40
Z1000U HVAC MATRIX Bypass
Low Harmonic Drive Bypass for HVAC Applications
Quick Start Procedure
Type: Z1D1
Models:
To properly use the product, read this manual thoroughly and retain
for easy reference, inspection, and maintenance. Ensure the end user
receives this manual.
208 V: 7.5 to 75 HP
480 V: 7.5 to 350 HP
MANUAL NO. TOEP YAIZ1D01A
Z1000U Bypass
Quick Start Procedure
CONTENTS
Page 2
of 2
STEP 1:
STEP 2:
STEP 3:
STEP 4:
STEP 5:
STEP 6:
STEP 7:
STEP 8:
STEP 9:
STEP 10:
Z1000U BYPASS MODEL IDENTIFICATION AND INSTALLATION ..3
MECHANICAL INSTALLATION ...........................................................4
CONNECT MOTOR AND LINE POWER ..............................................5
ADJUST MOTOR OVERLOAD RELAY AND INPUT BREAKER ........8
WIRE INTERLOCK CIRCUITS .............................................................9
HOA KEYPAD TUTORIAL .................................................................11
CONFIGURE THE HAND AND AUTO SPEED COMMANDS ...........12
VERIFY COMMON PARAMETER SETTINGS ...................................17
CHECK MOTOR ROTATION DIRECTION .........................................22
HAND MODE OPERATION ................................................................25
STEP 11:
STEP 12:
STEP 13:
STEP 14:
AUTO MODE OPERATION ................................................................27
TROUBLESHOOTING ........................................................................30
BACNET COMMUNICATIONS (OPTIONAL) .....................................32
CONNECTION DIAGRAM ..................................................................34
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
r
Quick Start Procedure
STEP
Z1000U Bypass Model Identifi cation and Installation
1
Page 3
of 37
Safety Symbols in
this Document
WARNING!
Read and understand
users manual before
using this equipment.
Failure to follow users
instructions may result
in serious injury or
death.
WARNING!
Hazardous Voltage.
Contact may cause
electric shock or burn.
Turn-off and lock-out
system and facility
power before servicing.
WARNING!
Stay Clear- Equipment
starts automatically.
Clear all personnel
from equipment, install
shields or guards, locate
and verify emergency
SHUT-OFF is functional.
Failure to comply may
result in serious injury
to personnel.
This Z1000U Quick Start Procedure serves as general guide to help install, confi gure and perform test run
operation. Refer to Z1000U Bypass Technical Manual No. SIEPYAIZ1D01 for complete instructions and to
confi gure the Z1000U Bypass for each specifi c installation site.
1.1 Verify the correct Z1000U Bypass model and ratings.
a. Locate the Z1000U Bypass nameplate and your order information.
b. Verify the Z1000U Bypass Model No: (E) matches the line item(s) on your order, to confi rm receipt of
the correct model.
c. Locate the nameplate of motor that will be connected to the Z1000U Bypass.
d. Confi rm the motor nameplate Amperage, Voltage, and Frequency (Hz) are within the Output
specifi cations (B) shown on the Z1000U Bypass nameplate.
A.C. INPUT
Volts: 480
Phase: 3
SCCR: 65kA rms sym.,480V max.
Volts: 0-460
Phase: 3
Designator Rating
F1,F2 FNQ-R1.5A,600V
A.C. OUTPUT
Hz: 50/60
Amps:114.0
Hz: 0-60
Amps:124.0
Type
A
B
C
WARNING!
Improper Operation
Sequence. DO NOT
RUN THE MOTOR.
Failure to comply may
result in serious injury
to personnel.
WARNING!
Do not operate
equipment with covers
or guards removed.
Install or replace cover
and/or guards before
operation. Failure to
comply may result
in serious injury to
personnel.
A- Input specifications
B- Output specifications
C- Control transformer fuse specs
Serial No.:4W14Z5747540001
Model No. :Z1D1D002PM
Type: Z1000U BYPASS
W.D.: DS.Z1D1.01
Inst. Manual:SIEPYAIZ1D01,
TOEPC71063611
D- Serial number
E- Bypass model number
F- Schematic document numbe
D
E
F
1.2 Verify main power source is adequate by reviewing the Input
specifi cations (A) shown on the Z1000U Bypass nameplate.
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
Quick Start Procedure
STEP
Mechanical Installation
2
2.1 Verify installation environment.
Mechanical installation and mounting footprint vary by bypass model. Refer to the Z1000U HVAC Matrix Bypass Technical Manual
No. SIEPYAIZ1D01, Chapter 2: Mechanical Installation for mechanical installation details. Ensure the installation conditions are
suitable for the Z1000U Bypass to prolong and optimize performance life.
Environment Conditions
Installation Area Indoors
Ambient Temperature -10 to + 40 °C (+14 to +104 °F) NEMA Type 1 Enclosure
Humidity 95% RH or less and free of condensation
Storage Temperature -20 °C to +60 °C (-4 °F to +104 °F)
Surrounding Area Install the drive in an area free from:
• oil mist and dust
• metal shavings, oil, water, or other foreign materials
• radioactive materials
• combustible materials (e.g., wood)
• harmful gases and liquids
• excessive vibration
• chlorides
• direct sunlight.
Altitude Up to 1000 meters without derating. Up to 3000 meters with output current and voltage derating
Orientation Install the bypass vertically to maintain maximum cooling effects.
Page 4
of 37
2.2 Maintain installation clearances.
Ensure the back panel is placed against a closed fl at
Top/Bottom Clearance
Side Clearance
B
A
D024 and B011 to B021
D030 to D074 and B027 to B077
D088 to D114 and B096 to B124 165 mm (6.5 in.)
D143 to D211 and B156 to B414 - - 127 mm (5.0 in.)
B
Models
C
D
D
Minimum Bypass Installation Spacing
ABC D
152 mm (6.0 in.)
102 mm (4.0 in.)
152 mm (6.0 in.)
surface for proper cooling.
NOTICE: Abnormal Operation. Avoid placing peripheral
devices, transformers, or other electronics near the bypass
as the noise created can lead to abnormal operation.
Take proper steps to shield the bypass from electrical
interference if such devices must be used in close
proximity to the Bypass.
NOTICE: Equipment Damage. Prevent foreign matter such
as metal shavings and wire clippings from falling into the
bypass during installation. Failure to comply could result in
damage to the bypass. Place a temporary cover over the
top of the drive during installation. Remove the temporary
cover before bypass start-up, as the cover will reduce
ventilation and cause the bypass to overheat.
914 mm (36.0 in.)
Airfl ow direction
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
Quick Start Procedure
STEP
Connect Motor and Line Power
3
3.1 Open enclosure front covers
AB C
Page 5
of 37
ON
OFF
Models D024 to D114 and B011 to B124
A – Turn circuit breaker to the “OFF” position
B – Turn the fl at head screw fasteners on the cover 1/2 turn counter-clockwise
C – Swing open door
ON
OFF
AB
Models D143 to D211 and B156 to B414
A – Turn circuit breaker to the “OFF” position
B – Turn the door handle 1/4 turn to the left and open the door (Models B302 to B414 have two doors)
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
Quick Start Procedure
STEP
Connect Motor and Line Power (continued)
3
3.2 Select the proper diagram for the model being installed.
WITH POWER OFF, make input power and motor terminal electrical connections.
Page 6
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Models D024 to D114
and B011 to B124
A
E(G)
IGR+ R- S+ S-
M1 M2 M3 M4
MD ME MF
V+AC A1 A2 A3 FM AM AC 24VRP AC
MA MB MC
S1S2 S3 S4 S5 S6 S7 S8 SN SC SP
Models D143 to D211
and B156 to B414
A
B
C
B
C
D
E(G)
IGR+ R- S+S-
M1 M2 M3 M4
MD ME MF
V+ACA1 A2A3 FMAM AC 24VRP AC
MA MB MC
S1S2 S3S4 S5S6 S7 S8 SNSC SP
A – Control, frequency reference, and communications wiring
B – Motor output circuit
C – Main input power circuit
D – Bypass grounding terminal
3.3 Connect building ground circuit to the bypass grounding terminal (D) of the bypass.
D
Note: Grounding terminal location varies by model.
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
Quick Start Procedure
STEP
Connect Motor and Line Power (continued)
3
3.4 Connect three-phase main input power (C) to the input circuit breaker (L1, L2, L3).
C
L1 L2 L3
WARNING! Fire Hazard. Do not connect the AC power line to T1, T2, T3 output terminals. Failure to comply could result in death or
serious injury by fi re as a result of drive damage from line voltage application to output terminals.
3.5 Connect the motor
a. Verify the motor leads within the motor junction box are properly connected for the application voltage for dual voltage motors.
b. Connect the motor ground wire to the bypass drive ground terminal (D).
Note: Grounding terminal location varies by model.
Page 7
of 37
D
c. Connect the motor leads to (B) the bypass motor output circuit terminals, labeled T1, T2, T3.
Note: T1, T2, T3, location varies by model.
B
L1 L2 L3
T1 T2 T3
NOTICE: Route motor leads T1, T2, and T3 separate from all other leads to reduce possible interference related issues. Failure to
comply may result in abnormal operation of drive and nearby equipment.
NOTICE: Equipment damage. Do not connect phase-advancing capacitors or LC/RC noise fi lters to the output motor circuit T1, T2, T3.
Failure to comply could result in damage to the drive, phase-advancing capacitors, LC/RC noise fi lters or ground fault circuit interrupters.
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
Quick Start Procedure
STEP
Adjust Motor Overload Relay and Input Breaker
4
4.1 Input circuit breaker adjustment
Note: Input breaker illustrations are not representative of all models.
Page 8
of 37
Models: D024 to D114 and
B011 to B124
T1 T2 T3
L1 L2 L3
Models: D143 to D211 and B156 to B414
T1 T2 T3
L1 L2 L3
4.1.1 Set input circuit breaker FLA to match motor FLA, and Inrush Level to AUTO 1 as shown.
Input disconnect/Non-fusible
WARNING! Fire Hazard. Install branch circuit protection according to applicable local codes and the requirements listed on the bypass
nameplate. Failure to comply could result in fi re and damage to the bypass and drive or injury to personnel.
Short Circuit Rating
Bypass models without soft-starter option PW are suitable for use on a circuit capable of delivering not more than 100,000 RMS
symmetrical amperes, 208 Vac and 480 Vac.
Bypass models D169 to D211 and B180 to B414 with option PW are also suitable for use on a circuit capable of delivering not more than
100,000 RMS symmetrical amperes, 208 Vac and 480 Vac.
Bypass models D024 to D143 and B011 to B156 with option PW are suitable for use on a circuit capable of delivering not more than
65,000 RMS symmetrical amperes, 208 Vac and 480 Vac.
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
Models: D024 to D114
and B011 to B124
Models: D143 to D211
and B156 to B414
L1 L2 L3
T1 T2 T3
T1 T2 T3
L1 L2 L3
D
D
Quick Start Procedure
STEP
Adjust Motor Overload Relay and Input Breaker (continued)
4
4.2 Adjust motor overload relay
Verify that the connected motor full load amperage (FLA) is within the operation range of the motor overload relay (D).
Note:
Motor overload relay
illustrations are not
representative of all
models.
Page 9
of 37
STEP
Wire Interlock Circuits
5
5.1 Install “Run Interlock” and “Run Enable” safety circuit on Bypass Control Board TB2
Note: Refer to wiring illustration on the next page terminal location.
a. Install a Run (Auto Mode) switch or jumper at Bypass Control Board terminals TB2 DI-1 to DI-10
Circuit closure is required for the motor to run in AUTO mode. Utilize an electrical contact from a building automation system
(BAS) or other remote controller for auto mode control.
b. Install a Run Enable (Safety) switch or jumper at Bypass Control Board terminals TB2 DI-2 to DI-10
The HOA keypad will display a “Safety Open FB01” fault and prevent bypass operation if this circuit is not closed. Connect
safety devices in a normally-closed series circuit, such as: freeze up thermostats, smoke/fi re sensors, high pressure limits,
temperature limits, or vibration detectors.
Note: FBO1 Fault will occur if this circuit is not closed.
c. Install a BAS interlock switch or jumper at DI-3 to DI-10
Building Automation System (BAS) Interlock. The HOA keypad will display an “INTRLOCK OPN” fault and prevent drive and
bypass operation if this circuit opens. The HOA keypad may also display “BAS Ilock-open” alarm or “BAS Ilock TO” if this
circuit opens.
Note: AL02 Fault will occur if this circuit is not closed.
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
Quick Start Procedure
STEP
Wire Interlock Circuits (continued)
5
This fi gure illustrates locations of the Bypass Control Board terminal blocks.
Note: The Bypass Control Board mounting location varies slightly by model.
Page 10
of 37
Bypass
Control
Board
Auto-RUN
Closed to RUN
(Customer
supplied)
Jumper
or
switch
TB2
12. SHIELD
11. SHIELD
10. IG24
9. IG24
8. DI-8
7. DI-7
6. DI-6
5. DI-5
4. DI-4
3. DI-3 Run Interlock (BAS)
2. DI-2 Run Enable (Safety)
1. DI-1 Run (Auto Mode)
TB3
TB1
Line
L1 L2 L3
E(G)
IG R+ R- S+ S-
M1 M2 M3 M4
MD ME MF
V+AC A1A2 A3 FM AM AC 24VRPAC
MA MB MC
S1S2 S3 S4 S5 S6 S7 S8 SN SC SP
Motor
T1 T2 T3
A
NOTICE: Equipment Malfunction. Separate control circuit wiring from main circuit wiring (terminals R/L1, S/L2, T/L3, p1, n1, U/T1, V/T2,
W/T3) and other high-power lines. Improper wiring practices could result in drive malfunction due to electrical interference.
5.1 Initial power application.
Follow these precautions prior to energizing the bypass.
Remove tools: Remove all tools and debris is from the enclosure.
Check wiring: Verify correct termination of main and motor power connections.
Check main supply: Verify correct input voltage at main switch or breaker is present.
Clear personnel: Ensure all personnel are clear of drive and motor and motor shaft is free to rotate.
Locate power off: Be familiar with emergency power off switch/breaker location.
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
F22F1
1
AU
AU
U
U
O
O
F
NTEEEESE
ESCCC
Quick Start Procedure
STEP
HOA Keypad Tutorial
6
6.1 Review this tutorial to become familiar with HOA Keypad operation before proceeding.
DIGITAL OPERATOR JVOP-183
ALM
12
Page 11
of 37
1
2
3
10
ESC
4567
F2F1
M M
HAND
ENTERRESET
AUTO OFF
11
9
8
No. Display Key or Indicator Name Function
1
Function F1 (RLY) Selects Drive Test Mode
Note: Applies specifi cally to drives confi gured with 3-contactor. Pressing the
F1 (RLY) key places the drive in Drive Test Mode. Power is applied to the drive
in the bypass mode.
Function F2 (BYP/DRV) Toggles selection between Bypass Mode and Drive Mode.
2
ESC • Returns to the previous display.
• Moves the cursor one space to the left.
• In Drive Mode, repeatedly pressing this button will return to the Frequency
Reference display.
• In Bypass Mode, repeatedly pressing this button will return to the UB-01
“Bypass Current” display.
• During parameter entry, allows aborting the current edited value and exits
the parameter editing mode.
3 RESET • Moves the cursor to the right.
• Resets the bypass or drive to clear a fault situation
• Certain drive conditions may require pressing the OFF key before the
RESET key will clear a fault..
4
AUTO Selects AUTO mode.
5
Up Arrow Scrolls up to display the next item, selects parameter numbers, and
increments setting values.
6
Down Arrow Scrolls down to display the previous item, selects parameter numbers, and
decrements setting values.
7
OFF Key If the drive was operating the motor, the motor will stop according to the
stopping method selected in b1-03. If the bypass was operating the motor, the
bypass contactor opens and the motor coasts to a stop.
8 ENTER • Enters parameter values and settings.
• Selects a menu item to move between displays.
9
10
HAND Selects HAND mode.
AUTO Light Lit or fl ashing while the drive is in AUTO mode.
AUTO
11
12
HAND Light Lit while the drive is in HAND mode.
ALARM Light • Flashing: Indicates Alarm (minor fault)
• Solid: Indicates Fault (major fault)
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
Z1000U Bypass
Quick Start Procedure
STEP
HOA Keypad Tutorial (continued)
6
Page 12
of 37
Display
DRV
(not blinking)
DRV
(blinking)
BYP
(not blinking)
BYP
(blinking)
Display FUNCTION KEY 1 (F1)
HELP Press F1 to display the Help menu.
<-- Press F1 to scroll the cursor to the left.
HOME Press F1 to return to the top menu
ESC Press F1 to return to the previous
RLY Press F1 to select/deselect Drive Test
Display FUNCTION KEY 2 (F2)
DATA Press F2 to scroll to the next display.
--> Press F2 to scroll the cursor to the
DRV/BYP Press F2 to toggle selection between
BYPASS/DRIVE STATUS
DISPLAY
Drive Mode. The bypass will run in
Drive Mode when a Run command
is present.
Drive Mode, but a condition is
making the bypass run in Bypass
Mode. Example: Smoke Purge Bypass Mode
Bypass Mode. The bypass will run
in Bypass Mode when a Run command is present. In a three-contactor bypass, drive input contactor
K1 is open and the drive will be
powered down.
Bypass Mode with Drive Test Mode
set. The bypass will run in Bypass
Mode when a Run command
is present. In a three-contactor
bypass, drive input contactor K1 is
closed and the drive is powered on.
(Frequency Reference).
display.
Mode. During Drive Test Mode, power
is applied to the drive while in Bypass
Mode by forcing the drive input contactor to close (3-contactor bypass only).
right.
Bypass Mode and Drive Mode
Display BYPASS STATUS DISPLAY
AUTO XFER EN Running in Auto Transfer,
ENRGY SAVE EN Running in Energy Savings
MTR STOPPING Fault is removed but motor is
FAULTED Fault has been detected caus-
㼉
a fault was detected and
switched to Bypass Mode.
Mode
still ramping down.
ing motor output contactors
to open.
Freq Ref (AUTO)
㼉
Display AUTO/HAND Display
RSEQ
AUTO Mode (running or stopped).
RREF
LSEQ
HAND or OFF Mode.
LREF
Display BYPASS STATUS DISPLAY
POWERUP Bypass is powering up.
OFF No Run command is present and
the safety circuit is closed.
WAIT FOR RUN AUTO mode:
-Safety circuit is closed
-Bypass waits for Run input.
SAFETY OPEN The safety circuit input is open.
INTRLOCK OPN Run command is present, the
safety circuit is closed, but the
Interlock input is open.
PRE RUN DRIVE Bypass is running in the Pre-Run
State at the programmed frequency for the programmed time.
RUN DRIVE Running in Drive Mode.
RUN BYPASS Running in Bypass Mode.
RMOT XFER EN Running in Remote Transfer.
SMOK PRG BYP Running in Smoke Purge Bypass.
SMOK PRG DRV Running in Smoke Purge Drive.
Display DATA DISPLAY
— Displays specifi c data and operation
data.
Display AUTO/HAND Display
AUTO AUTO or OFF Mode (running or stopped).
HAND HAND Mode
STEP
Confi gure the HAND and AUTO Frequency Reference
7
• The HAND and AUTO frequency references can be set independently.
• The factory default for HAND frequency reference originates from the HOA keypad.
• The factory default for AUTO frequency reference originates from drive analog inputs A1 or A2.
7.1 Ensure the HOA keypad cable is fi rmly connected between the HOA keypad door mounted
cable port and communications port CN2 on the bypass controller board.
7.2 Energize the Bypass.
YASKAWA TOEP YAIZ1D01A Z1000U Matrix Bypass Quick Start Procedure
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