA

OUTPUT

VCC

COM.

AC+V

SEE

NOTE 2

(96)

(95)

111

1L1

(GRN) (YEL) (YEL) (YEL)

(W)

(B)

(R)

L15/1.32 L14/1.31

SEE

1T1

1T2

(1)

(2)

5T2

5T1

(2) (4) (6)

S12

(1) (3) (5)

(T2)

(T1) (T3)

A.C. MOTOR #2A.C. MOTOR #1

1L2

1L3

B1A1

L1 L2 L3

REMOVE JUMPER FOR DC BUS CHOKE OPTIONS X OR Z

CN1

CN2

CONTROL

BOARD

MANUAL REF. IN 0-10VDC

(20K OHM) +15VDC

20mA MAX.

ANALOG

COM.

AUTO REF. IN (AS SET

BY H3-08) ANALOG

COM.

(G) TB3

SHIELD

OPTION N

GREEN

LEAD WIRE

1T3

(1)

F10F12 F11

(2)

5T3

NOTE 1

L1/1.04

C2C1B2A2

PG1 SEE

CN2

STD.

(96)

(95)

TO A2TO A2

(L1)

(T1)

(U) (V) (W)

(L1)

(T1)

1T1

(2) (4) (6)

(1) (3) (5)

111

L2/1.07

(L2)

(L3)

(T2)

(T3)

2L1

2L2

L1 L2 L3

(R) (S) (T)

OPTION G, H, L,

or Q

SEE THE APPROPRIATE TECHNICAL MANUAL FOR NETWORK CONNECTIONS

DRIVE

DIP SWITCH S1

OFF

TERMINAL

BOARD

T1 T2 T3

2T1

2T2

(L2)

(L3)

(T2)

(T3)

1T2

(T2)

(T1) (T3)

A.C. MOTOR

2L3

2T3

1T3

SEE

NOTE 2

S10

(1)

F4 F5

(2)

L1/A1

L2/B1

LINE

GND1 GND2

LOAD

L1/A2

L2/B2

DRIVE FAULT

DRIVE RUNNING

SERIAL COMM. RUN

BYPASS DRIVE

FAULT RESET

HAND/AUTO

SEQ. COM.

JUMPER

3T1

2T1

(L1)

K4 K5

(T1)

A.C. MOTOR #1

RUN FWD

ENABLE

COM.

+24V

4T1

(L2)

(T2)

(T1)

3T2

3T3

B1A1

C2C1B2A2

2T2

2T3

SEE

NOTE 2

4T2

4T3

(L3)

(T3)

(T2)

(T3)

L3/C1

L3/C2

OPTION K

5% LOAD

REACTOR

1T1

(2) (4) (6)

S10

(1) (3) (5)

(L1)

(T1)

A.C. MOTOR #2

OPTION F

DRIVE INPUT

FUSES

OPTION E

INPUT

RFI

FILTER

L1/1.04

L3/1.14

L4/1.15

L5/1.16

L6/1.17

L7/1.18

L8/1.20

L9/1.21

1T2

(L2)

(T2)

(T1) (T3)(T1) (T3)

1L3

1L1

1L2

(L2)

(L3)

(L1)

(T2)

(T3)

(T1)

1T1

1T2

1T3

(96)

(95)

111

(L3)

TO A2

(T3)

2 MOTOR

"OR"

OPTION D

Electrical Installation 2 - 20

EG1

DG1

INPUT CONTACTOR

OUTPUT CONTACTOR

BYPASS CONTACTOR

MANUAL SPEED POT OPTION S

MOTOR #1 CONTACTOR

MOTOR #2 CONTACTOR

2 MOTOR

"OR"

OPTION D

1L1

1L2

PG2 SEE

NOTE 1

104

128

111

112

109

138 135 133

138 136 131

(A2) (A1)

TO A1

TO A1 OR A4

(A2) (A1)

(1) (2)

(A2) (A1)

(1) (2)

(13) (14)

/1.39

/1.12

L2/1.39

(A1)

114

(62)

(61)

116

(62)

(61)

L3/1.14

L4/1.16

L5/1.17

L6/1.18

L7/1.20

L8/1.23

L9/1.24

L12/1.17

L11/1.18

L13/1.19

(13) (14)

121

(62)

(61)

123

(61)

(62)

RC4

RC5

CONTROL TRANSFORMER

100

(X2)

CN102A

100

111

112

113

114

115

116

CN102B

BYPASS RELAY

CONTROLLER PCB

PART NUMBER

UTC000036

(W)

(B)

(R)

122

124

100

UTC000036

CN102C TB1

DISABLE

(TOP)

AUTO-TRANSFER TO BYPASS

DISABLE

(TOP)

REMOTE TRANSFER TO BYPASS

DISABLE

(TOP)

SMOKE PURGE

S103

S104

S105

PG2

ENABLE

(BOTTOM)

ENABLE

(BOTTOM)

ENABLE

(BOTTOM)

F6T1

(X1)

(1)

SEE NOTE 6

TB1

CN103

JUMPER

CONTROL TRANSFORMER PRIMARY CONNECTIONS

INPUT

VOLTS

208

(H1)

230/240

460/480

CONTACTS FOR CUSTOMER USE

RATED: 1A, 120VAC MAX.

CUSTOMER MUST PROVIDE PROPER SHORT CIRCUIT PROTECTION AND MEANS OF DISCONNECT.

(H1)

(H1) (H4)

(2)

REMOTE TRANSFER TO BYPASS CONTACT (CLOSED=BYPASS) MIN. RATING:

0.1A,120VAC

OPTION D

MOTOR #1/MOTOR #2 SELECT CONTACT (CLOSED=MOTOR #2) MIN. RATING:

0.1A,120VAC

120VAC,1 PHASE

100VA MAX. POWER FOR CUSTOMER USE

CUSTOMER TO

PROVIDE FUSING (BUSSMANN FNQ-R-1.25 IS RECOMMENDED)

120VAC DAMPER SOLENOID 40VA MAX.

SMOKE PURGE CONTACT (CLOSED=PURGE) MIN. RATING:

0.1A,120VAC

MOTOR OVERLOAD OR CUSTOMER SAFETIES FAULT

DRIVE FAULT

BYPASS RUN

DRIVE RUN

FOR INSERTION OF NORMALLY OPEN BLDG. AUTOMATION SYSTEM INTERLOCK, OR NORMALLY OPEN DAMPER END SWITCH

SEE NOTE 4

AUTO MODE RUN/STOP CONTACT (CLOSED = RUN)

FOR INSERTION OF NORMALLY CLOSED CUSTOMER SAFETY CONTACTS

SEE NOTE 3

TERMINALS AB

(H2) NONE

(H4)

CN203

MOTOR OL/

SAFETIES FAULT

TEST NORMAL

JUMPER

LOCATION

(H1) TO (H3) (H2) TO (H4) (H2) TO (H3)

CABINET DOOR OPERATOR PANEL

PART NUMBER UOPN0001

CN1

DRIVE

KEYPAD

BYPASS OPERATOR

INTERFACE PCB

PART NUMBER UTC000037-2

CONTROL

BYPASS

POWER ON

RUN

CN206A

114

CABINET

BLOWER(S)

(IF REQUIRED)

DS201

SMOKE PURGE

DS206DS202

BYPASS DRIVE

S201

100

HAND AUTO

CN206B

121

B2,B4,B6B1,B3,B5

114

CABINET

BLOWER(S)

(IF REQUIRED)

DS205

S203

TO A1 CONTROL BOARD CN1

MANUAL SPEED POT

OPTION S

MANUAL SPEED POT

ASSEMBLY

PART NO. URSN0001 MAX. SPEED TRIM

POT PCB

CN204

(B) (B)

CN205

CN207

(R) (R)

125

126

DRIVE

RUN

DS204

DRIVE FAULT

DS203

OFF

S202

100

- INDICATES COMPONENTS NOT SUPPLIED BY YASKAWA.

- INDICATES CUSTOMER WIRING. SEE SHEET 2 FOR NOTES AND TABLES.

(W)(W)

2 MOTOR "OR"

OPTION D

MTR #1

(1L3)

(1R1)

AUTO

MANUAL SPEED

2.5K OHM

MTR #2

00X (1L4)

0XX

(1R2)

Items within dashed line boxes are optional equipment

Electrical Installation 2 - 21

Logic Diagram

FROM

CUSTOMERS

A.C. LINES

EARTH

GROUND

MANUAL SPEED POT OPTION S

MAX. SPEED

TRIM

MANUAL

SPEED

2.5K

STANDARD AUTO MODE SPEED REFERENCE INPUT

ISOLATED AUTO MODE SPEED REFERENCE

2.0K 2

4-20MADC (WITH PARAMETER

H3-08=1)

0-10VDC (WITH PARAMETER H3-08=0, AND CONTROL BOARD DIP SWITCH S1-2 OFF)

CN204

GND LUG

CB1

GNDLUA

CN103/

CN203

CN103/

CN102C

CN203

SHIELD

SEE SH.3,

NOTE 5

1L1

1L2

1L3

2L1

2L3

2L2

CN102B

+24V

COM.

CN102B

L1 L2 L3 (R) (S) (T)

+15 V

MANUAL REF. IN

0 TO 10VDC (20k ohm)

ANALOG COM.

AUTO REF. IN

(AS SET BY PARAMETER H3-08)

ANALOG COM.

(G) TB3

SHIELD

(E)

(U) (V) (W) T1 T2 T3

BYPASS DRIVE

SEQ. COM

FAULT RESET

HAND/AUTO

RY1

DRIVE

RUNNING

RY2

SERIAL

COMM. RUN

RY3

DRIVE FAULT

RUN FWD

ENABLE

JUMPER

K110 K116 K119

(3) (5) (5) (1)

L1/2.10

L2/2.10

L3/2.18

L4/2.18

L5/2.06

L6/2.06

(4) (6)

K122

(1) (3)

(3) (5)

ALSO SHOWN IN CONTROL RELAY LOGIC CIRCUIT

- INDICATES COMPONENTS NOT SUPPLIED BY YASKAWA

2T1

2T2

2T3

1T3

1T2

1T1

(L1)

(L3)

(L2)

S12

(T1)

(T2)

(T1)

SEE SH. 2

(T3)

(T2)

(T3)

A. C. MOTOR *

Electrical Installation 2 - 22

OPTION D

CN102C

CN102B

REMOVE THE

BYPASS RELAY

PCB JUMPER

S101

(1)

S101

(3) (5)

(NOT USED)

K123

(1) (5)

K125

1L1

1L2

1L3

(2)

(5)(1)

1L2

MA 100

(5) (1)

(6) (4)

(5) (3)

PRESENT ONLY

WITH 350VA,

OR GREATER

CN102A CN102A

1 2

DAMPER CONTROL AND 120 VOLT POWER

K104

K116

K118

CONTROL TRANSFORMER

(X1)

L7 L8

/2.01 /2.01 /2.40

K111K114

(5) (3)(5) (3)

TB1 TB1

21 22

CUSTOMER MUST PROVIDE PROPER

RV101

(1) (2)

TO SHEET 2

120VAC, 1PH., 60HZ.

FOR CUSTOMER USE

SHORT CIRCUIT PROTECTION

GND

(X2)

/2.01 /2.01 /2.40

TB1 TB1

19 20

DAMPER ELECTRIC

PNEUMATIC SOLENOID

K108

(5) (3)

K125

(2)(6)

K108

(6) (4)

K125

(6) (4)

AUTO

CN205

1T1

1T2

1T3

CN102C

MTR#1

MA 125

AUTO

MTR#1

(MTD. SEPARATELY ON CABINET DOOR)

STOP

MA 119 120119 120

CN103/

CN203

CN207

2 MOTOR "OR" OPTION D

CN102C

MTR#2

OOX

MTR#2

OXX

CN103/ CN203

CN205

CN103/ CN203

CN205

126

(MTD. SEPARATELY ON CABINET DOOR)

CN207 CN207

CN103/

CN203

CN102C CN102C

122 121

124 123

TB1

MOTOR SELECT

(CLOSED = MTR#2)

RUN

119 120

(6) (10)

(A1) (A2)

(MTD. ON PANEL)

(A1) (A2)

(MTD. ON PANEL)

TB1

CN103/ CN203

RC4

RC5

(MTD. ON PANEL)

CN102C

100

R123 C117

K125

(2) (7)

(7) (8)

(13) (14)

RC28

MOTOR #1 CONTACTOR

MOTOR #2 CONTACTOR

MOTOR SELECT CONTROL RELAY

(2) FORM C

RUN/STOP

100

CONTROL RELAY

RUN/STOP ENGINEERED OPTION

(OPERATIONAL ONLY IN THE HAND MODE)

Electrical Installation 2 - 23

(5)(3)

(5) (1)

K104

(6) (4)

120VAC FROM SHEET 1

K106

(5) (3)

R107

CN103/ CN203

DS201

(1)

DS202

(1)

R113

R114

L5/1.27

L1/1.23

CN102B

CN102C

K115

L6/1.29

L2/1.24

M3 M4

TB1 TB1

AUTO MODE

RUN/STOP CONTACT

(CLOSED = RUN)

L3/1.25 L4/1.26

REMOVE JUMPER

FOR RUN/STOP PB OPTION

(2)

117 118

(11) (7)

K123

(6)(4)

K124 K124

(1) (5) (5) (3)

K110

(4) (6)

REMOTE TRANSFER

TO BYPASS CONTACT

(CLOSED = BYPASS)

S102

K120

K121

MCMA

CN203

CN103/

CN203

CN102B

(1)

(1) (3)

(6)(6)(2) (4)

K124K124

K106

(6) (2)

CN102B

CN102C

CN103/ CN203

CN103/

CN203

CN102A

CN103/ CN203

CN103/

(2)

CN203 CN103/

(2)

CN203

R101 C101

CN103/

R115

CN203

R102 C102

R103 C103

JUMPER

BAS INTERLOCK/

DAMPER END

SWITCH

(CLOSED =

DAMPER OPEN)

R112 C111

R120

CN102A

B1,B3,B5

CN206A

B2,B4,B6

CN206B CN206B

CN102A

CN103/ CN203

CN102A

(2) FORM A

221, 228 C109R110

(2) FORM A

113, 118

R105

R106

R116

R108 C107

R109 C108

K104

(7) (8)

K105

(7) (8)

DS203

(1)

K106

(7) (8)

K107

(7) (8)

K108

(7) (8)

K109

(7) (8)

K110

(7) (8)

R104 C104

K111

(7) (8)

(A1) (A2)

CN206A

(A1) (A2)

DS204

(1)

(A1) (A2)

K112

DS205

(1)

K113

(7) (8)

K114

(7) (8)

K115

(7) (8)

K116

(7) (8)

C115

C105

C106

(2)

100112

100114113

(2)

100115 116

(8)(7)

(2)

L8/1.06

L7/1.06 L8/1.06

CN103/ CN103/

CN203

K109

(2) (6)

L7/1.06

K119

(3)(5)

AUTO TRANSFER

TO BYPASS

S103

(BOTTOM)

ENABLE

(1) (2)

IS "DISABLE")

TO BYPASS

S104

ENABLE

(1) (2)

IS "DISABLE")

K117

S12

111MA

(95)

(96)

TB1 TB1 TB1 TB1TB1TB1

CN102A

JUMPER

CUSTOMER

SAFETY INTERLOCKS

(TOP)

DISABLE

(FACTORY SETTING

REMOTE TRANSFER

(TOP) (BOTTOM)

DISABLE

(FACTORY SETTING

(1)(5)

K113

(1) (5)

K107

(6) (4)

K113

(6) (4)

K115

(6) (4)

K119

(5) (1)

K117

(4) (6)

K114

(1) (3)

(6) (4)

K120

K121

(3) (5)

CONTROL

POWER ON

MOTOR OVERLOAD/

CUSTOMER SAFETIES FAUL

DRIVE FAULT RELAY

(2) FORM A

(1) FORM C

DRIVE FAULT

DRIVE RUN RELAY (2) FORM A

(2) FORM A

(1) FORM C

MOTOR OVERLOAD/

CUSTOMER SAFETIES

FAULT RELAY (1) FORM A, (1) FORM C

RUN RELAY (2) FORM A

DAMPER OPTION

CONTROL RELAY

(1) FORM A

INPUT CONTACTOR

CABINET BLOWER(S)

(360VA. MAX. TOTAL FOR ALL BLOWERS COMBINED)

OUTPUT CONTACTOR

DRIVE RUN

BYPASS CONTACTOR

BYPASS PILOT RELAY (1) FORM A

BYPASS RUN

AUTO TRANSFER RELAY

(2) FORM A

REMOTE TRANSFER RELAY

Electrical Installation 2 - 24

L7/1.06 L8/1.06

SMOKE PURGE

S105

(TOP)

(BOTTOM)

DISABLE

(1R3) (1R4)

(NORMALLY OPEN (NO))

(1L3) (1L4)

(NORMALLY OPEN (NO))

(1R3) (1R4)

(NORMALLY OPEN (NO))

(1R3) (1R4)

(NORMALLY OPEN (NO))

ENABLE

(1) (2)

(FACTORY SETTING

IS "DISABLE")

BYPASS

DRIVE

S201

OFF

AUTO

HAND

OOX

S202

OFF

AUTO

HAND

XOO

S202

TEST

NORMAL

S203

TB1 TB1

SMOKE PURGE

CONTACT

(CLOSED = PURGE)

CN103/ CN203

K117

R111 C110

CN103/

R122

CN203

R118 C113

R119 C114

R121 C116

(7) (8)

K118

(7) (8)

DS206

(1)

(2)

K119

(7) (8)

C112R117

K120

(7) (8)

K121

(7) (8)

K122

(7) (8)

K123

(7) (8)

K124

(7) (8)

SMOKE PURGE RELAY

(2) FORM A

(1) FORM A

SMOKE PURGE

BYPASS-DRIVE CONTROL RELAY

(1) FORM A, (1) FORM C

AUTO MODE

CONTROL RELAY (2) FORM A

HAND MODE CONTROL RELAY

(2) FORM A

(1) FORM A

TEST-NORMAL CONTROL RELAY

(2) FORM A

(1) FORM C

BYPASS RELAY PCB UTC000036 CONNECTORS OPERATOR PCB UTC000037-2 CONNECTORS

CN102A

CN102B

CN102C

CN103

TB1

- CUSTOMER CONNECTION POINT ON 26 POINT, 1 PIECE PHOENIX

CONNECTOR. TORQUE WIRE CONNECTIONS TO 4.4 POUND-INCH.

- 8 POINT MOLEX HEADER.

USED TO CONNECT THE PANEL HARNESS TO THE BYPASS RELAY PCB.

- 8 POINT MOLEX HEADER.

USED TO CONNECT THE PANEL HARNESS TO THE BYPASS RELAY PCB.

- 14 POINT, 1 PIECE PHOENIX CONNECTOR.

USED TO CONNECT PANEL MOUNTED OPTIONS TO THE BYPASS RELAY PCB.

- 26 POINT RIBBON CABLE HEADER. USED TO CONNECT TO THE CABINET DOOR MOUNTED OPERATOR PCB CONNECTOR CN203.

CN203

- 26 POINT RIBBON CABLE HEADER.

CN204

CN205

CN206A

CN206B

CN207

USED TO CONNECT TO THE BYPASS RELAY PCB CONNECTOR CN103.

- 3 POINT, 2 PIECE PHOENIX CONNECTOR.

USED TO CONNECT THE OPTIONAL CABINET DOOR MOUNTED MANUAL SPEED POT TO THE OPERATOR PCB/PANEL.

- 3 POINT, 2 PIECE PHOENIX CONNECTOR.

USED TO CONNECT THE OPTIONAL CABINET DOOR MOUNTED 2 MOTOR "OR" SELECTOR SWITCH TO THE OPERATOR PCB/PANEL.

- 2 POINT, 2 PIECE PHOENIX CONNECTOR.

USED TO CONNECT THE OPTIONAL CABINET DOOR MOUNTED BLOWER(S) TO THE OPERATOR PCB/PANEL.

- 2 POINT, 2 PIECE PHOENIX CONNECTOR.

USED TO CONNECT THE OPTIONAL CABINET DOOR MOUNTED BLOWER(S) TO THE OPERATOR PCB/PANEL.

- 3 POINT, 2 PIECE PHOENIX CONNECTOR.

USED TO CONNECT THE OPTIONAL CABINET DOOR MOUNTED PARTS (AND THE "HAND" MODE RUN AND STOP PUSHBUTTONS) TO THE OPERATOR PCB/PANEL.

RUN AND FAULT CONTACT ANNUNCIATION

RATED: 1AMP, 120VAC MAX.

TB1 TB1 TB1 TB1 TB1 TB1 TB1 TB1 TB1 TB1

78910111213141516

DRIVE RUN BYPASS RUN MOTOR OVERLOAD OR

K105 K105K107 K109 K109K112

(3) (5) (5) (1)(5)(3) (5)(3) (1)(5)(3) (5)

K105 K105

(6)(4) (6) (2)

DRIVE FAULT

CUSTOMER SAFETIES FAULT

Electrical Installation 2 - 25

Notes:

Electrical Installation 2 - 26

Chapter 3

Control Panel

This chapter describes the displays and functions of the Control Panel.

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

Digital Operator Keys ...... ...........................................................3

Drive Mode Indicators ................................................................4

Control Panel Indicator Light s ... .................... .. .................... .......5

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

Main Menu Structure ................................................................. 9

DRIVE - Operation Menu .........................................................10

QUICK - Quick Setting Menu ..................................................13

ADV- Programming Menu .......................................................14

VERIFY - Modified Constants (Parameters) Menu .................15

A.TUNE - Auto-Tuning Menu ..................................................15

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

Digital Operator 3 - 1

Digital Operator and Control Panel Display

The various items included on the Digital Operator Display and Control Panel are described below.

Drive Mode Indicators

See Table 3.2

Menu Display

See Table 3.12

Key Descriptions

See Table 3.1

Indicating Lights

-DRIVE- Rdy

Frequency Ref

U1-01 = 60.00Hz

- - - - - - - - - - - - - - - - - - - - - - - - - - - - -

U1-02= 60.00Hz U1-03= 10.05A

{

Blue White

Red

Amber

Green

Red

Ready Display

Drive can operate when a drive

command is input

Data Display

Displays monitor data, parameter

numbers and settings

1 line x 13 cha racters

3 lines x 16 characters

RUN & STOP Indicators

See Tables 3.4 and 3.5

Selector Switches

Fig 3.1 P7 Bypass Control Panel Component Names and Functions

Digital Operator 3 - 2

! Digital Operator Keys

The names and functions of the Digital Operator Keys are described in Table 3.1.

Table 3.1 Digital Operator Keys

Key Name Function

MENU Key S crolls from one of the five main menus to the next.

ESCAPE Key Returns to the display before the DATA/ENTER key was pressed.

MONITOR Key Selects the monitor (-DRIVE-) mode from any display location.

INCREASE Key Increases parameter numbers and set values. Used to move to the next item or data.

DECREASE Key

SHIFT/RESET Key

DATA/ENTER Key Pressed to enter menus and parameters as well as to set values.

Decreases parameter numbers and set va lues. Used to move to the previous item or data.

Selects the digit to be changed. The selected digit will blink. Also resets the Drive when a fault has occurred.

Digital Operator 3 - 3

! Drive Mode Indicators

The definition of the Drive mode indicators are shown in Table 3.2.

Table 3.2 Drive Mode Indicators

Indicator Definition

FWD Lit when a forward run command is input. Also lit when the Drive is in “Hand” Mode.

REV Lit when a reverse run command is input. AUTO SEQ Lit when set up for remote run command, see Table 3.3. AUTO REF Lit when set up for remote speed command, see Table 3.3.

ALARM Lit when a fault has occurred and flashing when an alarm has occurred.

" Drive AUTO Sequence (SEQ) and AUTO Reference (REF) indicators

The Bypass operates differently than a stand alone Drive with regard to these two indicators. The Bypa ss control logic interfaces with the Drive via terminals that would be used, in a Drive only installation, for the AUTO Sequence (Run Command), and AUTO Reference (Speed Command).

Since these terminals are active and the appropriate parameters configured for the Bypass unit operation (see Tables 5.1 and

5.2), the AUTO Sequence and AUTO Reference LED’s will be lit even when the H/O/A is in HAND position (local control), providing both the run and speed command from the local control panel. The control signals are “Local” to the Drive and Bypass unit, but “Remote” (AUTO) from the Drive itself.

Table 3.3 AUTO Sequence (SEQ) and Reference (REF) Indicator

Hand Mode Auto Mode

On On

Digital Operator 3 - 4

" Drive Run Indicator

The status of the “RUN” indicator is shown in Table 3.4 when the Drive is either in the “Hand” or “Auto” mode.

Table 3.4 RUN Indicator

Indicator St a t us Description

On Drive is running

Blinking Drive is decelerating to a stop

Off Drive is stopped

" Drive Stop Indicator

The status of the “STOP” indicator is shown in Table 3.5 when the Drive is either in the “Hand” or “Auto” mode.

Table 3.5 STOP Indicator

Indicator St a t us Description

On Drive is decelerating to a stop or stopped

Blinking Drive is in a run condition but the speed command is zero

Off Drive is running

! Control Panel Indicator Lights

" Control Power Indicator

Table 3.6 Cont rol Power Indicator

Indicator St a t us Condition

Off

" Drive Run Indicator

Indicator St a t us Condition

3 Phase Power is applied to the Bypass unit and the control power transformer is functioning.

3 Phase Power is disconnected f r om the Bypass unit or a control power transformer fuse has cleared.

Table 3.7 Drive Run Indicator

The Drive has been given a run command in hand or auto mode and the Bypass circuit is de-energized.

Off

The Drive has no run command in either the hand or auto modes. The unit may be operating i n B ypass mode.

Digital Operator 3 - 5

" Bypass Run Indicator

Indicator Status Description

Table 3.8 Bypass Run Indicator

The Bypass has been given a run command in the HAND or AUTO mode.

Or, the operation has been remotely transferred to Bypass using the switch selectable “Remote Transfer to Bypass” feature (S104) via a customer supplied contact closure at terminals TB1-25 and TB1-26.

Or, the operation has been automatically transferred to Byp ass after a Drive fault condition via the switch selectable “Auto Transfer to Bypass” feature (S10 3).

Or, the operation has been transferred to Bypass using the switch-selectable “Smoke Purge” feature (S105) via a con tact closure at terminals TB1-17 and TB1-18.

The motor is running at full speed across-the-line and the Drive is deenergized.

Off

" Motor OL/Safeties Fault Indicator

Table 3.9 Motor OL/Safeties Fault Indicator

Indicator Status Description

Off The motor overload (S10) and NC “motor safety circui t ” are satisfied.

The Bypass has no run command in either the HAND or AUTO modes. The unit may be operating in Drive mode .

The motor overload (S10) has tripped OFF de-energizing both the Drive and Bypass Circuits.

Or, the NC “motor safety circuit” connected to terminals TB1-1 and TB1-2 has an open circuit condition.

Digital Operator 3 - 6

" Drive Fault Indicator

Indicator Status Description

On The Drive has tripped OFF due to an internal Drive fault.

Off The Drive i s ready for operation, or operating normally.

" Smoke Purge Indicator

Indicator Status Description

Off Smoke Purge is not active, the Drive & Bypass are operating normally.

Table 3.10 Drive Fault Indicator

Table 3.11 Smoke Purge Indicator

The Smoke Purge function has been selected by closing switch S105 on PCB A2 and the building fire control system has closed a contact between terminals TB1-17 an d TB1-18.

Digital Operator 3 - 7

Drive Main Menus

The Drive’s parameters and monitoring functions are organized into groups called menus that make it easier to read and set parameters. The Drive is equipped with five menus. The five menus and their primary functions are shown in Table 3.12 and are directly available by pressing the MENU key.

Table 3.12 Drive Main Menus

Main Menu Primary Function(s)

- DRIVE -

Operation

- QUICK -

Quick Setting

- ADV -

Programming

- VERIFY -

Modified Constants

(Parameters)

- A.TUNE -

Auto-Tuning

The Drive can be run in this menu. Also called the “Monitor” menu. Use this menu for monitoring values such as frequency re ference or output current, displaying fault history or displaying the fault traces.

The Drive can be programmed in this menu. Use this menu to set/read the most commonly used parameters.

The Drive can be programmed in this menu. Use this menu to set/read every parameter.

The Drive can be programmed in this menu. Use this menu to set/read the parameters that have been modified from their factory default settings.

For Bypass units Auto-Tuning can only be accomplished through the DriveWizard software. A free download from www.drives.com. The Drive can be programmed in this menu. Use this menu to auto-tune the Drive in order to utilize the bi-directional speed search feature.

Digital Operator 3 - 8

! Main Menu Structure

The menu selection display will appear when the MENU key is pressed from a monitor or setting disp lay. While viewing the menu selection display, press the MENU key repeatedly to scroll between the menu selections.

-DRIVE-

** Main Menu **

- - - - - - - - - - - - - Operati on

-DRIVE-

** Main Menu **

- - - - - - - - - - - - - -

Quick Setting

-DRIVE-

** Main Menu **

- - - - - - - - - - - - - -

Pr ogrammi ng

-DRIVE-

** Main Menu **

- - - - - - - - - - - - - -

Modified Consts

-DRIVE-

** Main Menu **

- - - - - - - - - - - - - -

Press the DATA/ENTER key to enter the desired menu selection.

Modified Consts = Modified Parameters

Auto-Tuning

Digital Operator 3 - 9

! - DRIVE - Operation Menu

This menu is used for setting a speed command or monitoring values such as output frequency and output current. It is also used for displaying the fault history and the fault traces. The Drive may be limited to this menu in order to accept a run command, see parameter b1-08 in Chapter 5 and Table 5.1.

" U1 Monitor Parameter List

Follow the key operations below to access the Operation Menu.

-DRIVE-

** Main Menu **

- - - - - - - - - - - - - -

Operation

Use and keys to scroll through the U1 “Monitor” parameter list.

Monitor Parameters

U1-01 Frequency Ref U1-02 Output Freq U1-03 Output Current U1-06 Output Voltage U1-07 DC Bus Voltage U1-08 Output kWatts U1-10 Input Term Sts U1-11 Output Term Sts U1-12 Int Ctl Sts 1 U1-13 Elapsed Time U1-14 FLASH ID U1-15 Term A1 Level U1-16 Term A2 Level U1-18 Mot SEC Current U1-20 SFS Output U1-24 PI Feedback U1-28 CPU ID U1-29 kWh U1-30 MWh U1-34 OPE Detected U1-36 PI Input U1-37 PI Output U1-38 PI Setpoint U1-39 Transmit Err U1-40 FAN Elapsed Time U1-51 Auto Mode Fref U1-52 Hand Mode Fref U1-53 PI Feedback 2

-DRIVE- Rdy Frequency Ref

U1-01 = 0.00Hz

- - - - - - - - - - - - - - - - - - - -

U1-02= 0.00Hz

U1-03= 0.00A

Digital Operator 3 - 10

" U2 Fault Trace Paramet e r List

After viewing the “Monitor” parameter list, in order to view the “Fault Trace” parameter list, follow the example below.

-DRIVE- Rdy Monitor

U1-01= 0.00Hz

- - - - - - - - - - - - - - - - - - - -

U1-02= 0.00Hz U1-03= 0.00A

-DRIVE- Rdy Fault Trace

U2-01= None

- - - - - - - - - - - - - - - - - - - -

U2-02= None

U2-03= 0.00Hz

Use and keys to scroll through the U2 “Fault Trace” parameter list.

Fault Trace Parameters

U2-01 Current Fault U2-02 Last Fault U2-03 Frequency Ref U2-04 Output Freq U2-05 Output Current U2-07 Output Voltage U2-08 DC Bus Voltage U2-09 Output kWatts U2-11 Input Term Sts U2-12 Output Term Sts U2-13 AC Drive Status U2-14 Elapsed Time

-DRIVE- Rdy Current Fault

U2-01 = None

- - - - - - - - - - - - - - - - - - - -

U2-02= None U2-03= 0.00Hz

Digital Operator 3 - 11

" U3 Fault History Parameter List

After viewing the “Fault Tr ace” parameter list, in order to view the “Fault History” parameter list, follow the example below .

-DRIVE- Rdy Fault Trace

U2-01= None

- - - - - - - - - - - - - - - - - - - -

U2-02= None U2-03= 0.00

Use and keys to scroll through the U 3 “Fault History” parameter list.

Fault History Parameters

U3-01 Last Fault U3-02 Fault Message 2 U3-03 Fault Message 3 U3-04 Fault Message 4 U3-05 Elapsed Time 1 U3-06 Elapsed Time 2 U3-07 Elapsed Time 3 U3-08 Elapsed Time 4 U3-09 Fault Message 5 U3-10 Fault Message 6 U3-11 Fault Message 7 U3-12 Fault Message 8 U3-13 Fault Message 9 U3-14 Fault Message 10 U3-15 Elapsed Time 5 U3-16 Elapsed Time 6 U3-17 Elapsed Time 7 U3-18 Elapsed Time 8 U3-19 Elapsed Time 9 U3-20 Elapsed Time 10

-DRIVE- Rdy Fault History

U3-01= None

- - - - - - - - - - - - - - - - - - - -

U3-02= None

U3-03= None

-DRIVE- Rdy Last Fault

U3-01 = None

- - - - - - - - - - - - - - - - - - - -

U3-02= None U3-03= None

Digital Operator 3 - 12

! - QUICK - Quick Setting Menu

This menu is used to set/read a limited set of parameters in the Dr ive. Follow the key oper ations below to access the Quick Setting Menu.

-QUICK-

** Main Menu **

- - - - - - - - - - - - - -

Quick Setting

Use and keys to scroll through the “Quick Setting” parameter list.

Parameter

Number

A1-00 Langu age Selection

b1-01 Frequency Reference Sele ction b1-02 Run command Selection b1-03 Stopping Method Selection b1-04 Reverse Operation Selection

b5-XX PI Mode Parameters

b8-01 Ener gy Savings Control Selection C1-01 Acceleration Time 1 C1-02 Deceleration Time 1

d2-01 Frequency Reference Upper Limit

d2-02 Frequency Reference Lower Limit E1-01 Input Voltage Setting E2-01 M ot or Rat ed Current F6-01 Operation Selection After Communication Error H3-02 Terminal A1 Gain Setting H3-03 Terminal A1 Bias Setting H3-10 Terminal A2 Gain Setting H3-11 Terminal A2 Bias Setting L2-01 M omentary P o w er Loss Det e ction Selection L2-02 M om entary Power Loss Ride-t hru Time L4-05 Frequency Reference Loss Detection Selection L4-06 Frequency Reference Level at Loss Frequ ency L5-01 Number of Auto Restarts Attempts L5-03 Maximum Restart Time After Fault L6-01 Torque Detection Selection 1 L6-02 Torque Detection Le vel 1 L6-03 Torque Detection Time 1 L8-11 Heatsink Cooling Fan Op er at i on D elay Time

o1-01 User Monitor Selection

o1-05 LCD Brightness Adjustment

o1-07 Second Line User M oni t or Selection

o1-08 Third Line User Monitor Selection

o2-03 User Parameter Default Value

o2-05 Frequency Operation Time Selectio n

o2-08 Cumulative Operation Time Selection

o3-02 Read Allowed Selec tion

Parameter Name

-QUICKReference Source

- - - - - - - - - - - - - - - - - - - -

B1-01= 1 *1*

Terminals

“1”

Digital Operator 3 - 13

! - ADV- Programming Menu

This menu is used to set/read every parameter in the Drive. Follow the key operations below to access the Programming Menu.

-ADV-

** Main Menu **

- - - - - - - - - - - - - -

Programming

-ADVInitialization

- - - - - - - - - - - - - - - - - - - -

A1-00= 0

Select Language

Use , , and keys to scroll through the “Programming” parameter group list. For a complete parameter list see Appendi x A.

Parameter Group Functions

A1 Initialization A2 User Parameters b1 Sequence b2 DC Braking b3 Speed Search b4 Delay Timers b5 PI Control b8 Energy Saving C1 Accel/Decel C2 S-Curve Acc/Dec C4 Torque Comp C6 Carrier Freq d1 Preset Reference d2 Reference Limits d3 Jump Frequencies d4 Sequence d6 Field-Weakening E1 V/F Pattern E2 Motor Setup F6 Com OPT Setup H1 Digital Inputs H2 Digital Outputs H3 Analog Inputs H4 Analog Outputs H5 Serial Com Setup L1 Motor Overload L2 PwrLoss Ridethru L3 Stall Prevention L4 Ref Detection L5 Fault Restart L6 Torque Detection L8 Hdwe Protection n1 Hunting Prev n3 High Slip o1 Monitor Select o2 Key Selections o3 COPY Function

Digital Operator 3 - 14

! - VERIFY - Modified Constants (Parameters) Menu

“

This menu is used to set/read only those parameters that have been modified from the Drive’s original factory default settings. Follow the key operations below to access the Modified Constants (Parameters) Menu.

-VERIFY-

** Main Menu **

- - - - - - - - - - - - - -

Modified Consts

See Note 1

Note 1: If there are not any parameters that have been modified from their original factory default settings, then the display

will state “None Modified”. Otherwise, use the “increase” and “decrease” keys to scroll through the “Modified Constants” (Parameters) list.

! - A.TUNE - Auto-Tuning Menu

For P7 Bypass units Auto-Tuning can only be accomplished through the DriveWizard software. A free download from www.drives.com.

This menu is used to auto-tune the Drive in order to utilize the bi-directional speed search feature. Follow the key operations below to access the Auto-Tuning Menu.

-A.TUNE-

** Main Menu **

- - - - - - - - - - - - - -

Auto-Tuning

-A.TUNEMtr Rated Power

- - - - - - - - - - - - - - - - - - - -

1-02 = 0.40kW

(0.00~650.00)

0.40kW”

Use and keys to scroll through the “Auto- Tuning” parameter list.

Auto-Tuning Parameters

T1-02 Mtr Rated Power T1-04 Rated Current

Digital Operator 3 - 15

Example of Changing a Parameter

“

Table 3.13 provides an example of how to change parameter “C1-02” (Deceleration Time 1) from 30 sec to 40 sec.

Table 3.13 Changing a Parameter in the Programming Menu

Step

Number

1 The Drive is first powered up.

2 Press the MENU key to scroll to “Operation” menu.

3 Press the MENU key to scroll to “Quick Setting” menu.

4 Press the MENU key to scroll to “Programming” menu .

Digital Operator Display Description

-DRIVE- Rdy Frequency Ref

U1-01= 0.00Hz

- - - - - - - - - - - - - - - - - - - -

U1-02= 0.00Hz U1-03= 0.00

-DRIVE-

** Main Menu **

- - - - - - - - - - - - - -

Operation

-QUICK-

** Main Menu **

- - - - - - - - - - - - - Quick Setting

-ADV-

** Main Menu **

- - - - - - - - - - - - - Programming

-ADV-

Initialization

5 Press the DATA/ENTER key to enter “Programming” menu.

6 Press the INCREASE key until C1-01 (Accel/Decel) is displayed.

7 Press the SHIFT/RESET key to move flashing digit to the right.

- - - - - - - - - - - - - - - - - - - -

A1-01= 0

Select Language

-ADV-

Accel/Decel

- - - - - - - - - - - - - - - - - - - -

C1-01= 1.0sec

Accel Time 1

-ADVAccel Time 1

- - - - - - - - - - - - - - - - - - - -

C1-01= 30.0sec

(0.0~6000.0)

30.0sec”

Digital Operator 3 - 16

Table 3.13 Changing a Parameter in the Programming Menu (Continued)

“

Step

Number

8 Press the INCREASE key to display C1-02 (Decel Time 1).

9 Press the DATA/ENTER key to access setting display.

10 Press the SHIFT/RESET key to move the flashing digit to the right.

Digital Operator Display Description

-ADVDecel Time 1

- - - - - - - - - - - - - - - - - - - -

C1-02= 30.0sec

(0.0~6000.0)

30.0sec”

-ADVDecel Time 1

- - - - - - - - - - - - - - - - - - - -

C1-02= 0030.0sec

(0.0~6000.0)

30.0sec”

-ADVDecel Time 1

- - - - - - - - - - - - - - - - - - - -

C1-02= 0030.0sec

(0.0~6000.0)

30.0sec”

-ADVDecel Time 1

- - - - - - - - - - - - - - - - - - - -

C1-02= 0030.0sec

(0.0~6000.0)

30.0sec”

Press the SHIFT/RESET key to move the flashing digit to the right.

-ADVDecel Time 1

14 The monitor display for C1-02 returns.

- - - - - - - - - - - - - - - - - - - -

C1-02= 0040.0sec

(0.0~6000.0)

30.0sec”

-ADV-

Entry Accepted

-ADVDecel Time 1

- - - - - - - - - - - - - - - - - - - -

C1-02= 30.0sec

(0.0~6000.0)

30.0sec”

-DRIVE-

** Main Menu **

- - - - - - - - - - - - - Operation

-DRIVE- Rdy Frequency Ref

U1-01= 0.00Hz

- - - - - - - - - - - - - - - - - - - -

U1-02= 0.00Hz U1-03= 0.00

Press the INCREASE key to increase the set data.

Press the DATA/ENTER key to enter the set data. “Entry Accepted” is displayed for 1.0 sec after the data set ting has been confirmed.

Press the MENU key to scroll to “Operation” menu.

Press the DATA/ENTER key to enter “Operation” menu.

Digital Operator 3 - 17

Notes:

Digital Operator 3 - 18

Chapter 4

Start Up and Operation

This chapter describes the procedures to prepare for and conduct the P7B Drive and Bypass unit start up.

Start Up Introduct io n ..... .. ............... ............................. ...................2

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

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

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

Selector Switch Functions .........................................................9

Switch Selecta ble F u nctions ........... ............................. ............ 1 0

Contact Closure Inputs and Outputs .............................. .. .......10

Start Up and Operation 4 - 1

Start Up Introduction

In order to provide you with the most reliable Drive and Bypass unit available, and to avoid any extra costs related to loss or reduction of warranty coverage, an authorized Yaskawa service representative should complete this start up procedure. Please complete the checklist in this document and maintain it in a secured location. Should you have a need to contact Yaskawa in the future, technical service personnel may request information from this document.

CAUTION

Procedures within this document assume that start up is being accomplished by a Yaskawa authorized service person who has training on the product and is capable of working through the detailed steps with power applied to the Bypass unit while the enclosure door is open.

Start Up and Operation 4 - 2

BYPASS START UP PREPARATION

! 1. Review this Bypass Technical Manual and any option instructions and schematics shipped with the Drive and Bypass

unit.

! 2. Verify that the model numbers and voltage ratings are as specified in the purchase order by matching the nameplate

data for each unit to the purchase order.

! 3. Verify that the unit has been installed in accordance with Chapter 1, Receiving and Mechanical Installation and

Chapter 2, Electrical Installation.

! 4. Inspect the security of the supply line power, ground connections and all control circuit connections as identified in

Chapter 2, Electrical Installation.

Double check all the power wires and motor wires.

Verify that the electrical supply power lines are connected to the input circuit breaker and that the motor leads are connected to the output terminals of the overload relay. Ensure that all connections are tight may cause intermittent problems or overheating. Factory connections sometim e s come loose during shipment.

! 5. Review the installer’s “as wired” schematic. Determine if a driven motor “safety circuit” is connected. This is a series

circuit of NC contacts from devices such as a smoke/fire sensor, freeze-up thermostat or high static pressure limit switch. Verify that these customer emergency contacts are properly terminated in the Bypass safety shutdown circuit. These contacts should be wired between terminal TB1-1 and TB1-2. No field programming i s required.

, loose wire connections

Verify that all other field installed wir e s ar e correctly term inated (included the shields).

! 6. Verify that the motor

Voltage _____________________________ Full Load Amps (FLA) _________________________________

! 7. Verify that the input voltag e matches the Bypass unit rating.

! 8. Verify that the motor rated full load amps (FLA) does not exceed the rated output current of the Drive and Bypass

controlling it. When multiple motors are simulaneously operated by the Drive, the sum of all m otor FLA val ues must be less than or equal to that of the Drive and Bypass controlling them.

! 9. Record any other connections to the Bypass unit, by terminal number to determine if special programming of any of

the following is required. (see Chapter 5 for programming details).

• Multi-function Digital Inputs

• Multi-function Digital Outputs

• Analog Outputs

• Differential PI control

! 10. Verify that the customer supplied logic is ready for the start, stop and speed command functions.

is wired for the application voltage. Record the motor nameplate information:

(or Rated Load Amps (RLA)

Start Up and Operation 4 - 3

BYPASS UNIT START UP PROCEDURE

(Please review “Bypass Start Up Preparation” on page 4-3)

! 1. Before applying power, make sure that the following conditions are met:

•The DRIVE/BYPASS switch is in the DRIVE position.

•The HAND/OFF/AUTO switch is in the OFF position.

•The NORMAL/TEST switch is in the NORMAL position. [Note: If the TEST position is selected while the DRIVE/BYPASS switch is in the DRIVE position, the fault code “UV, DC Bus Undervolt” will be briefly displayed and the Drive will shut down. TEST mode is only available when in the BYPASS position.]

• The VAV terminal unit dampers, in supply fan applications, are open to prevent duct flexing or damage in a full speed, across the line starting situation.

• The electro-mechanical motor OverLoad Relay (OLR) (S10) is adjusted to equal the Full Load Amps (FLA) value from the motor nameplate.

The OLR is mounted to the contactor assembly or back panel (depending on rating), just above the Bypass contactor. See Figure 4.1. Electrically on the output power side of the Bypass unit, the adjustable thermal OLR provides o verload protection for the motor in both the Drive and Bypass operating modes. The OLR is set u p in the factory to be a manual reset device, requiring operator attention if an overload trip-out is experienced.

OverLoad Relay

Adjustment Dial

Reset Button

Bypass Contactor

Fig 4.1 Typical Motor Overload and Contactors

IMPORT ANT

! 2. Apply power to the Drive and Bypass package. Ensure that all three phases are present and that the input voltage is

correct for the system being set up. The CONTROL POW E R ON, STOP and AUTO SEQ and REF LEDs on the control panel should be ON and the display will be in the “-DRIVE-/Operation” menu showing the active speed command. [Note: If the MOTOR OL/SAFETIES FAULT light is ON, press the reset button on the motor OLR (S10) and check the “safety device” circuit between terminals TB1-1 and TB1-2.].

To maintain overcurrent, short-circuit, and ground-fault protection, the manufacturer’s instructions for setting the motor OLR must be followed.

Start Up and Operation 4 - 4

! 3. Various menus are directly available by pressing the MENU key (see Chapter 3). When in the “-DRIVE-/Operation”

menu, the Drive can accept a run com mand fro m local (Han d mo de) or r e mote ( Auto mo de) sources. Press the MENU key until the “-ADV-/Programming” menu is displayed. From here, any of the parameters can be accessed and changed using the “-VERIFY-/Modified Consts” menu can be used to review or modify only those parameters that have been changed from the Drive’s default values. Using the are correct for the Drive and installation conditions. See the Factory Parameter Settings pri nted in Table 1 and Ta ble 2 on page 2 of the Schematic Diagram that was shipped with the unit. Consider any additional parameter settin g s th at may be needed by this specific application.

The Factory Parameter Settings table documents Drive parameter settings, required to interface with the Bypass logic circuit, that have been established at the factory and stored in a dedicated location in memory as “User Initialization” values (think of it as a “back-up file”). If additional parameters are set to the specific needs of the application project, and the system operation has been checked and verified should be stored in memory again by selecting and entering “1: Set Default” in parameter o2-03.

When there is a need for re-initialization of the “user” parameters (re-setting to the “User Initialization” values) of the Bypass unit, then a “User Initialization” function should be carried out by selecting “1110: User Initialize” in parameter A1-03. This will re-establish the drive set-up required for the Bypass application and any “user” parameter values that have been stored.

The factory parameter settings required to interface with the bypass logic circuit have also been stored in the digital keypad memory. If there is a need for re-initialization (re-setting to a known factory starting point for trouble-shooting purposes) of the Bypass unit, then the “back-up file” in the digital keypad memory can be copied to the drive. In parameter o3-01 select “2: OP->INV WRITE” to carry out the copy function.

",#, and DATA/ENTER keys. See Appendix A for a list of programmable features. The

",#, and DATA/ENTER keys as needed, verify that the parameters

, then the “User Initialization” values

Table 1 of the schematic is also used to document parameters that have been factory set to typical values for fan and pump applications. These parameters may be changed to meet the needs of the specific application. In Table 5.1 of this manual shading is used to distinguish between settings required by the Bypass logic and those that may be changed.

! 4. From the “-ADV-/Programming” menu, go to parameter E1-01 and select the nominal input voltage that the Drive will

receive in this specific application. The overall voltage classification of the Drive can not be changed by this parameter. However, the input voltage should be adjusted within the range available for the given voltage “class” of the Drive to match the input voltage level normally found on the jobsite. For example, 480 VAC class Drives may be employed on nominal three phase voltage distribution systems of: 380, 400, 415, 440, 460 or 480 VAC. The factory default values may need to be changed to meet the needs of the application distribution voltage.

! 5. From the “-ADV -/Programming” menu, go to parameter E2-01 and enter the Motor rated current. Set this parameter to

the Full Load Amps (FLA) rating shown on the motor nameplate. This is essential for proper Drive operation and motor overload protection.

! 6. If the unit being started has the Speed Potentiometer option, proceed directly to step 7. Otherwise, press the

MONITOR key to return to the “-DRIVE-/Operation” menu. The AUTO SEQ and REF LEDs and the STOP and CONTROL POWER ON LEDs on the control panel should be ON at this time.

To start the motor in Drive mode, move the HAND/OFF/AUTO switch to HAND. The DRIVE RUN LED will turn

ON and the Drive will ramp up to “6 HZ”. Verify that motor rotation is correct. [Note: In Bypass packages, the Drive is programmed at the factory for 5 seconds of DC injection braking at start (to stop a rotating motor when switching from BYPASS to DRIVE), expect to see this delay each time the Drive is started.]

If the direction of motor rotation is wrong, turn the HAND/OFF/AUTO switch to OFF; and turn the P ow e r OFF W ait for the Red CHARGE LED (near the Drive power terminals) to go out. When it does, swap the wires in the motor junction box for T1 & T2 or on the output terminals of the motor OLR (S10). Tighten the terminal lugs, reapply the power, turn to HAND and re-check the rotation direction.

Start Up and Operation 4 - 5

! 7. If a Speed Potentiometer option is present, turn the Speed Potentiometer fully counterclock wise to ens ure th at the

local speed command is zero. If necessary, press the MONITOR key to return to the “-DRIVE-/Operation” menu. The AUTO SEQ and REF LEDs and the ST OP and CONTROL POWER ON LEDs on the control panel should be ON at this time.

To start the motor in Drive mode, move the HAND/OFF/AUTO switch to HAND, then rotate the Speed Potentiometer clockwise to establish a speed command in the 6 to 10 Hz range. The DRIVE RUN LED will turn ON and the Drive will ramp up to this setting. Verify that motor rotation is correct. [Note: In Bypass packages the Drive is programmed at the factory for 5 seconds of DC injection braking at start (to stop a rotating motor when switching from BYPASS to DRIVE), expect to see this delay each time the Drive is started.]

If the direction of motor rotation is wrong, turn the HAND/OFF/AUTO switch to OFF; and turn the Power OFF W ait for the Red CHARGE LED (near the Drive power terminals) to go out. When it does, swap the wires in the mo tor junction box for T1 & T2 or on the output terminals of the motor OLR (S10). Tighten the terminal lugs, reapply the power, turn to HAND; and re-check the rotation direction.

! 8. With correct motor rotation, press the MONITOR key, if necessary, to return to the “-DRIVE-/Operation” menu.

Using the observing operation. If excessive vibration of the driven load is noted at specific input frequencies, the Jump Frequency function may be used to eliminate this vibration, by programming d3-01 through d3-04.

! 9. Determine whether the remote speed command is a 0-10 VDC or a 4-20 mA signal. The positive side of the signal

should be connected to terminal A2 of the Drive terminal strip. The COMMON of the remote speed command signal should be connected to terminal AC of the Drive. See the connection diagram on page 1 of the Bypass schematic. [Note: The factory def ault is 4-20 mA, to change t o 0 to 1 0 VDC adjust parameter H3-08 to “0: 0-10VDC” and move Drive DIP switch S1-2, on the Drive terminal PCB to the OFF position.]

! 10. Observe if the remote speed command can achieve the minimum and maximum speeds desired. If not, perform the

following (see Chapter 5):

For 0-10 VDC input at Terminal A2

For 4-20 mA input at Terminal A2

",#, and DATA/ENTER keys, manually run the Drive throughout its entire operating range, while

1. With no input, adjust the Bias (H3-11 setting) until an output o f “0.0 Hz” is obtained.

2. With full scale input, adjust the Gain (H3-10 setting) until an output of “60.0 Hz” (or other desired maximum

frequency) is obtained.

1. With 4 mA input, adjust Bias (H3-11 setting) until an output of “0.0 Hz” is obtained.

2. With 20 mA input, adjust Gain (H3-10 setting) until an output of “60.0 Hz” (or other desired maximum

frequency) is obtained.

! 11. Turn the HAND/OFF/AUTO switch to AUTO, then request a run command and speed reference signal from the

building automation system to confirm remote (auto) operation.

! 12. In preparation for testing the Bypass, observe the trip setting of the circuit breaker (CB1). The trip point is factory set

at the lowest possible setting and must be adjusted for each application. This breaker will trip due to inrush current and load inertia unless it is reset!

• For fan applicati ons ad just the trip setting to ten times motor FLA.

• For pum p appli cations adjust the trip setting to six times motor FLA.

If circuit breaker tripping is experienced at these settings during motor starting on Bypass, increase the setting gradually until the motor can be started without circuit breaker tripping.

Start Up and Operation 4 - 6

Trip Setting Adjustment Dial

MCP

Adjustment Dial Label

Fig 4.2 Typical MCP Circuit Breaker

IMPORT ANT

To maintain overcurrent, short-circuit, and ground-fault protection, the manufacturer’s instructions for setting the instantaneous-trip circuit breaker must be followed.

! 13. Turn the HAND/OFF/AUTO switch to OFF and the DRIVE/BYPASS switch to BYPASS. The Drive will ramp the

motor to zero speed, then the Drive will be de-energized and control transferred to Bypass mode. Be prepared to monitor the rotation direction of the motor in Bypass operation. “Bump” the HAND/OFF/AUTO switch to the

HAND position and quickly back to OFF. Check the motor rotatio n. Do not allow the motor to continue operating in BYPASS until rotation is correct!

If the rotation direction in Bypass is correct, skip the rest of this step. If not, carry out the following corrections:

1. Turn OFF established, do not

2. Instead, verify that power to the circuit breaker is OFF breaker/disconnect switch (CB1). This will affect rotation in Bypass operation only

the incoming power feed to the Drive. Since the correct rotation in Drive mode was previously

change any output wires at the motor.

. Then swap L1 & L2 on the input side of the circuit

. Once connections are complete and tight, reapply the incoming power and repeat the previous step to re-check the rotation direction in Bypass mode.

! 14. Run the motor in Bypass by placing the HAND/OFF/AUTO switch in HAND. Record all the phase voltages and

currents at this time.

! 15. Select the OFF position of the HAND/OFF/AUTO switch and place the BYPASS/DRIVE switch in DRIVE. Turn to

the HAND position and scroll the Speed Command to “60 HZ” operation. Monitor the voltages and currents in each of the output phases at full speed to make sure the voltages are balanced and the currents are within the motor nameplate rating during accel, stable speed, and decel.

! 16. If this application requires the Drive to operate in PI mode, see Chapter 5.

! 17. For fan applications, with the HAND/OFF/AUTO switch set to AUTO, have the building automation system give the

Drive a run command and a speed command. Put the BYP ASS/DRIVE switch into BYPASS and let the load speed up and stabilize. Then move the switch to DRIVE. Observe if the DC braking is enough to stop the fan in the time period set in parameter b2-03 (5 sec factory setting). If not, set this parameter to its maximum setting, which is 10.0 seconds. If this is not enough, slowly increase the braking current setting (parameter b2-02) but do not go abo ve 90% to p rotect the Drive output devices.

Start Up and Operation 4 - 7

Bypass Operation Description

(For manual switch positions, control inputs and switch selectable functions.)

The Bypass has two modes of operation: Bypass and Drive. When in the Bypass mode the connected motor is run directly from the incoming AC line, whereas in Drive mode the motor is run from the Drive output. The DRIVE/BYPASS switch located on the front panel determines operating mode. Within each operating mode are two methods of control; HAND and AUTO. The HAND/OFF/AUTO switch on the front panel determines this control method.

T able 4.1 provides a look at various combinations of the control panel selector switch positions, control inputs to TB1 and the status of the switch selectable options.

Table 4.1 Bypass Inputs and Operating Mode

Selector Switches Contact Clo s ure Inputs Switch Selectable Functions

Run

H/O/A D/B N/T

O 0None HDN X X 0 0 0 Drive HDN 0 X 0 0 0 None HDN X 0 0 0 0 None HDT X X 0 0 0 None HBN X X Bypass HBT X X Bypass* HBN 0 X 0 None HBN X 0 0 None ADNX X X 0 0 0 Drive ADNX 0 X 0 0 0 None ADNX X 0 0 0 0 None ADTX X X 0 0 0 None ABNX X X Bypass ABTX X X Bypass* ABNX 0 X 0 None ABNX X 0 0 None HDN X X X 0 X 0 X 0 Drive HDN X X X X Bypass HDN X X X X Bypass HDN X X X X Bypass ODN X X X X Bypass ADNX X X X 0 X 0 X 0 Drive ADNX X X X X Bypass ADNX X X X X Bypass ADNX X X X X Bypass

TB1

3 & 4

Enable

TB1

5 & 6

Safety

TB1

1 & 2

Auto Xfer Remote Xfer Smoke Purge

S103

DRV

FLT

S104

TB1

25 & 26

S105

TB1

17 & 18

Operating Mode

Result

Note: A blank cell indicates the input can be in any of the possible positions. * = Drive energized, output contactor open. T a b le 4.1 Defini t ions :

H/O/A = Hand/Off/Auto TB = Terminal Block D/B = Drive/Bypass S10X = Slide Switch Number N/T = Normal/Test X = Closed Contacts or Enabled DRV FLT = Drive Fault Contacts 0 = Open Contacts or Disabled

Start Up and Operation 4 - 8

For additional influences on the Drive behavi or in D rive op erating mode, co nsult Table 5.1 and T able 5.2 . These tables explain the settings of Drive parameters required by the Bypass logic (Table 5.1) and those that are also dependent upon the control options present on the unit (Table 5.2). For Example: In the second line of Table 5.2, for a Bypass equipped with no options and switch S1-2 in the off position, the hand mode speed command is based on the setting of d1-02 and the auto mode speed command signal is 0-10VDC.

$ Selector Switch Functions

Operating in HAND position - Drive mode:

The Drive can be operated locally from the control panel by first placing the DRIVE/BYPASS switch in DRIVE. Then placing the HAND/OFF/AUTO switch in the HAND position gives the front panel control of the Drive operation. Moving the switch to HAND also provides the run command to the Drive. When placed into HAND mode the Drive begins running at the hand mode speed command.

Operating in AUTO position - Drive mode:

The Drive can be operated remotely by placing the DRIVE/BYPASS switch in DRIVE. Then placing the HAND/OFF/ AUTO switch in the AUTO position gives a remote device (separate source or DDC) control of the Drive. In the AUTO position the Drive will look for a run command contact closure at terminals TB1-3 and TB1-4 on the relay PCB A2. Speed command signal level and source is determined by the parameter settings and the options present in the unit, see T ables 5.1 and 5.2. The AUTO speed command must be wired directly to the Drive term inals A2 and AC, not the control terminal block TB1. Consult Figures 2.7 and 2.8 in Chapter 2, Electrical Installation for correct configuration of the speed command (analog frequency reference).

Operating in HAND position - Bypass mode:

The Bypass can be operated locally from the front control panel by placing the DRIVE/BYPASS switch in BYPASS. In

BYPASS mode the Bypass contactor coil can be energized manually by placing the HAND/OFF/AUTO switch in HAND position. In Bypass m ode, movi ng the HAND/OFF/AUTO switch to HAND causes the motor to run at full speed,

directly “across the line”.

Operating in AUTO position - Bypass mode:

The Bypass can be operated remotely by placing the DRIVE/BYPASS switch in BYPASS and the HAND/OFF/AUTO switch in AUTO. In the AUTO position the Bypass will look for a run command contact closure at terminals TB1-3 and TB1-4 on the relay PCB A2, to control the run/stop status of “across the line” full speed motor operation.

Operating in TEST position - Bypass mode:

TEST position is used to energize the Drive input contactor while operating in the Bypass mode. The only valid use of the TEST position is in Bypass mode. In Drive mode, switching from NORMAL to TEST position will remove the Drive

run command and the motor will stop. In Bypass mode, the test position powe rs the Driv e for pro gram ming or other “tests” while keeping it isolated from the motor.

Start Up and Operation 4 - 9

$ Switch Selectable Functions

The switch selectable functions, Smoke Purge, Auto Transfer and Remote Transfer represent various methods of transfer- ring from the Drive mode of o perati o n t o th e By pas s m ode. They may be enabled in any combinat ion from none of them to all of them. See Table 4.1 for a summary of some common combinations of these switch selectable inputs.

Smoke Purge: When enabled (switch S105) this function allows a contact closure between terminals TB1-17 and TB1-18 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. [Note: Smoke purge overrides all other control inputs and selector switches. Smoke purge operation can only be terminated by opening the contact closure at terminals TB1-17 and TB1-18 or by opening the Circuit Breaker (CB1).]

Auto Tr ansfer to Bypass: When enabled (switch S103), the Bypass unit will automatically switch into Bypass mode on a Drive fault. After clearing the Drive fault condition, the function resets by moving the HAND/OFF/AUTO switch to the OFF position and waiting for the keypad to go blank. CAUTION: Before selecting this function in fan applications, care must be taken to ensure that the ductwork is designed to handle the pressur e res ul ting from full speed operation with the VAV terminal unit dampers at minimum position or closed.

Remote Transfer to Bypass: When enabled (switch S104), this function allows a customer supplied contact closure, between terminals TB1-25 and TB1-26, to transfer motor operation from Drive mode to Bypass mode. This remote transfer to Bypass function overrides the DRIVE/BYPASS manual switch. An open contact causes operation in Drive mode and a closed contact results in Bypass mode.

$ Contact Closure Inputs and Outputs

Customer Safety Interlocks Input: Terminals TB1-1 and TB1-2 are used as a Drive or Bypass override from the NC contacts of the customer’s safety device series circuit. Anytime all the safety device contacts are closed, the Drive or Bypass will operate. When any one of these contacts open, the Drive or Bypass will immediately stop operating. This input is momentary, when a customer safety device contact re-closes, the Drive or Bypass will return to operation.

Auto Mode Run/Stop Contact Input: TB1-3 and TB1-4 are input terminals used for the Run/Stop command when in the AUTO mode. When these input contacts close, the unit will begin running. When the contacts reopen, the unit will cease

running.

Customer Supplied Interlock or Drive Enable Input: An open contact at TB1-5 and TB1-6 will override the run command, preventing Drive or Bypass operation until these input contacts are closed. For example this input could insure that the system dampers achieve an operating position before the fan is started in order to protect the ductwork from over pr essure.

Drive Run Contact Output: Terminals TB1-7 and TB1-8 are an output contact that closes whenever the motor is running in Drive mode. If the Drive is receiving a run command, but a fault condition occurs, this contact will not

Bypass Run Contact Output: Terminals TB1-9 and TB1-10 are an output contact that closes whenever the motor is running in Bypass mode. If the Bypass is receiving a run command, but a fault condition occurs, this contact will not

Drive Fault Contact Output: Terminals TB1-11, TB1-12 and TB1-13 are a Form C set of output relay contacts, NO and NC that are activated when the Drive is in a fault condition.

be closed.

Start Up and Operation 4 - 10

Motor Overload or Customer Safeties Fault Contact Output: Termin als TB1-14, TB1-15 and TB1-16 are a Form C set of output relay contacts, N.O. and N.C. that are activated when one of the N.C. contacts of the Customer Safety device input series circuit or the motor overload relay contacts is opened.

120VAC Damper Actuator Output: Output terminals TB1-19 and TB1-20 are provided to energize a damper actuator circuit or solenoid air valve, typically for outdoor air intake dampers. When the motor is stopped, the output voltage is removed in order to close the dampers. Whenever the Drive or Bypass is running, the terminals output 120VAC to power a 40VA damper actuator circuit.

120VAC Control Power Output: Output terminals TB1-21 and TB1-22 are provided to energize add ition al, cus tomer def ined control logic circuits. A maximum of 100VA control power is available, the user must provide the short circuit protection.

Optional Two Motor “OR” Selection Input: Terminals TB1-23 and TB1-24 are used only when the “Two Motor OR option” is part of the unit. These input terminals are used for choosing between motor 1 or motor 2 when the optional MOTOR 1/AUTO/MOTOR 2 selector switch is in the AUTO position.

Start Up and Operation 4 - 11

Notes:

Start Up and Operation 4 - 12

Chapter 5

Programming

This Manual contains descriptions of all parameters in the Drive that may be useful in Bypass applications. Parameters are listed in alpha-numerical order. Parameter number and name, along with a detailed description and its settings are described on the following pages.

Bypass Basic Pr o gr a m m i n g P a ra meters . ... .................................... 2

Discussion of Table 5.2 Option-Dependent Bypass

Parameter Settings: ................................................................... 5

A1 Initializ a tio n ...................................... ............................ ........ 9

b1 Sequence ...........................................................................11

b2 DC Braking ..................... .. ................ ............................ ...... 16

b3 Speed Search .....................................................................18

b5 PI Functio n ......................... ............................. ...................22

b8 Energy Sav in g s ....... .. ............................. ............................ 3 7

C1 Accel/De c e l ...................... ............................. ..................... 38

d1 Preset Re fe r e nc e s ................... ............... ............................ 39

d2 Reference (Speed Command) Limits ..................................41

d3 Jump Frequencies ..............................................................42

d4 Sequence ...........................................................................43

E1 V/f Patter n .................... .. ............................. ....................... 44

E2 Motor Setu p ...................... ............................. ..................... 50

F6 Com OPT Setup

(Applies onl y to the L on Works® option) ....... ....................... 51

H1 Digital Inputs ......................................................................52

H2 Digital Outpu ts ............................. ............................. .......... 57

H3 Analog Inputs .....................................................................58

L2 Momentary Power Loss Ride-thru Function .......................64

L3 Stall Prevention .......... ... ............................ .......................... 6 5

L4 Speed Command Loss Detection ............................ .. .........68

L5 Fault Resta rt ...... .. .. ............................. ............................ ....69

L6 Torque Detection ................................................................71

L8 Hardwar e Pr ot e c tio n .................. .. ....................................... 7 3

o1 Monitor C onfiguration ....................... ............................ ......75

o2 Key Selections ............................... ............................. ........ 79

o3 Digital Operator Copy Function ..........................................82

T1 Auto-Tuning ............................. ............................ ............... 85

Programming 5 - 1

Bypass Basic Programming Parameters

The basic Drive programming for a Bypass unit is different from that of a Drive installation without th e Bypass option.

Several Drive parameters have been programmed at the factory to meet the needs of the Bypass logic circuit. See Table 5.1 below, the highlighted parameters are required by the Bypass logic circuit.

Table 5.1 Bypass Parameter Settings

PARAMETER

NUMBER

b1-01 SEE

b1-07 1 0 N/A Local/Remote Run Selection – Determines accept-

b1-08 1 0 N/A Run Command Selection During Programming –

b2-03 5.0 0.0 SEC DC Injection Braking Time At Start – Sets the

d1-01 10.0 0.0 HZ Frequency R eference 1 – Hand Mode Speed Refer-

d1-02 6.0 0.0 HZ Frequency Reference 2 – Hand Mode Speed Refer-

d1-04 40.0 0.0 HZ Frequency Reference 4 – Speed Reference, used with

E1-01 208,

F6-01 3 1 N/A Operation Selection After Communication Error –

H1-01 70 24 N/A Terminal S3 Function Selection – Set for Drive run

H1-02 SEE

H1-03 SEE

H2-02 3B A N/A Terminals M3 - M4 Function Selection – Set for

H3-02 SEE

H3-08 SEE

SETTING

For

Bypass

TABLE

5.2

240 or

480

TABLE

5.2

TABLE

5.2

TABLE

5.2

TABLE

5.2

Drive

Default

240 or

480

14 N/A Terminal S4 Function Selection – Set for fault reset

100.0 % Terminal A1 Gain Setting Terminal A1 Gain /

UNITS DESCRIPTION

1 N/A Frequency Reference Selection – Selects the speed

command input source

ability of a remote run command when switching from hand (local) mode to auto (remote) mode

Selects if run command is accepted in DRIVE Operation menu only or in all menus.

braking time at Drive start, to stop a coasting motor before starting

ence, used with serial communication, see Table 5.2 and H1-03

ence, used without serial communication, see Table

5.2 and H1-03

serial communication loss an d H5-04 = “4: Run at d1-04”

VOLTSInput Voltage Setting – Set to the nominal Voltage

Setting for the incoming line

Selects the serial com error response, alarm and continue operation

enable

or Frequency Refer ence 1

3 N/A Termin al S5 Functio n Sele ction – Se t For Fre quenc y

Reference 1 or Serial Communication

serial communication run command

2 N/A Terminal A2 Signal Level –Signal selection, 0 to 10

VDC (Drive control board switch S1-2 off) or 4 to 20 mA (Drive control board switch S1-2 on)

KEYPAD DISPLAY

For Bypass Setting

Reference Source / Terminals

LOC/REM RUN Sel / Accept Extrn RUN

RUN CMD at PRG / Enabled

Dcinj Time@Start / (0-10)

Reference 1 / (0-60)

Reference 2 / (0-60)

Reference 4 / (0-60)

Input Voltage / (range)

Com Bus Flt Sel / Alarm Only

Term ina l S3 Se l / Drive Enable

Te rmina l S4 Se l / MultiStep Ref 1

Te rmina l S5 Se l / MultiStep Ref 1

Term M3-M4 Sel / Com RUN Command

(0-1000)

Term A2 Signal / 0-10 VDC

Programming 5 - 2

Table 5.1 (Continued)Bypass Parameter Settings

PARAMETER

NUMBER

H3-09 SEE

H3-13 SEE

L4-05 0 1 N/A Frequency Reference Loss Detection Selection –

L5-01 10.0 0 N/A Number of Re-start Attempts – Sets the number of

L5-03 600 180 SEC Maximum Restart Time After Fault – If not success-

o2-02 0 1 N/A OFF Key Function During Auto Run - Enables or

o2-03 1 0 N/A User Initialization - Factory set parameter for user

o2-15 0 1 N/A Hand Key Functio n Selection - Enables or disables

o3-02 1 0 Read Allowed Selection – Enables or disables keypad

SETTING

For

Bypass

TABLE

5.2

TABLE

5.2

Drive

Default

UNITS DESCRIPTION

2 N/A Terminal A2 Function Selection – Selects how this

input will be used by the Drive

0 N/A Master Frequency Referen ce Terminal Selection –

Determines which terminal (A1 or A2) will be the main speed reference source.

Determines Drive response to loss of the frequency speed command

times the Drive will perform an automatic re-start

fully started after this time, restart attempts stop and Drive faults

disables the Off key.

default values.

the Hand and Auto keys.

copy functio ns

KEYPAD DISPLAY

For Bypass Setting

Terminal A2 Sel / Aux Reference

TA1/A2 Select / Main Fref TA1

Ref Loss Sel / Stop

Num of Restarts / (0-10)

Max Restart Time / (.5-600.0)

Oper STOP Key / Disabled

Hand Key / Disabled

Read Allowable / Enabled

Shaded Areas = Parameter settings required by the Bypass logic

The shaded Bypass Parameter Settings in Table 5.1 document Drive parameter settings, required to interface with the Bypass logic circuit, that have been established at the factor y an d s t ored in a dedicated location in the memory as “User Initialization” values (think of it as a “back-up file”).

Table 5.1 is also used to document parameters that have been factory set, for convenience, to typical values for fan and pump applications. These parameters may be changed to meet the needs of the specific application.

If additional parameters are set to the specific needs of the application project, and the system operation has been checked and verified, then the “User Initialization” values should be stored in memory again by selecting and entering “1: Set Default” in parameter o2-03.

Programming 5 - 3

Table 5.2 Option Dependent Bypass Parameter Settings

Parameters Effected by Options Specified and

Settings

Options

None 1* 14* 3* 0.0 2* 0 1 Off* On* X X None11430.000 1OffOff X X

P and S 1 14 3 100* 2 2* 1 Off On X X X

G , H, Q, V0146C0.02 20*OffOnX X X

G , H, Q, V0

b1-01H1-02H1-03H3-02H3-08H3-09H3-

P 11430.0201OffOn X X X

S 1143100221OffOn XX S 1143100021OffOff X X

6C 0.0 0 2 0 Off Off X X X

Drive PCB

Switch S1

1 2

Resulting Hand Speed

Command Source

Keypad

d1-

Speed

Pot.

Resulting Auto Speed

Command Signal

Terminal A2

4-20 mA0-10

VDC

PSIG

3-15

Serial Com Run Speed

G , H, Q, V and P

G , H, Q, V and S

L 0 14 6C 0.0 2 2 0 On On X X X

L0 L and P 0 L and S 1 14 6C 100 2 2 0 On On X X X

1146C100220OffOn X XX

6C 0.0 2 2 0 Off On X X X X

6C 0.0 0 2 0 On Off X X X

6C 0.0 2 2 0 On On X X X X

Definitions: L = LonWorks Option Card * = The Drive factory default S = Speed Potentiometer # = The H/O/A switch must be in the AUTO position V= Native Protocol (Modbus) to allow serial com. to control the Drive. P = Pneumatic Pressure Transducer (3-15 PSIG) @ = Jumpers required from S5 to S6 and S4 to SN G = DeviceNet Option Card H = Profibus Option Card Q = Ethernet Option Card

Parameter Reference: b1-01: Speed Command Input Source H3-13: Master Frequency Reference Terminal Selection

0: Operator 0: Main Fref TA1 1: Terminals 1: Main Fref TA2

H1-02: Terminal S4 Function Sel ection d1-01: Frequency Reference 1

3: Multi-step Ref 1 d1-02: Frequency Reference 2 14: Fault Reset d1-04: Frequency Reference 4

H1-03: Terminal S5 Function Selection

3: Multi-step Ref 1 6C: Com/Inv Sel 2

H3-02: Terminal A1 Gain Setting Note: Hand mode run/stop for Drive and Bypass is always via H3-08: Terminal A2 Signal Level the front control panel HAND/OFF/AUTO switch.

0: 0 - 10 VDC 2: 4 - 20 mA

H3-09: Terminal A2 Function Selection

0: Frequency Bias 2: Aux Reference

Programming 5 - 4

! Discussion of Table 5.2 Option-Dependent Bypass Parameter Settings:

Drive Parameter Settings for Various Combin ations of Bypass and Options Notes:

See Appendix D, Communications, for additional information on serial communication. Hand mode run/stop for Drive and Bypass is always via the front control panel HAND/OFF/AUTO switch. The HAND/OFF/AUTO switch must be in AUTO position if serial communication is to be used to control the Drive. For "monitoring only" of Drive parameters and operation, via serial communication, the user needs only to set-up the

H5-0X "Serial Com Setup" parameters. All other parameters may remain as they were factory programmed for the Bypass uni t and options.

Option L, LonWorks serial communication always requires DIP switch S1-1 (terminating resistor) to be ON.

" Options - None; Bypass with no options:

Hand mode speed command from Keypad/Operator. Auto mode speed command input signal, 4-20 mA applied to Drive terminal A2. Auto mode run/stop contact closure for Drive and Bypass applied to terminals TB1-3 and TB1-4.

Significant

Parameter Setting

b1-01 = 1: Terminals (default) Speed command source = Terminals H3-13 = 1: Main Fref TA2 Specific speed command source = Terminal A2 H3-08 = 2: 4-20 mA (def au lt) Terminal A2 is pr og ra mm e d for 4-20 mA (Note – Control PCB DIP switch S1 - 2

must also be ON) H3-02 = 0.0 Terminal A1 gain = 0.0 (To insure no stray signal level at this unused terminal) H3-09 = 0: Frequency Bias Terminal A2 function is set to “bias” the terminal A1 input. Terminal A1 is not

used, therefore the A2 “bias” signal becomes the speed command. H1-03 = 3: Multi-Step Ref 1

(default)

A terminal S5 input contact closure selects d1-02 (keypad) as a preset speed. This

input contact is closed when H/O/A = Hand.

Result

" Options - None; Bypass with no options:

Hand mode speed command from Keypad/Operator. Auto mode speed command input signal, 0-10 VDC applied to Drive terminal A2. Auto mode run/stop contact closure for Drive and Bypass applied to terminals TB1-3 and TB1-4.

Significant

Parameter Setting

b1-01 = 1: Terminals (default) Speed command source = Terminals H3-13 = 1: Main Fref TA2 Specific speed command source = Terminal A2 H3-08 = 0: 0-10 VDC T erminal A2 is programmed for 0-10 VDC (Note – Control PCB DIP switch S1-2

must also be OFF) H3-02 = 0.0 Terminal A1 gain = 0.0 (To insure no stray signal level at this unused terminal) H3-09 = 0: Frequency Bias Terminal A2 function is set to “bias” the terminal A1 input. Terminal A1 is not

used, therefore the A2 “bias” signal becomes the speed command. H1-03 = 3: Multi-Step Ref 1

(default)

A terminal S5 input contact closure selects d1-02 (keypad) as a preset speed. This

input contact is closed when H/O/A = Hand.

Result

Programming 5 - 5

" Options - P "Pneumatic Pressure T ransducer" ; Bypass with pneumatic input for speed control:

Hand mode speed command from Keypad/Operator. Auto mode speed command input signal from the pneumatic transducer, or 4-20 mA applied to Drive terminal A2. Auto mode run/stop contact closure for Drive and Bypass applied to terminals TB1-3 and TB1-4.

Significant

Parameter Setting

b1-01 = 1: Terminals (default) Speed command source = Terminals H3-13 = 1: Main Fref TA2 Specific speed command source = Terminal A2 H3-08 = 2: 4-20 mA (default) Terminal A2 is programmed for 4-20 mA (Transducer output is 4-20 mA) (Note

– Control PCB DIP switch S1-2 must also be ON) H3-02 = 0.0 Terminal A1 gain = 0.0 (To insure no stray signal level at this unused terminal) H3-09 = 0: Frequency Bias Terminal A2 function is set to “bias” the terminal A1 input. Terminal A1 is not

used, therefore the A2 “bias” sign al becomes the speed command. H1-03 = 3: Multi-Step Ref 1

(default)

A terminal S5 i np u t contact closure selects d1-0 2 ( keypad) as a pr e s e t spe e d.

This input contact is closed when H/O/A = Hand.

Result

" Options - P and S " Pneumatic Pre ssure Transducer" and "Speed Pot."; Bypass wit h pneumati c input and speed potentiometer for speed control:

Hand mode speed command from speed potentiometer. Auto mode speed command input signal from the pneumatic transducer, or 4-20 mA applied to Drive terminal A2. Auto mode run/stop contact closure for Drive and Bypass applied to terminals TB1-3 and TB1-4.

Significant

Parameter Setting

b1-01 = 1: Terminals (default) Speed command source = Terminals H3-13 = 1: Main Fref TA2 Main speed command source = Terminal A2 and the Aux speed command source

= Terminal A1 H3-08 = 2: 4-20 mA (default) Terminal A2 is programmed for 4-20 mA (Transducer output is 4-20 mA) (Note

– Control PCB DIP switch S1-2 must also be ON) H3-09 = 2: Aux Referen ce (default) Aux Terminal (A1) function is set to be a speed command input. H1-03 = 3: Multi-Step Ref 1

(default)

A terminal S5 input contact closure selects Aux Terminal (A1) as a preset speed.

This input contact is closed when H/O/A = Hand.

Result

" Options - S "Speed Pot."; Bypass with speed potentiometer for speed control:

Hand mode speed command from speed potentiometer. Auto mode speed command input signal, 4-20 mA applied to Drive terminal A2. Auto mode run/stop contact closure for Drive and Bypass applied to terminals TB1-3 and TB1-4.

Significant

Parameter Setting

b1-01 = 1: Terminals (default) Speed command source = Terminals H3-13 = 1: Main Fref TA2 Main speed command source = Terminal A2 and the Aux speed command source

= Terminal A1 H3-08 = 2: 4-20 mA (default) Terminal A2 is programmed for 4-20 mA (Note – Control PCB DIP switch S1-2

must also be ON) H3-09 = 2: Aux Referen ce (default) Aux Terminal (A1) function is set to be a speed command input. H1-03 = 3: Multi-Step Ref 1

(default)

A terminal S5 input contact closure selects Aux Terminal (A1) as a preset speed.

This input contact is closed when H/O/A = Hand.

Result

Programming 5 - 6

Yaskawa P7B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Warnings and Cautions

Introduction

Bypass Model Number and Enclosure Style

Enclosure Data

Confirmations upon Delivery

Bypass Product Options

Bypass Component Descriptions

Exterior and Mounting Dimensions

Checking and Controlling Installation Site

Termination Configuration - Power Wiring

Control Wiring

Wiring Diagram

Logic Diagram

Digital Operator and Control Panel Display

Drive Main Menus

Example of Changing a Parameter

Start Up Introduction

BYPASS START UP PREPARATION

BYPASS UNIT START UP PROCEDURE

Bypass Operation Description

Bypass Basic Programming Parameters