mg13a122 vertical bypass non bypass panel.pdf
TRANSCRIPT
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MAKING MODERN LIVING POSSIBLE
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Safety
WARNING
EQUIPMENT HAZARD
The vertical bypass/non bypass panel contains dangerous
voltages when connected to mains voltage. It is strongly
recommended that all electrical work conform to the
National Electrical Code (NEC) and all national and local
regulations. Installation, start-up and maintenance should
be performed only by qualified personnel. Failure to follow
the NEC or local regulations could result in death or
serious injury.
Motor control equipment and electronic controls are
connected to hazardous mains voltages. Extreme care
should be taken to protect against shock. The user must
be protected against supply voltage and the motor must
be protected against overload in accordance with
applicable national and local regulations. Be sure
equipment is properly grounded. Wear safety glasses
whenever working on electric control or rotating
equipment.
Grounding
Correct protective grounding
established in accordance wi
Ground currents are higher t
Safety Guidelines
1. Disconnect the driv
bypass panel from m
service work
2. DO NOT touch elec
bypass/non bypass
connected. After ma
wait 15 minutes befcomponents or read
bypass/non bypass
3. The user must be p
voltage and the mo
overload in accorda
and local regulation
4. While programming
t t ith t i
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Contents
1 Introduction
1.1.1 Purpose of the Manual
1.1.2 Overview
1.1.3 Typical Bypass Operation
1.2 Bypass Circuits
1.2.1 Three-contactor Bypass
1.3 Bypass Options
1.3.1 Common Run/Stop with Bypass
1.3.2 Automatic Bypass
1.3.3 Run Permissive in Bypass
1.3.4 Basic Fire Mode in Bypass
1.3.5 Advanced Fire Mode in Bypass
1.3.6 Overload Protection
1.4 Bypass Platform Configurations
1.5 Switch Mode Power Supply
1.5.1 Control Transformer
1 6 Di
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3.2.1 Lifting
3.2.2 Hoist or Overhead Lift
3.2.3 Forklift
3.2.4 Shipping Weights
3.3 Cooling
3.4 Electrical Installation3.4.1 Component Identification & Customer Connection
3.4.2 Wire and Cable Access
3.4.3 Wire Size
3.4.4 Wire Type Rating
3.4.5 Terminal Tightening Torques
3.4.6 Input Line Connection3.4.7 Motor Wiring
3.4.8 Grounding (Earthing)
3.4.9 Control Wiring
3.4.10 Serial Communication Bus Connection
3.4.11 Drive Control Terminals
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6.1.5 ECB Hand/OFF/Auto
6.1.6 ECB Mode of Operation
6.1.7 Bypass Status Word Bit Examples
6.1.8 ECB Auto Bypass
6.1.9 ECB Run Permissive
6.1.10 ECB Overload6.1.11 ECB Safety Interlock
6.1.12 ECB Common Run/Stop
6.1.13 ECB Advanced Fire Mode
6.1.14 ECB Fault Reporting
7 Start Up Troubleshooting
7.1.1 Option Panel Alarm and Warnings
8 Appendix
8.1.1 Dimensions
8.1.2 Mechanical Diagrams
8.1.3 Typical Wiring Diagrams
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Contents | Figure
Figure 1.1: Basic Non Bypass Circuit
Figure 1.2: Basic Bypass Circuit
Figure 2.1: Sample Panel Label
Figure 3.1: Proper Lifting Method
Figure 3.2: Side Cooling ClearanceFigure 3.3: Cooling Airflow
Figure 3.4: Power Connections
Figure 3.5: P2 Bypass Mechanical Layout Diagram
Figure 3.6: P2 Non Bypass Mechanical Layout Diagram.
Figure 3.7: P3 Bypass Mechanical Layout Diagram.
Figure 3.8: P3 Non Bypass Mechanical Layout Diagram.
Figure 3.9: P4 Bypass Mechanical Layout Diagram.
Figure 3.10: P4 Non Bypass Mechanical Layout Diagram.
Figure 3.11: P5 Bypass Mechanical Layout Diagram.
Figure 3.12: P5 Non Bypass Mechanical Layout Diagram.
Figure 3.13: Bypass Panel Conduit Entry Diagram
Figure 3.14: Non Bypass Panel Conduit Entry Diagram
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Figure 8.8: EMB2, Part 2
Figure 8.9: ECB, Part 1
Figure 8.10: ECB, Part 2
Figure 8.11: ECB with Control Relays, Part 1
Figure 8.12: ECB with Control Relays, Part 2
Figure 8.13: Non-bypass
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Contents | Table
Table 1.1: Contactor Operation
Table 1.2: Bypass Configurations
Table 1.3: Tier Definitions and Features
Table 1.4: Panel Voltage and Frame Ratings
Table 3.1: Tools Required Table 3.2: Drive Fuses 208 V
Table 3.3: Drive Fuses 230 V
Table 3.4: Drive Fuses 460 V
Table 3.5: Drive Fuses 600 V
Table 3.6: Sample Fuse Rating Label
Table 3.7: Approximate Shipping Weights
Table 3.8: Reference Designator Definitions
Table 3.9: Wire Size Chart, 208 and 230 V
Table 3.10: Wire Size Chart 460 and 600 V
Table 3.11: Tightening Torques, 208 and 230 V
Table 3.12: Tightening Torques, 460 V
Table 3.13: Tightening Torques, 600 V
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1 Introduction
1.1.1 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and operation of the vertical panel used in
conjunction with a Danfoss variable frequency drive (VFD). To enable efficient handling of the equipment,
requirements are provided for installation of mechanical,
electrical, control wiring, proper grounding, and environ-
mental considerations. Pre-start and start up procedures
are detailed. Also included is a detailed overview of the
panel bypass function. In addition, identification of other
optional components and their operation and start up
troubleshooting instructions are included. For the electron-
ically controlled bypass, additional programming and
operation information is provided.
1.1.2 Overview
A variable frequency drive regulates the speed and
operation of an electric motor. The drive is programmable
and offers many features and savings compared to
inputs, and status reporting.
backed up by an independen
supply so that, even if the dr
communication functions are
and display are provided by tof the ECB is the ability to ac
building automation system
operational status in return.
See more detailed descriptio
chanical Bypass (EMB2) Opera
Controlled Bypass (ECB) Opera
1.1.3 Typical Bypass O
With contactors M1 and M2 c
open, the motor is running in
contactor M2 removes powe
drive to remain under power
mode. With contactors M1 an
closed, the motor is running
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Contactor Drive Mode OFF Bypass
Mode
Test Mode
M1 Closed Open Open Closed
M2 Closed Open Open Open
M3 Open Open Closed Closed
Table 1.1 Contactor Operation
INPUTPOWER
EARTH
GROUND
TYPE 1 ENCLOSURE
W/98
U/96
V/97
VFDL1
L2
L3Fuse
Fuse
Fuse
DISCONNECT
DS1
DRIVE
1L1
1L2
1L3
2L1
2L2
2L3L2/92
L1/91
L3/93
Figure 1.1 Basic Non Bypass Circuit
1.3 Bypass Options
1.3.4 Basic Fire Mode
This option switches the pan
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1.4 Bypass Platform Configurations
The two bypass platform configurations are ECB and EMB2.
The features available as options with each platform are
listed in Table 1.2. The ECB, also listed below, has all option
features available. See 5 Electromechanical Bypass (EMB2)
Operation for additional details on the EMB2 and
6 Electronically Controlled Bypass (ECB) Operation for the
ECB.
Control Features
Safety Interlock
Common Start / Stop
Automatic Bypass
Run Permissive
Basic Fire Mode
Advanced Fire Mode
Serial Communication
Table 1.2 Bypass Configurations
W/98
U/96
V/97
Fuse
Fuse
Fuse
F u s e
F u s e
INPUTPOWER
2T1
2T2
2T3
MK902
2
24 V DC SMPS
MK901
1
MK903 MK904
3 4
EARTHGROUND
Type 1 EnclosureVFD
EARTHGROUND
2L3
M12L1
2L2L2/92
L1/91
L3/93
TRANSFORMERCONTROL
6 0 0 V
6 0 0 V
3L3
3L1
3L2
MAIN DISCONNECT
DS1
Fuse
Fuse
Fuse1L1
1L2
1L3
L2
L3
L1
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the option panel door can be opened. (Bypass
panel only.)
•
Disconnect without fuses.
For user-supplied fuses
option. (Bypass panel only.)
•
Main circuit breaker. A thermal/ magnetic current
interrupt device using an ON/TRIP/OFF/RESET
switch. When in the ON position, a trip fault
removes power from the drive/bypass circuit andthe switch moves to the TRIP setting. The switch
must be moved to the RESET position
momentarily after the fault has been cleared to
reset the circuit breaker. (Bypass panel only.)
•
Main Disconnect with drive fuses. Non-bypass
panel two-position (ON/OFF) rotary switch that
disconnects the main AC line power to the drive
only.
1.6.2 Mode Selector Switch
The mode selector switch is used for 3-contactor bypass
on EMB2 units. The selector switch allows the operator to
select from four modes of operation.
Drive mode: When drive mode is selected, the M1 and M2
contactors are closed allowing power to flow in and out of
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1.6.3 Panel Configurations
The VLT FC Drive Series comes in two panel enclosure types. One is the non bypass and the o
Table 1.3 for descriptions and available options.
Non bypass Bypass
1 3 0 B X 3 6 3 . 1
0
1 3 0 B
X 3 6 5 . 1
0
1 3 0 B X 3 6 2 . 1
0
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1.6.4 Panel Voltage and Frame Ratings
Table 1.4Table 1.5 defines the voltage and hp ratings of the frames sizes for the panel. See 8 Ap
mounting dimensions.
Panel P2
(B3 - Drive)
Bypass Non By
FC102/202/322 FC102/202/322
Volts VAC HP (KW)
208 & 230 7.5 (5.5) - 15 (11) 7.5 (5.5) - 15 (11)
460 & 600 15 (11) - 25 (18.5) 15 (11) -25 (18.5)
Panel P3
(B4 - Drive)
Bypass Non By
FC102/202/322 FC102/202/322
Volts VAC HP (KW)
208 20(15)20 (15) - 25 (18.5)
230 20 (15) - 25 (18.5)
460 & 600 30 (22) - 50 (37) 30 (22) - 50 (37)
Panel P4
(C3 - Drive)
Bypass Non By
FC102/202/322 FC102/202/322
Volts VAC HP (KW)
208 25 (18.5) - 40 (30)30 (22) - 40 (30)
230 30 (22) - 40 (30)
460 & 600 60 (45) - 75 (55) 60 (45) - 75 (55)
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2 Pre-installation
2.1.1 Receiving Inspection
Inspect the packaging and equipment closely when
received. Any indication of careless handling by the carrier
should be noted on the delivery receipt, especially if theequipment will not be immediately uncrated. Obtain the
delivery person’s signed agreement to any noted damages
for any future insurance claims. Ensure that the model
number and power match the order and intended use for
the drive.
IMPORTANT!LOST OR DAMAGED GOODS
INSPECT THIS SHIPMENT IMMEDIATELY UPON ARRIVAL
If goods are received short or in damaged condition, insist
on a notation of the loss or damage across the face of the
freight bill. Otherwise no claim can be enforced against
the transportation company. If concealed loss or damage is
discovered, notify your carrier at once and request an
inspection. This is absolutely necessary. Unless you do this
the carrier will not entertain any claim for loss or damage.
2.1.2 Pre-installation C
1. Compare panel mod
ordered.
2. Ensure each of the same voltage:
•
Drive
•
Panel
•
Power line
•
Motor
3. Ensure that the pan
greater than motor
motor performance
•
Motor pow
for proper
•
If panel ra
motor out
4. Check motor wiring
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dirt. If the unit does not have power applied to it,
supply a protective covering. It is important to
ensure that the components stay as clean as
possible. It may be necessary to clean the interior
once construction is completed.
•
Keep drawings and manuals accessible for
detailed installation and operation instructions. It
is important that the manuals be available for
equipment operators.
2.2 Harsh Environments
The mechanical and electrical components within the
panel can be adversely affected by the environment. The
effects of contaminants in the air, either solid, liquid, or
gas, are difficult to quantify and control.
2.2.1 Airborne Liquids
Liquids in the air can condense in components. Water
carried in the air is easily measured as relative humidity,
but other vapors are often more difficult to measure or
control. Steam, oil and salt water vapor may cause
corrosion of components. In such environments, use TYPE
12 enclosures to limit the exchange of outside air into the
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3 Installation
3.1.1 Tools Required
In addition to the standard tool kit, the tools in Table 3.1
are recommended for installation of the panel.
TO
Spreader bar capable of lifting u
Max diameter 0.5 in.
Forklift, crane, hoist or other lift
up to 750 lbs. (Qualified device the equipment.)
Metric Socket Set: 7 - 19mm
Socket Extensions: 4, 6, and 12 i
Torx driver set: T10 - T40
Torque wrench: 6 - 375 lbs-in
Allen Wrenches:1/8, 3/16, 1/4, &
Metric or English wrenches: 7 -
Table 3.1 Tools Required
3.1.2 Drive Fuses
To maintain UL, the drive fuses should be replaced only with the fuses specified in , , , and . If
desired please consult the factory. See the specifications label inside the cover of the unit for a
fuses. A sample of this data can be seen in Table 3.6
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230 V AC
HP (KW)
UL Motor
Current
Panel
(FC102/202/322)
Non Bypass &
Bypass
Main Fuse
(FC102/202/322)
Danfoss (Bussman)
Drive Fuse
(FC102/202/322)
Danfoss (Bussman)
Transformer Fuse
(FC102/202/322)
Danfoss (Bussman
7.5 (5.5) 22
P2
34042600 (LPJ-35-
SP)176F8953 (JJN-50)
10 (7.5) 2834042700 LPJ-45-
SP176F8953 (JJN-50)
15 (11) 4234042800 (LPJ-70-
SP)176F8955 (JJN-60)
20 (15) 54
P3
34042900 (LPJ-90-
SP)176F8957 (JJN-80)
25 (18.5) 6834043000 (LPJ-100-
SP)176F8960 (JJN-125)
30 (22) 80
P4
34043100 (LPJ-125-
SP)176F8960 (JJN-125)
40 (30) 10434043200 (LPJ-150-
SP)
174N6538
(JJN-150)
50 (37) 130
P5
34043400 (LPJ-200-
SP)
174N6839
(JJN-200)
34046200 (FNQ-
R-1.25)
60 (45) 15434042300 (LPJ-250-
SP)
174N6840
(JJN-250)
34046200 (FNQ-
R-1.25)
Table 3.3 Drive Fuses 230 V
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460 V AC
HP (KW)
UL Motor
Current
Panel
(FC102/202/322)
Non Bypass &
Bypass
Main Fuse
(FC102/202/322)
Danfoss (Bussman)
Drive Fuse
(FC102/202/322)
Danfoss (Bussman)
Transformer
Fuse
(FC102/202/322
) Danfoss
(Bussman)
15 (11) 21
P2
34042600 (LPJ-35-
SP)176F8952 (JJS-40)
20 (15) 27 34035600 (LPJ-40-SP)
176F8952 (JJS-40)
25 (18.5) 3434035700 (LPJ-50-
SP)176F8954 (JJS-50)
30 (22) 40
P3
34035800 (LPJ-60-
SP)176F8956 (JJS-60)
40 (30) 52176U5037 (LPJ-80-
SP)176F8958 (JJS-80)
50 (37) 6534043000 (LPJ-100-
SP) 176F8959 (JJS-100)
60 (45) 77
P4
34043100 (LPJ-125-
SP)176F8961 (JJS-125)
75 (55) 9634043200 (LPJ-150-
SP)176F9078 (JJS-150)
100 (75) 124
P5
34043400 (LPJ-200-
SP)34051200 (JJS-200)
34046000 (FNQ-
R-0.60)
125 (90) 15634042300 (LPJ-250-
00002051 (JJS-250)34046000 (FNQ-
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600 V AC
HP (KW)
UL Motor
Current
Panel
(FC102/202/322)
Non Bypass &
Bypass
Main Fuse
(FC102/202/322)
Danfoss (Bussman)
Drive Fuse
(FC102/202/322)
Danfoss (Bussman)
Transformer
Fuse
(FC102/202/32
Danfoss
(Bussman)
15 (11) 17
P2
34035500 (LPJ-30-
SP)176F9076 (JJS-35)
20 (15) 22 34042600 (LPJ-35-SP)
176F9076 (JJS-35)
25 (18.5) 2734042700 (LPJ-45-
SP)176F9077 (JJS-45)
30 (22) 32
P3
34035700 (LPJ-50-
SP)176F8954 (JJS-50)
40 (30) 4134035800 (LPJ-60-
SP)176F8956 (JJS-60)
50 (37) 52176U5037 (LPJ-80-
SP) 176F8958 (JJS-80)
60 (45) 62
P4
34043000 (LPJ-100-
SP)176F8959 (JJS-100)
75 (55) 7734043100 (LPJ-125-
SP)176F8961 (JJS-125)
100 (75) 99
P5
34043200 (LPJ-150-
SP)176F9078 (JJS-150)
34053600 (FNQ
R-0.50)
125 (90) 12534043400 (LPJ-200-
130G0488 (JJS-175)34053600 (FNQ
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3.1.3 Internal Main Panel Fuses
Use only the specified fuse or an equivalent replacement for the internal main fuses. See the s
cover of the unit for acceptable replacement main fuses. A sample of this can be seen in Table
Fuse Description Manufacturer
F13A & C Primary Transformer Bussmann
F15A, B, & C Main Fuses Bussmann
F16A, B, & C Drive Fuses Bussmann
F900, F901,F902 SMPS - Power Supply Bussmann
Table 3.6 Sample Fuse Rating Label
3.2 Mechanical Installation
3.2.1 Lifting
Check the weight of the unit before attempting to lift.
Ensure that the lifting device is suitable for safely lifting
the panel. If necessary, plan for a hoist, crane or forklift
with appropriate rating to move the units.
3.2.2 Hoist or Overhead Lift
3.2.4 Shipping Weigh
Weights listed in Table 3.7 ar
Options can add or reduce w
are in lbs.
Frame Non Byp
P2 3
P3 6
P4 1
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3.3 Cooling
•
Only mount the drive and panel vertically.
•
Panels rely on the ambient air for cooling. It is
important to observe the limitations on ambient
air temperature. The maximum ambient
temperature for all bypass panels is 40°C and
45°C for non bypass panels. Derating concerns
start above 3300 feet elevation above sea level.
•
Most panels may be mounted side-by-side
without additional side clearance. However, the
P2 (B3 frame size) units require 1.5 in. minimum
clearance between units (see Figure 3.2).
•
Top and bottom clearance is required for cooling
(see Figure 3.3). Generally, 2 to 10 inches (50 to
250mm) minimum clearance is required,
depending upon the hp (kW) of the unit. See the
dimensional drawings in 8 Appendix for specific
requirements.
•
No additional back plate is required for drives
with the bypass and non bypass panels.
38.1 [1.5] . 1 0
50.8 [2.0] min
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3.4 Electrical Installation
WARNING
EQUIPMENT HAZARD
Rotating shafts and electrical equipment can be hazardous.
It is strongly recommended that all electrical work conform
to all national and local regulations. Installation, start-up
and maintenance should be performed only by qualified
personnel. Failure to follow local regulations could result in
death or serious injury.
•
Motor control equipment and electronic controls
are connected to hazardous line voltages.
Extreme care should be taken to protect against
electrical hazard.
•
Correct protective grounding of the equipment
must be established. Ground currents are higher
than 3mA.
•
A dedicated ground wire is required.
•
Wear safety glasses whenever working on electric
control or rotating equipment.
NOTE
Make all power connections with a minimum of 60 C/
•
Power into the pan
distribution panel)
•
Power from the pan
insulated motor gro
•
Control wiring
Control wiring should always
voltage power wiring.
Avoid getting metal chips int
Follow the connection proce
drawing provided with the u
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3.4.1 Component Identification & Customer Connection
Mechanical layout drawings are intended to provide the installer or equipment user with comp
location for that specific unit. Figure 3.5 represents a typical layout drawing. Table 3.8 provides
reference designators. (Not all reference designators are shown.)
(EMB2 OPTION ONLY)
(ECB OPTION ONLY)
(EMB2 OPTION ONLY)
(EMB2 OPTION ONLY)
CUST. CONNECTION
EMB2 CONTROL WIRES
14
15
17
7
10
4,5,6
19
18
1
2
1 3 0 B X 3 7 2 . 1
2
27
26
CUST. CONNECTION
DRIVE CONTROL
TERMINALS
CUSTOMER CONNECTION TERMINAL BLOCK 1
CUST. CONNECTION
ECB CONTROL WIRES
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7
17
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(EMB2 OPTION ONLY)
(EMB2 OPTION ONLY)
14
15
10
7
17
CUST. CONNECTION
DRIVE CONTROL
TERMINALS
Installation Vertical Bypass/Non Bypass Panel
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17
5
CUST. CONNECTION
DRIVE CONTROL
TERMINALS
CUST. CONNECTION
OUTPUT GROUND
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(EMB2 OPTION ONLY)
(EMB2 OPTION ONLY)
4,5,6
7
17
14
15
CUSTOMER CONNECTION
DRIVE CONTROL
TERMINALS
27
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CUSTOMER CONNECTION
DRIVE CONTROL TERMINALS
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4,5,6
12
7
17
14
15
(EMB2 OPTION ONLY)
(EMB2 OPTION ONLY)
CUSTOMER CONNECTION
DRIVE CONTROL
TERMINALS
Installation Vertical Bypass/Non Bypass Panel
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5
8
CUSTOMER CONNECTION
DRIVE CONTROL
TERMINALS
CUSTOMER CONNECTION
INPUT GROUND
CUSTOMER CONNECTION
OUTPUT GROUND
27
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3.4.2 Wire and Cable Access
•
Refer to through for wire routing and termination
locations.
•
Removable access knockout covers are provided
for cable connections (see Figure 3.13 and
Figure 3.14).
•
Access holes are provided for input power, motor
leads, and control wiring.
•
Run input power, motor wiring, and control
wiring in three separate conduits for isolation.
NOTE
RUN INPUT POWER, MOTOR WIRING AND CONTROL
WIRING IN THREE SEPARATE METALLIC CONDUITS OR
RACEWAYS FOR HIGH FREQUENCY NOISE ISOLATION.
FAILURE TO ISOLATE POWER, MOTOR AND CONTROL
WIRING COULD RESULT IN LESS THAN OPTIMUM DRIVE
AND ASSOCIATED EQUIPMENT PERFORMANCE.
•
The drive always resides in the upper section of
the panel. Connections to the ECB and EMB2 are
in this area except on the P2 bypass panels.
•
Power connections are typically towards the
bottom side of the panel
BYPASS PANEL CONDUIT ENTRY D
USE EITHER CONDUIT PLATE FOR CO
Figure 3.13 Bypass Panel Condu
CONTROL WIRES
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INPUT POWER WIRES
OUTPUT POWER WIRES
CONTROL WIRESINPUT POWER WIRES
Non Bypass
Bypass
Figure 3.15 P2 Panel
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CONTROL WIRES
INPUT POWER WIRESCONTROL WIRES
INPUT POWER WIRES
OUTPUT POWER WIRES
BypassNon Bypass
Figure 3.17 P4 Panel
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CONTROL WIRES
OUTPUT POWER WIRES
INPUT POWER WIRESCONTROL WIRES
INPUT POWER WIRES
Non Bypass Byp
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208 V AC
HP (KW)
UL Motor
Current
Panel
(FC102/202/322)
Non Bypass &
Bypass
Panel (FC302)
Non Bypass
Maximum Field
Wiring Size Class
B or C
Field G
Wiring S
B o
7.5 (5.5) 24.2
P2P2
8 AWG 10 A
10 (7.5) 30.8 8 AWG 10 A
15 (11) 46.2P3
4 AWG 10 A
20 (15) 59.4 P3 3 AWG 10 A
25 (18.5) 74.8P3 - Non Bypass
P4 -Bypass P42 AWG 8 A
30 (22) 88P4
2 AWG 8 A
40 (30) 114P5
1/0 AWG 6 A
50 (37) 143P5
3/0 AWG 6 A
60 (45) 169 4/0 AWG 6 A
230 V AC
HP (KW)
UL Motor
Current
Panel
(FC102/202/322)
Non Bypass &
Bypass
Panel (FC302) Non
Bypass
Maximum Field
Wiring Size
Class B or C
Field
Wir
Cla
7.5 (5.5) 22
P2P2
10 AWG 1
10 (7.5) 28 8 AWG 1
15 (11) 42P3
6 AWG 1
20 (15) 54P3
4 AWG 1
25 (18 5) 68 3 AWG 8
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460 V AC
HP (KW) UL Motor Current
Panel
(FC102/202/322)
Non Bypass &
Bypass
Panel (FC302) Non
Bypass
Maximum Field
Wiring Size Class
B or C
Field
Wiring
B
15 (11) 21
P2P2
10 AWG 10
20 (15) 27 8 AWG 10
25 (18.5) 34
P3
6 AWG 10
30 (22) 40P3
6 AWG 1040 (30) 52 4 AWG 10
50 (37) 65P4
3 AWG 8
60 (45) 77P4
1 AWG 8
75 (55) 96P5
1 AWG 8
100 (75) 124P5
2/0 AWG 6
125 (90) 156 3/0 AWG 6
600 VAC
HP (KW) UL Motor Current
Panel
(FC102/202/322)
Non Bypass &
Bypass
Panel (FC302) Non
Bypass
Maximum FieldWiring Size Class
B or C
FielWirin
15 (11) 17
P2P2
10 AWG 1
20 (15) 22 10 AWG 1
25 (18.5) 27
P3
8 AWG 1
30 (22) 32
P3
8 AWG 1
40 (30) 41 6 AWG 1
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Installation Vertical Bypass/Non Bypass Panel
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Installation Vertical Bypass/Non Bypass Panel
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Field Connection Tightening Torque lb-in (N-m) Temper
L1, L2, L3/Ground 25 (2.8) 25 (2.8) Use 75°C
2T1, 2T2, 2T3/Ground 25 (2.8) 25 (2.8) Use 75°C
TB1 25 (2.8) 25 (2.8) Use 75°C
Table 3.14 Sample Tightening Torque and Wire Rating Label
3.4.6 Input Line Connection
CAUTION
Run input power, motor wiring and control wiring in three
separate metallic conduits or raceways for high frequency
noise isolation. Failure to isolate power, motor and control
wiring could result in less than optimum drive and
associated equipment performance.
•
Connect 3-phase AC input power wire toterminals L1, L2, and L3. See the connection
drawing inside the cover of the unit.
•
Depending on the configuration of the
equipment, input power may be connected to a
circuit breaker or disconnect switch.
•
Torque terminals in accordance with the
information provided inTable 3.11 and Table 3.12
WARNING
INDUCED VOLTAGE
Run output motor cables from
Induced voltage from output
can charge equipment capac
turned off and locked out. Fa
cables separately could result
NOTE
Run input power, motor wirin
separate metallic conduits or
noise isolation. Failure to isol
wiring could result in less tha
associated equipment perform
•
Connect the 3-phas
terminals T1 (U), T2
connection drawing
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3.4.8 Grounding (Earthing)
WARNING
GROUNDING HAZARD
for operator safety, it is important to ground the option
panel properly. Failure to do so could result in death or
serious injury.
NOTE
It is the responsibility of the user or certified electrical
installer to ensure correct grounding (earthing) of the
equipment in accordance with national and local electrical
codes and standards.
•
Follow all local and national codes for proper
electrical equipment grounding (earthing).
•
Correct protective grounding of the equipment
must be established. Ground currents are higher
than 3 mA.
•
A dedicated ground wire is required for input
ground.
•
Connect the ground wire directly to a reliable
earth ground. Grounding studs are provided on
1
Figure 3.19 Control Terminals L
1. EIA-485 terminal
2. Jumper wire
3. Control terminals
4. Grounded restrainin
3 4 10 Serial Commun
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Programming
Serial communication point maps, parameter settings, and
other details for bypass option functionality are included in
the serial communication materials supplied with the unit.
3.4.11 Drive Control Terminals
Definitions of the drive terminals are summarized inTable 3.15.
•
Connector 1 provides four digital inputs; two
selectable digital inputs or outputs, 24 V DC
terminal supply voltage, and a common for
optional customer supplied 24 V DC voltage.
•
Serial communications use EIA-485 connector 2
with terminal 68 (+) and 69 (-).•
Connector 3 provides two analog inputs, one
analog output, 10 V DC supply voltage, and
commons for the inputs and output.
•
A USB port, connector 4, is also available for use
with the MCT 10 Set-up Software available on the
Danfoss website.
•
Also provided are tware in various locati
configuration and s
Figure 3.20 Removable Drive C
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4 Start Up
1. Input power to the unit must be OFF and locked
out per OSHA requirements. Do not rely on panel
disconnect switches.
WARNING
HIGH VOLTAGE
if input and output connections have been connected
improperly, there is potential for high voltage on these
terminals. If power leads for multiple motors are
improperly run in same conduit, there is potential for
leakage current to charge capacitors within the panel, even
when disconnected from line input. For initial start up,
make no assumptions about power components. Follow
pre-start procedures described below. Failure to do so
could result in death, serious injury or damage to
equipment.
2. Use AC voltmeter to verify there is no voltage on
input terminals L1, L2, and L3, phase-to-phase
and phase-to-ground, and output terminals T1,
T2, and T3, phase-to-phase and phase-to-ground.
3 Use ohmmeter to confirm continuity of the motor
11. For multiple windin
wired on run windin
CAUTION
EQUIPMENT DAMAGE
if motor FLA (full load amper
maximum amps, drive and pa
one of appropriate rating. Do
Failure to match FLA to unit m
result in equipment damage.
12. Confirm motor FLA
maximum panel ou
have higher than no13. Check that the over
connected motor. S
overload relay. Rela
14. For drive start up p
instruction manual.
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4.1.1 Inspection Prior to Start Up
Before applying power to the unit, inspect the entire installation as detailed in Table 4.1.
Inspect For Description
Auxiliary equipment
Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breake
power side of drive or output side to motor. Examine their operational readines
all respects for operation at full speed. Check function and installation of pressu
used for feedback to drive. Remove power factor correction caps on motor, if pr
Cable routing
Ensure that input power, motor wiring, and control wiring are in three separate
frequency noise isolation. Failure to isolate power, motor, and control wiring co
drive and associated equipment performance.
Control wiring
Check for broken or damaged wires and connections. Check the voltage source
use of shielded cable or twisted pair is recommended for serial communication
correctly.
EMC considerations Check for proper installation with regard to electromagnetic capability.
Environmental
conditions
See panel label for the maximum ambient operating temperature. Humidity lev
condensing. Attitude less than 3300 feet.
Fusing and circuit
breakers
Check that all fuses are inserted firmly and in operational condition and that all
position.
Grounding
The panel requires a dedicated ground wire from its chassis to the building gro
motor be grounded to the panel chassis. The use of conduit or mounting of the
considered a suitable ground. Check for good ground connections that are tigh
insulated motor ground wire back to panel in conduit with motor wires.
Input and outputCheck for loose connections Check for proper fusing or circuit breakers
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CAUTION
MOTOR START
Ensure that motor, system, and any attached equipment is
ready for start. Failure to do so could result in personal
injury or equipment damage.
5. If a bypass is connected, place the Mode Selector
Switch in drive mode. Apply power by turning
the main disconnect switch to the ON position.
6. Enter drive programming data per the drive
instruction manual.
7. Check motor rotation direction in drive control as
follows.
7a Put panel in drive mode.
7b Hand start drive at minimum speed (see
drive instruction manual for details).
7c Confirm directional rotation.
7d If incorrect, stop the drive, remove
power, and lock out.
7e Reverse connection of T1 & T2 motor
leads. Do not change incoming power
leads.
9a Put the un
9b Check mot
T1, T2, and
are within
and are ba
see 7.1 Sta
isolation p
9c Check inp
L1, L2, andwithin FLA
3%. If inco
shooting fo
10. Check motor curren
motor terminals.
10a Put the un
10b Check full
T2, and T3
within mo
balanced w
7.1 Start Up
procedure
For steps 11-13, see 5 Electro
Operation and 6 Electronically
Operation for details
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Start Up Vertical Bypass/Non Bypass Panel
4
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5 Electromechanical Bypass (EMB2) Operation
5.1.1 Typical Control Connections for Common HVAC Applications
Drive Terminal Parameter Number Parameter Name Value Number Value Na
27 500 Digital I/O Mode 0 PNP
27 501 Term 27 mode 0 Input
29 502 Term 29 Mode 1 Outpu
18 510 Term 18 digital input 8 Start
19 511 Term 19 digital input 52 Run Permi
27 512 Term 27 digital input 7 External Int
29 531 Term 29 digital output 160 No Alar
01 & 02 540 [0] Relay 1 function 167 Start Comman
01 & 02 540 [0] Relay 1 off delay 0.00 seconds Off Del
Table 5.1 EMB2 Default Parameter Settings for Common HVAC Applications
If the drive is reinitialized, be sure that these settings are maintained or reset for proper bypas
Name Function Drive Terminals
Remote Drive Start (with common start/stop) Input Command
Remote Drive Start (without common start/stop) Input Command 13, 18
Motor Running on Drive Output Status 04, 05, 06
f
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(A2)M3
(A1)
(A2)(A1)M2
(A1)M1
(A2)
1-2
CONTACT
5-6
7-8
3-4
TEST
X
X
X
X
X
BYPASSOFFDRIVE
X
X INDICATES CONTACT CLOSED
CONTACT SEQUENCE CHART FOR S1
POSITION
USE CLASS 1 CO
CUSTOMER CON
CONDUCTOR SI
CLASS 2 POWER
REQUIRED FOR
3
M1, M2, AND M3
10
7
9
8
4
6
5
MK 106
O.L. RELAYEXTERNAL
1
2
3
4
1
2
MK 107
1
MK 105
2 3 54 6
MK 100
10
8
9
7
10
12
11
9
24 V SUPPLY
CONTACT
CONTACTORS
1
2
3
4
6
7
8
5
D/O/B/T SWITCH28
100
73
72
71
70
CR9
RL6
S1
30
(3) (4)
31
(5) (6)S1
40
94
91
28
M342
M23334
M2
91
90
94
92
83
84
60
PL2
R
BLUE100
OL1
(95)(96)
35
30
BLUE
24 VDC, 1 ARESISTIVE LOAD
MAXIMUM
RESISTIVE LOAD24 VDC, 1 A
MAXIMUM
M3
27
(8)S1
(7)S1
91 27
(2) (1)
10094
BLUE
(13)(14)
(32) (31)
(31)(32)
43
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
8
NC
NC
NC
DRIVEMK 103
11
12
NC
NC
M2
(34)(33)
M3
(34)(33)
BLUE/WHT
BLUE
BLUE
B L U E
B L U E
B L U E
B L U E / W H T
B L U E
B L U E
B L U E
(X2)(X1)
S1051
2
O N
TO SMPS
CONTACT CLOSEINDICATES
FIREMANS OVER
CU
FIREMA
DAMPER MOTOR(CONTACT
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5.1.2 EMB2 Auto Bypass
General Information
Auto bypass allows a fault condition in the drive to
activate running the motor in bypass without operator
intervention. Activation of the function is through setting
DIP switches (S100) located on the EMB2 bypass control
card (see Figure 5.1). A fault condition enables a delay
timer prior to tripping the drive into bypass. The fault trip
and running in bypass are reported as output from the
bypass control card. The auto bypass function is built in.
Prior to Enabling Auto Bypass
•
Complete the start-up procedure to verify that
the motor rotation direction in bypass is correct
and that the system is ready in all respects for
continuous full speed operation in bypass.
WARNING
HIGH VOLTAGE
Remove power to the bypass panel before setting auto
bypass dip switch settings. Bypass can contain high
voltage. Failure to remove power to bypass panel before
setting dip switches could result in death or serious injury.
•
All OFF = no auto b
•
Switch 1 only ON =
•
Switch 2 only ON =
•
Switch 3 only ON =
•
Switch 4 = Always O
5.1.3 EMB2 Common
General Information
The common run/stop functi
stop control of the motor in
stop, the motor would autom
whenever the bypass is activa
provides drive control as wel
this one input common to bo
enabled by factory default. W
permissive function, common
operation in bypass.
Prior to Enabling Common Ru
•
Complete the start-
rotation direction in
the system is ready
full speed operation
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5.1.4 EMB2 Run Permissive
General Information
Run permissive allows a remote signal to notify the drive
to start, indicating the system is safe to operate. Run
permissive works in drive or bypass mode. Run permissive
is enabled by factory default and can be disabled by
switching dip switch #4 on S105 to the on position or
placing a jumper wire between terminal 1 and 2 of the
X55 customer connector.
Prior to Enabling Run Permissive
•
Complete the start-up procedure to verify that
motor rotation direction in bypass is correct and
that the system is ready in all respects for
continuous full speed operation in bypass.
•
Verify that the drive is programmed for the run
permissive function. See the drive supportmanual provided for information on
programming the run permissive function.
Operation
•
A start command can be from local hand start on
the drive keypad or a remote auto start signal
through digital input connector X55 terminals 3
and 4, or via the serial communications input.
5.1.5 EMB2 Overload
General Information
The overload device provides
the motor when running in b
overload monitors motor cur
power to the motor if a susta
exists. A Class 20 overload is
setting for motor current. Tes
provided. In drive mode, the
and trip protection. Fuses pro
over current conditions.
Prior to Enabling Overload
•
Verify that the over
matches the motor
nameplate.
•
If the motor FLA is gof the current dial, r
and voltage are wit
drive) rating. If grea
replace the panel w
CAUTION
MOTOR DAMAGE
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trip when pressed. Use the reset pushbutton toreset the overload after the test.
•
Reset is used to reset the overload after it trips. If
the overload is still hot, wait until the motor
reaches normal operating temperature before
resetting. The overload offers a manual (hand) or
auto reset selection. It is highly recommended to
operate in the manual factory setting to prevent
the risk of damage to the motor.
T1 T2 T3
97NO 98NO 95NC 96NC
1 0
2 0 3 0
RESETTEST
MANUAL
AUTO
TRIP
5
1 3 0 B X 2 2 9 . 1
0
Figure 5.2 Sample Overload Device
5.1.6 EMB2 Safety Interlock
5.1.7 EMB2 Fire Mode
General Information
Fire mode runs the motor at
intended to ignore common
selector switch inputs in eme
will continue to run in bypas
or the unit fails.
Prior to Enabling Fire Mode
•
Complete the start-
rotation direction in
the system is ready
full speed operation
Operation
•
Activation of fire mo
closing connector X
•
When activated, a re
circuit, motor overlo
position.
•
Fire mode is deactiv
fuses blow.
•
Fire mode status ca
connector X55, term
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Fault Reporting Function Setup
•
Fault reporting status is connected to connector
X55, output terminals 5, 6, and 7.
5.1.9 EMB2 Switches
Mode selector switch.
A panel mounted Drive/OFF/Bypass/Test selector switch is
used to electrically select whether the motor is controlledby the drive (M1 and M2 contactors), connected to the
full-speed bypass (M3 contactor), or disconnected from
both. The test position allows for operation in bypass while
providing power to the drive (M1 and M3). See Figure 1.2.
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6 Electronically Controlled Bypass (ECB) Operation
6.1 Electronically Controlled Bypass (ECB)
Operation
6.1.1 Overview
Information provided in this section is intended to enable
the user to connect control wiring, program functions, and
operate the ECB and its optional features.
The ECB contains a local processor located on the ECB
control card, which interacts with the drive’s control logic
for programmable options, remote command input, and
output status reporting. Rather than panel-mountedoperator-activated selector switches, as on the electrome-
chanical option panel, ECB control is provided by the
drive’s processor.
The ECB also contains a power supply which provides back
up for the drive’s logic circuitry, so even if the drive loses
power, the control and communication functions are
1. LCP Display
2. Menu keys
3. Menu navigation
4. Control keys
Programming and display are
control panel. (LCP See Figur
An important feature of the
commands from a building a
to report operational status i
Control wiring connections a
control terminals (see Figure the ECB control card (see Fig
digital I/O terminals are mult
programmed for their intend
the ECB control card are ded
Programming options for driv
pressing the [Main Menu] ke
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Parameter Parameter name Setting title Setting
5-01 Term 27 Mode Input 0
5-02 Term 29 Mode Output 1
5-10 Term 18 digital input Start 8
5-11 Term 19 digital input Run Permissive 52
5-12 Term 27 digital input External Interlock 7
5-31 Term 29 digital output No Alarm 160
5-40(0) Relay 1 function Start Command Active 167
5-40(0) Relay 1 off delay Off Delay 0.00 S
Table 6.1 Parameter Group 5-** Factory Default Settings
6.1.2 ECB Control Card
The ECB control card (see Figure 6.2) provides input connector X57 for commanding bypass op
connector X59 for reporting the bypass mode of operation, either drive mode or running in by
See Table 6.2 for ECB control card terminal types and functions.
1
1 3 0 B X 2 3 2 . 1
0
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9
4
1
3
2
10
12
11
ECB
EXTERNAL
6
7
8
3
5
4
2
1
2
1
24 V SUPPLY
BOARD28
100
16
NC
NC
M3(A2) (A1)
(A1)(A2)M2
100
6
5
+ 24 V
RUNNING
+ 24 V
+ 24 V
15
SAFTY INTERLOCK
M2 STATUS
O.L. TRIP
NC
NC
NC
NC
NC
18
COM
MOTOR
CONTACT
0-24 VDC
MAXIMUM 1 A
DC RESISTIVE
22
CUSTOMER
CMS MOTOR SELEC
CUSTOMER
INTERLOCK
SUPPLIEDSAFETY
100 (95)(96)
M3
M2
OL119
20
21(14) (13)
USE CLASS 1 CONDUCTORS
CUSTOMER CONNECTIONS X56,X57,X59
CONDUCTOR SIZE 28-14 AWG
BLU/WHT
BLU
BLU
BLU
BLU/WHT
BLU/WHT
BLU
BLU
24 VDC, 0.25 A
CLASS 2 POWER SOURCE
REQUIRED FOR FIELD CONNECTION
17(A1)(A2)M1
BLU
BLU
BLU
TO PAGE 1
TO PAGE 1
TO PAGE 1
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Input Conn. Term. Function
X57
1 Digital input for safety stop User su
2 Common User su
3 Factory use only
4 No function
5 Factory use only
6 Factory use only
7 Factory use only
8 Digital input for remote bypass enable User su
9 Digital input overrides system to Bypass Mode ignoring all
other inputs and commands, except for safety stop on
terminal 1.
User su
10 Digital input for remote overload reset User su
Output Conn. Term. Function
X59
1 Common for binary I/O
2 Common for binary I/O
3 No function
4 No function
5 Digital output indicates panel is in Drive Mode. 24 VDC
6 Digital output indicates panel is in Bypass Mode 24 VDC
7 Common for binary I/O
8 Common for binary I/O
Relay Output Term. Function
X56
1 N.O. contact for running in bypass or drive Relay o
2 N O contact for running in bypass or drive Relay o
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6.1.3 ECB Drive or Bypass Selection
Use the LCP and display to switch between the motor running in drive mode or bypass when
display in operating mode is shown below.
1. Press [Drive Bypass]. Display changes to show
bypass and drive mode options (shown in Step 2). 1 3 0 B X 2 3 4 . 1
0
1 = Display
2 = Info key
3 = Drive/Bypass Option
2. When running in drive mode, press [OK] on LCP
to activate bypass mode or press CANCEL to
d d b h ll
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1 3 0 B X 2 3 8 . 1 0
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6.1.4 ECB Programming
Use the LCP and display for programming ECB functional options. All programming options ap
parameters. Parameters are arranged in groups by related functions. Programming is performe
parameters through a menu and selecting from displayed options or entering numerical value
materials for detailed programming instructions.
Access parameters to program bypass functions in accordance with the following instructions:
1. Press [Main Menu] on the LCP to access parameter groups.
(Note that the memory function of the menu returns to the
most recently used function. Use [Back] to return to the main
menu index when necessary.)
2. Press [▲] or [▼] to scroll through parameter groups. Adotted outline surrounds the selected group. Bypass options
are found in parameter group 31-** Bypass.
3. Press [OK] to enter the selected parameter group.
4. Press [▲] or [▼] to scroll through the parameter list.
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6.1.5 ECB Hand/OFF/Auto
General Information
The [Hand on], [Off Reset], and [Auto on] keys on the LCP control both the drive and bypass (
allows the user to locally select drive or bypass mode of operation. It does not necessarily star
Prior to Enabling Hand/Off/Auto
•
Complete the start-up procedure to verify that motor rotation direction in bypass is c
ready in all respects for continuous full speed operation in bypass.
Programming Key Functions
For [Off Reset] and [Drive Bypass], Table 6.3 lists the parameters that select functions for the co
protection can also be assigned in these parameters.
Operation
•
[Hand on] allows the user to start the motor locally from the LCP. Press the [Hand on
either in drive or bypass mode.
•
[Off Reset] allows the user to stop the motor locally from the LCP. Press the [Off Rese
either in drive or bypass mode.•
[Auto on] allows the motor to be started remotely from digital input or serial commu
activate the remote motor start and stop from a digital input or serial communication
•
Press [Drive Bypass] to initiate the display to toggle between drive or bypass mode o
accept the change or [Cancel] to cancel the action.
Parameter No. Key Funct
00 44 [Off R t] Thi di bl bl th [Off R
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•
Auto bypass mode: When in drive mode, auto bypass is a timed interval that allows a
to activate running the motor in bypass without operator intervention.
Mode of Operation Select
•
Mode of operation is programmed through parameter group 31-** . See Table 6.4.
Par. No. Selection
31-00 Bypass Mode Selects sour
(0) Drive (
31-01 Bypass Start Time Delay Sets a delay
allows for ex
to line starti
0-60
31-02 Bypass Trip Time Delay Setting a va
auto bypass
time before
the drive ha0-300
31-03 Test Mode Activation Setting enab
See the man
(0) disab
31-10 Bypass Status Word Read-only d
status in he
0, 2
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6.1.7 Bypass Status Word Bit Examples
1. Motor running and bypass in drive mode. Status word 22 hexadecimal converts to 00
Bit 10 9 8 7 6 5 4 3
Binary 0 0 0 0 0 1 0 0
1. External interlock fault (open) and bypass in bypass mode. Status word 208 hexadeci
binary.
Bit 10 9 8 7 6 5 4 3
Binary 0 1 0 0 0 0 0 1
6.1.8 ECB Auto Bypass
General Information
Auto bypass allows a fault condition in the drive to
activate running the motor in bypass without operator
intervention. Activation of the function is through setting
timer start parameters in the drive programming. Fault trip
and running in bypass are reported through the drive
display, digital outputs, and serial communications. In
addition, the independently powered ECB card is available
to report bypass status when the drive is inoperable
(control card operative) through its serial communications
- a remote s
- a safety is
- motor ove
•
Once auto bypass is
reset the unit back
intervention. Ensure
cleared, then press
mode.
Auto Bypass Function Setup
Enable auto bypass by chang
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1 3 0 B X 2 4 4
. 1 0
Figure 6.4 Drive Display with Bypass Start Time Delay Active
6.1.9 ECB Run Permissive
General Information
With run permissive active, the drive sends a run request
and waits for a remote response before notifying the
motor to start. The response indicates the system is safe to
operate. Run permissive operates from the LCP hand/off/
auto select in drive or bypass mode. Run permissive is
enabled by programming in the drive parameters.
Run Permissive Function Setu
•
See the drive manu
programming and w
terminals.
•
Wire the output run
terminals selected, a
run request.
•
Wire the input run c
terminals selected, arun permissive.
Disable Run Permissive
•
Disable run permiss
parameters and term
6.1.10 ECB Overload
General Information
An overload device provides
motor when running in bypa
overload monitors motor cur
power to the motor if a susta
exists. A Class 20 overload is
setting for motor current. Tes
provided In drive mode the
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delay of 20 sec. or less at 600% current and normal
operating temperature. This allows for high motor inrush
current for 20 sec. while the motor is ramping up to
synchronous speed. The trip time, however, is based on
the percentage of overload. The higher the overload, the
shorter the time.
T1 T2 T3
97NO 98N O 95NC 96NC
1 0
2 0 3
0
RESETTEST
MANUAL
AUTO
TRIP
5
1 3 0 B X 2 2 9 . 1
0
Figure 6.5 Sample Overload Device
Overload Function Setup
•
Set the overload current dial to the FLA of the
motor. DO NOT add the service factor of the
motor into the setting. A service factor of 1.2 x
FLA is designed into the overload.
•
Pressing the test pushbutton verifies the
operation of the overload. The overload should
trip when pressed Use the reset pushbutton to
X57 terminals 1 and 2 allows
safety input is connected. Th
when connecting in a safety
Safety Interlock Function Setu
•
Remove factory-inst
connector X57 term
terminals.
•
Wire safety input to
and 2.
•
For technicians fam
terminals 12 and 27
that ECB bypass op
external fault report
connector X57, as in
6.1.12 ECB Common R
General Information
The common run/stop functi
stop control of the motor wh
Without common run/stop, t
run at full speed whenever th
remote signal provides drive
control, making this one inpu
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6.1.13 ECB Advanced Fire Mode
General Information
Drive operation in advanced fire mode is programmable. In
the event the drive does not function, the motor is
operated in bypass at full speed. Fire mode is intended to
ignore common safety and overload inputs in emergency
situations. The fire mode function is built-in. See the drive
support materials for programmable options.
Prior to Enabling Fire Mode
•
Complete the start-up procedure to verify motor
rotation direction in bypass is correct and that
the system is ready in all respects for continuous
full speed operation in bypass.
•
Verify that the drive is programmed for the fire
mode function. See the drive support materials
for programming the fire mode function.
Operation
•
Activation of fire mode is accomplished by
programming the drive for fire mode.
•
When activated, the ECB ignores safety circuits
and motor overload.
•
Fire mode is deactivated only when the
The drive monitors the ECB c
detects when communication
communication error could c
using the phone number on
technical support if this happ
also be found on the label in
Fault Reporting Function Setu
•
Automatic function.
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7 Start Up Troubleshooting
7.1.1 Option Panel Alarm and Warnings
Code
Number
Title Definition
220 Overload Trip Motor overload has tripped. Indicates excess motor load. Check m
press [Off Reset]. Then, to restart the system, press [Auto on] or [H221 Bypass Interlock Bypass interlock has opened and caused the motor to stop. Correc
the setting of parameter 14-20, the system will either automaticall
[Off Reset] key to be pressed.
222 M2 Open Failed ECB: The contactor that connects the drive to the motor failed to o
operated.
223 M2 Close Failed ECB: The contactor that connects the drive to the motor failed to c
operated.
224 M3 Open Failed ECB: The contactor that connects the motor to the power line has
226 M3 Close Failed ECB: The contactor that connects the motor to the power line has
not be operated.
227 Bypass Com Error Communication between the main control card and the bypass op
lost. It will be possible to run the motor using Manual Bypass Over
228 APU Low Voltage The Panel Power Supply has failed, or there is a power problem.
229 Motor Disconn. Terminal 3 on connector X57 of the ECB control card shows an op
neither motor has been selected in contactor motor select. Select
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Symptom Possible cause Test Solutio
No function
Missing input power See startup guide for voltage checks. Correct
Missing or open fuses or circuit
breaker tripped
See open fuses and tripped circuit
breaker in this section for possible
causes.
Reset c
opens
Loose connections in panel Perform pre-startup check for loose
connections.
Tighten
Missing customer connections Missing customer connections can cause
the safety circuit or start signal to be
open.
See cu
sure al
made ocustom
Loose customer connections Check all customer connections for
tightness. Loose customer connections
can act like an open circuit.
Tighten
Customer wires incorrectly terminated See customer connection drawing and
make sure wires are connected to correct
terminals.
Correct
could p
panel.
Improper voltage applied See pre-startup check list. Correct
could p
Use ca
Incorrect power connections See pre-startup check list to see if motor
and power leads were swapped.
Correct
could p
panel.
Power disconnect open Verify that the disconnect or circuit
breaker is closed.
Correct
could p
l
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Symptom Possible cause Test Solution
Repeated
fuse or circuit
breaker fault.
Application problem Perform startup procedures. Check
panel output motor current at full
speed and check for excessive over
current.
If curre
on the
Panel problem Perform startup procedures. Check
panel input current at full load and
verify it is within acceptable range.
If curre
on the
Power problem Monitor incoming power for surges,
sags and overall quality.
Correct
Motor problem Test motor for correct function. Repair
found.
Open control
fuse
Improper voltage applied See pre-startup check list. Correct
potenti
caution
Customer wires incorrectly terminated See the customer connection drawing
and make sure the wires are connected
to the correct terminals.
Correct
could p
panel.
Control ground fault Check all control wires for a short to
ground.
Correct
could p
panel.
Control short Check control wires for a short in
supply voltage.
Correct
potenti
Improper voltage applied See pre-startup check list. Correct
potenti
i
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Symptom Possible cause Test Solution
Overload trips
Motor overloaded Motor is drawing too much current for
the application.
Perform
is within
load on
Loose connections Look for signs of overheating on
connections to OL.
Perform
connect
overhea
OL not set correctly An improperly set OL can cause the OL
to trip too soon. See pre-startup
procedure for correct setting.
Set corr
Contactor fails
to pull in
Contamination Remove contactor and check for
contamination.
If conta
replace.
Defective coil Compare coil resistance to contactor
specification. Inspect the coil for signs
of overheating and damages.
If readin
are visib
coil or c
Auxiliary contact binding action Remove auxiliary contacts and test
contactor action.
If conta
remove
Contactor fails
to drop out
Contamination Remove the contactor and check for
contamination.
If conta
replace.
Defective coil Compare coil resistance to functional
contactors of the same size.
If readin
visible s
or conta
Auxiliary contact binding action Remove auxiliary contacts and test
contactor action.
If the co
remove
Problem with mains power Rotate incoming power leads into
l
If the im
Start Up Troubleshooting Vertical Bypass/Non Bypass Panel
7
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8 Appendix
8.1.1 Dimensions
P2 NON-
BYPASS
P2 BYPASS
P3 NON-
BYPASS
P3 BYPASS
P4 NON-
BYPASS
P4 BYPASS
A 8.86 [225.0] 9.11 [231.4] 9.57 [243.0] 9.57 [243.0] 12.69 [322.3] 12.69 [322.2]
A1 6.66 [169.1] - - - - -B 29.92 [759.9] 41.77 [1061.0] 34.33 [872.0] 43.23 [1098.0] 39.58 [1005.4] 54.38 [1381.4
C 11.45 [290.9] 15.94 [405.0] 11.23 [285.2] 17.70 [449.6] 14.78 [375.5] 17.99 [457.0]
D - 1.10 [28.0] 0.59 [15.0] 0.59 [15.0] 0.59 [15.0] 0.59 [15.0]
a 5.51 [140.0] 7.87 [200.0] 7.87 [200.0] 7.87 [200.0] 10.63 [270.0] 10.63 [270.0]
b 28.80 [731.5] 41.02 [1042.0] 32.13 [816.0] 41.18 [1046.0] 37.32 [948.0] 51.89 [1318.0
c 0.27 [6.8] 0.27 [6.8] 0.33 [8.5] 0.33 [8.5] 0.33 [8.5] 0.33 [8.5]
d 0.39 [10.0] 0.43 [11.0] 0.47 [12.0] 0.39 [10.0] 0.47 [12.0] 0.59 [15.0]
e 0.49 [12.5] 0.65 [16.5] 0.72 [18.4] 0.61 [15.5] 0.91 [23.0] 0.75 [19.0]
f 0.27 [6.9] 0.27 [6.8] - - - -
g 0.47 [12.1] 0.47 [12.0] - - - -
h 0.49 [12.5] 0.65 [16.5] - - - -
j 0.31 [8.0] 0.31 [8.0] - - - -
k 0.32 [8.0] 0.31 [8.0] - - - -
Appendix Vertical Bypass/Non Bypass Panel
Appendix Vertical Bypass/Non Bypass Panel
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8.1.2 Mechanical Diagrams
A
ØD
B
SEE DETAIL A
8
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A1 a
B
C
SEE DETAIL A
SEE DETAIL B
A
Figure 8.2 P2 Non-bypass
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A
B
ØD
SEE DETAIL A
8
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ØD
ae
A
B
C
SEE DETAIL A
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8.1.3 Typical Wiring Diagrams
INPUT
POWER
EARTHGROUND
2T1
2T2
2T3
100 28
MK902
2
6
24 V DC SMPS
MK901
1
5
MK903 MK904
3
7
4
8- +
91
CONTROLBOARDT.B.
ADJUSTABLE FREQUENCY
60 100
27 29
DRIVE
(AFD)
90
32 33 37
EARTHGROUND
W/98
U/96
V/97
92
20
94
BLU/WHT BLU
BLK 14 AWG
(T3)(L3)
(T1)
(T2)
(L1)
(L2)
M1
L2/92
L1/91
L3/93
115VAC
TRANSFORMER
149
CONTROL
6 0 0 V
1 5 0
F 1 3 A
155153
153
2CR
152
1CR1
BLK 14
GRN/YEL
1 5 1
T1
6 0 0 V
F 1 3 B
B L U E
(6) (4)
(4)(6)
GD
24V
B L U E
B L U E
B L U E
B L U E
B L U E
X1
H4H3
H1 H2
X3
X2
1L3
1L1
1L2
FUSIBLE
L1
L3
L2
DISCONNECT
DF15
F15B
F15C
F15A
MAIN
GRN/YEL
(2(1)
SEEHIGH
83
01
84
02 03
B L U E
B L U E
04 05 06
12 13 18 19
FACTORYSAFETYINTERLOCKJUMPER (ONLYFUNCTIONALIF ORDERED)
4CR
(C)
(NO)
RED
TO EMB2 CONNECTOR MK103
TO EMB2 CONNECTOR MK103
2L3
2L1
2L2F16A
F16C
F16B
3L3
3L1
3L2
(4)(5)(6)
SEEHIGH POT
FOR DRIVEINPUT FUSE
REFER TO THEDRIVE
MANUAL
8
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(7)3CR
(8)
(7)(8)2CR
(8)1CR
(7)
1-2
CONTACT
5-6
7-8
3-4
TEST
X
X
X
X
X
BYPASSOFFDRIVE
X
X INDICATES CONTACT CLOSED
CONTACT SEQUENCE CHART FOR S1
POSITION
USE CLASS 1 CONDUCTORS
CUSTOMER CONNECTIONS X55,
CONDUCTOR SIZE 28-14 AWG
CLASS 2 POWER SOURCE
REQUIRED FOR FIELD CONNECT
4
3
M1, M2, AND M3
10
7
9
8
4
6
5
MK 106
EMB23
1
2
O.L. RELAY
EXTERNAL
1
2
3
4
1
2
MK 107
1
MK 105
2 3 54 6
MK 1007
6
5
10
8
9
7
10
12
11
9
24 V SUPPLY
CONTACT
CUSTOMER
CONNECTIONS
CONTACTORS
1
2
3
4
6
7
8
5
D/O/B/T SWITCH
BOARD
28
100
73
72
71
70
CR9
RL6
S1
30
(3) (4)
31
(5) (6)
S1
40
94
91
28
M342
M23334
M2
91
90
94
92
83
84
60
PL2
R
X55
BLUE100
OL1
(95)(96)
35
30
BLUE
24 VDC, 1 A
RESISTIVE LOAD
MAXIMUM
RESISTIVE LOAD
24 VDC, 1 A
MAXIMUM
JUMPERED
FACTORY
M3
27
(8)
S1
(7)
S1
91 27
(2) (1)
10094
BLUE
(13)(14)
(32) (31)
(31)(32)
43
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
8
NC
NC
NC
DRIVE
MK 103
14
11
13
12
NC
NC
NC
NC
M2
(34)(33)
M3
(34)(33)
BLUE/WHT
BLUE
BLUE
B L U E
B L U E
B L U E
B L U E / W H T
B L U E
B L U E
B L U E
(X2)(X1)
1
6
2
7
3
8
4
9
5
10
1
6
2
7
3
8
4
9 130B7290
REFERENCE T.B. TERMINAL NUMBERS
S1051
2
O N
TO SMPS
CON
(10
CONTACT CLOSED
INDICATES
FIREMANS OVERRIDE STATUS
CUSTOMER SUPPLIED(COMMON RUN/STOP)
DAMPER END SWITCHRUN PERMISSIVE
CUSTOMER SUPPLI
FIREMANS OVERRIDE CO
CUSTOMER SUPPLIED
INTE
CUS
SUP
REP
24 VDC, 2A RATED CONTA
24 VDC, 2A RATED C
24 VDC, 2A RATED CONTA
DAMPER MOTOR CONTROL
(CONTACT)
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INPUT
POWER
EARTHGROUND
MAIN
L1
L3
L2
DISCONNECT
DS1
2T1
2T2
2T3
100 28
MK902
2
6
24 V DC SMPS
MK901
1
5
MK903 MK904
3
7
4
8- +
91
CONTROLBOARDT.B.
ADJUSTABLE FREQUENCY
60 100
27 29
DRIVE
(AFD)
90
32 33 37
EARTH
GROUND
W/98
U/96
V/97
92
20
94
BLU/WHT BLU
BLK 14 AWG
(T3)(L3)
(T1)
(T2)
(L1)
(L2)
M1
L2/92
L1/91
L3/93
B L U E
GD
24V
B L U E
B L U E
B L U E
B L U E
B L U E
1L3
1L1
1L2
GRN/YEL
(2(1)
SEEHIGH
83
01
84
02 03
B L U E
B L U E
04 05 06
12 13 18 19
FACTORYSAFETYINTERLOCKJUMPER (ONLYFUNCTIONALIF ORDERED)
TO EMB2CONNECTOR MK103
TO EMB2 CONNECTOR MK103
TO PAGE 2
2L3
2L1
2L2F16A
F16C
F16B
3L3
3L1
3L2
(4)(5)(6)
SEEHIGH POT
FOR DRIVEINPUT FUSE
REFER TO THEDRIVE
MANUAL
8
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(A2)M3
(A1)
(A2)(A1)M2
(A1)M1
(A2)
1-2
CONTACT
5-6
7-8
3-4
TEST
X
X
X
X
X
BYPASSOFFDRIVE
X
X INDICATES CONTACT CLOSED
CONTACT SEQUENCE CHART FOR S1
POSITION
USE CLASS 1 CO
CUSTOMER CON
CONDUCTOR SI
CLASS 2 POWER
REQUIRED FOR
3
M1, M2, AND M3
10
7
9
8
4
6
5
MK 106
O.L. RELAY
EXTERNAL
1
2
3
4
1
2
MK 107
1
MK 105
2 3 54 6
MK 100
10
8
9
7
10
12
11
9
24 V SUPPLY
CONTACT
CONTACTORS
1
2
3
4
6
7
8
5
D/O/B/T SWITCH28
100
73
72
71
70
CR9
RL6
S1
30
(3) (4)
31
(5) (6)S1
40
94
91
28
M342
M23334
M2
91
90
94
92
83
84
60
PL2
R
BLUE100
OL1
(95)(96)35
30
BLUE
24 VDC, 1 ARESISTIVE LOAD
MAXIMUM
RESISTIVE LOAD24 VDC, 1 A
MAXIMUM
M3
27
(8) S1(7)S1
91 27
(2) (1)
10094
BLUE
(13)(14)
(32) (31)
(31)(32)
43
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
8
NC
NC
NC
DRIVEMK 103
11
12
NC
NC
M2
(34)(33)
M3
(34)(33)
BLUE/WHT
BLUE
BLUE
B L U E
B L U E
B L U E
B L U E / W H T
B L U E
B L U E
B L U E
(X2)(X1)
S1051
2
O N
TO SMPS
CONTACT CLOSEINDICATES
FIREMANS OVER
CU
FIREMA
DAMPER MOTOR(CONTACT
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INPUTPOWER
EARTHGROUND
(AFD)DRIVE
ADJUSTABLE FREQUENCY
CONTROLBOARDT.B.
L2
L3
L1
DISCONNECT
DS1
M1
(L2)
(L1)
(L3)
(T2)
(T1)
(T3)
MAIN
L2/92
L1/91
L3/93
GROUNDEARTH
V/97
U/96
W/98
GROUNDEARTH
(L2
(L3
(L2
(L3
(L1
(L1
2T1
2T2
2T3
04
05
06
CUSTOMER SUPPLIEDREQUEST TO RUN
BLK 14 AWG
02
03
01
4
8
MK904
MK901
-
1
5
100
2
6 +
3
7
28
24 V DC SMPS
MK903 MK902
BLUBLU/WHT
GD
24V
1L3
1L2
1L1
12 13 18 19 27 29 32 33 20 37
GRN/YEL
(3)(2)(1)
SEEHIGH POT
FACTORYSAFETY INTERLOCKJUMPER(ONLYFUNCTIONALIF ORDERED)
TO PAGE 2
2L3
2L2
2L1
F16B
F16C
F16A
3L3
3L2
3L1
(4)(5)(6)
SEEHIGH POT
FOR DRIVEINPUT FUSEREFER TO THEDRIVEMANUAL
4
5
6
2
3
1
Relay output
terminal block TB106
05
04
03
02
01
8
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9
4
1
3
2
10
12
11
ECB
EXTERNAL
6
7
8
3
5
4
2
1
2
1
24 V SUPPLY
BOARD28
100
16
NC
NC
M3(A2) (A1)
(A1)(A2)M2
100
7
6
5
8
+ 24 V
RUNNING
+ 24 V
+ 24 V
15
SAFTY INTERLOCK
M2 STATUS
M3 STATUS
O.L. TRIP
BYPASS MODE ENABLE
NC
NC
NC
NC
NC
18
COM
MOTOR
CONTACT
0-24 VDC
MAXIMUM 1 AMPS
DC RESISTIVE
22
CUSTOMER
CMS MOTOR SELECTED
CUSTOMER
INTERLOCK
SUPPLIEDSAFETY
100 (95)(96)
M3
M2
OL119
20
21
(14) (13)
(44) (43)
USE CLASS 1 CONDUCTORS
CUSTOMER CONNECTIONS X56,X57,X59
CONDUCTOR SIZE 28-14 AWG
BLU/WHT
BLU
BLU
BLU
BLU/WHT
BLU/WHT
BLU
BLU
24 VDC, 0.25 A
CLASS 2 POWER SOURCE
REQUIRED FOR FIELD CONNECTION
17(A1)(A2)M1
BLU
BLU
BLU
TO PAGE 1
TO PAGE 1
TO PAGE 1
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INPUT
POWER
EARTHGROUND
(AFD)
DRIVE
ADJUSTABLE FREQUENCY
CONTROLBOARDT.B.
L2
L3
L1
BREAKER
CB1
M1
(L2)
(L1)
(L3)
(T2)
(T1)
(T3)
CIRCUIT
L2/92
L1/91
L3/93
GROUNDEARTH
V/97
U/96
W/98
GROUNDEARTH
(L2
(L3
(L2
(L3
(L1
(L1
2T1
2T2
2T3
04
05
06
CUSTOMER SUPPLIEDREQUEST TO RUN
BLK 14 AWG
02
03
01
4
8
MK904
MK901
-
1
5
100
2
6+
3
7
28
24 V DC SMPS
MK903 MK902
BLUBLU/WHT
GD
24V
1L3
1L2
1L1
12 13 18 19 27 29 32 33 20 37
GRN/YEL
(3)(2)(1)
SEEHIGH POT
115VAC
TRANSFORMER
149
CONTROL
6 0 0 V
1 5 0
F 1 3 A
158
155
153
153
153
3CR
2CR
152
1CR154
BLK 14 AW
GRN/YEL
1 5 1
T1
6 0 0 V
F 1 3 B
(6) (4)
(4)(6)
(4)(6)
X1
H4H3H1 H2
X3
X2
4CR
(C)
(NO)
RED
FACTORYSAFETYINTERLOCKJUMPER
(ONLYFUNCTIONALIF ORDERED)
TO PAGE 2
2L3
2L2
2L1
F16B
F16C
F16A
3L3
3L2
3L1
(4)(5)(6)
SEEHIGH POT
FOR DRIVEINPUT FUSE
REFER TO THEDRIVE
MANUAL
8
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9
4
1
3
2
10
12
11
ECB
EXTERNAL
6
7
8
3
5
4
2
1
2
1
24 V SUPPLY
BOARD28
100
16
NC
NC
100
7
6
5
8
+ 24 V
RUNNING
+ 24 V
+ 24 V
15
SAFTY INTERLOCK
M2 STATUS
M3 STATUS
O.L. TRIP
BYPASS MODE ENABLE
NC
NC
NC
NC
NC
18
COM
MOTOR
CONTACT
0-24 VDCMAXIMUM 1 AMPSDC RESISTIVE
22
CUSTOMER
CMS MOTOR SELECTED
CUSTOMER
INTERLOCK
SUPPLIEDSAFETY
100 (95)(96)
M3
M2
OL119
20
21
(14) (13)
(44) (43)
USE CLASS 1 CONDUCTORS
CUSTOMER CONNECTIONS X56,X57,X59
CONDUCTOR SIZE 28-14 AWG
BLU/WHT
BLU
BLU
BLU
BLU/WHT
BLU/WHT
BLU
BLU
24 VDC, 0.25 A
CLASS 2 POWER SOURCE
REQUIRED FOR FIELD CONNECTION
17BLU
BLU
BLU
3CR(7) (8)
(8)(7)2CR
(8)(7)1CR
TO PAGE 1
TO PAGE 1
TO PAGE 1
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2L1
2L2
2L3 W/98
U/96
V/97INPUT
POWER
L1
L2
L3
EARTHGROUND GRN
EARTHGROUND
02 01 03
ADJUSTABLE FREQUENCY
27 20
DRIVE(AFD)
19 18 12
EARTHGROUND
13
C O A S T I N V E R S E
C O M M O N
P R O G . D I G I N P U T
S T A R T
05 04 06
29
32
33
37
53
54
55
42
39
+ 2 4 V O L T ( 1 3 0 m A )
JOG
PROG. DIG INPUT
PROG. DIG INPUT
SAFETY INTERLOCK JUMPERED TO TERMINAL13 TO RUN W/O
OPTIONAL: FACTORY
68
69
P RS-485
N RS-485
61COM RS-485
RS-485INTERFACE
50
CUSTOMERSUPPLIED
START
+ 2 4 V O L T ( 1 3 0 m A )
ANALOG OUTPUT
COMMON
ANALOG OUTPUT
ANALOG INPUT
ANALOG INPUT COMMON
ANALOG INPUT
+ 10 VOLT OUT (15 mA)RELAY 1RELAY 2
PROGRAMMABLESEE DRIVE MANUAL
PROGRAMMABLESEE DRIVE MANUAL
PROGRAMMABLESEE DRIVE MANUAL
SAFETY INTERLOCK
R L Y 2 N O
R L Y 2 C O M
R L Y 2 N C
R L Y 1 N O
R L Y 1 C O M
R L Y 1 N C
240 VAC, 2A
240 VAC, 2A
400 VAC, 2A
1F3
1F2
1F1
REFER TO THE DRIVEMANUAL FOR FUSE SIZE
DISCONNECT
DS1
DRIVE
1L1
1L2
1L3
L2/92
L1/91
L3/93
Figure 8.13 Non-bypass
8
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