Trane VLT AQUA Drive FC 202 VLT AutomationDrive FC 301, Instruction Manual

Page 1: ...MAKING MODERN LIVING POSSIBLE Instruction Manual Vertical Bypass Non Bypass Panel...

Page 2: ...ss panel is connected to mains the motor may be started by means of an external switch a serial bus command an input reference signal or a cleared fault condition Use appropriate cautions to guard aga...

Page 3: ...Safety Vertical Bypass Non Bypass Panel MG 13 A1 22 VLT is a registered Danfoss trademark...

Page 4: ...ol Transformer 2 3 1 6 Disconnects 2 3 1 6 1 Main Disconnect 2 3 1 6 2 Mode Selector Switch 2 4 1 6 3 Panel Configurations 2 5 1 6 4 Panel Voltage and Frame Ratings 2 6 1 7 Power Component Functions 2...

Page 5: ...Up 5 1 4 1 1 Inspection Prior to Start Up 5 2 4 1 2 Start Up Procedure 5 2 5 Electromechanical Bypass EMB2 Operation 6 1 5 1 1 Typical Control Connections for Common HVAC Applications 6 1 5 1 2 EMB2...

Page 6: ...ECB Safety Interlock 7 12 6 1 12 ECB Common Run Stop 7 12 6 1 13 ECB Advanced Fire Mode 7 13 6 1 14 ECB Fault Reporting 7 13 7 Start Up Troubleshooting 8 1 7 1 1 Option Panel Alarm and Warnings 8 1 8...

Page 7: ...am 3 16 Figure 3 14 Non Bypass Panel Conduit Entry Diagram 3 16 Figure 3 15 P2 Panel 3 17 Figure 3 16 P3 Panel 3 17 Figure 3 17 P4 Panel 3 18 Figure 3 18 P5 Panel 3 19 Figure 3 19 Control Terminals Lo...

Page 8: ...8 10 Figure 8 10 ECB Part 2 8 11 Figure 8 11 ECB with Control Relays Part 1 8 12 Figure 8 12 ECB with Control Relays Part 2 8 13 Figure 8 13 Non bypass 8 14 Contents Vertical Bypass Non Bypass Panel M...

Page 9: ...460 V 3 23 Table 3 13 Tightening Torques 600 V 3 24 Table 3 14 Sample Tightening Torque and Wire Rating Label 3 25 Table 3 15 Drive Control Terminals Functions 3 27 Table 4 1 Inspection prior to Start...

Page 10: ...ses contactors to provide power to the motor through the drive or bypass circuitry However the ECB contains a local processor that interacts with the drive s control logic for programmable options rem...

Page 11: ...to start The response indicates the system is safe to operate 1 3 4 Basic Fire Mode in Bypass This option switches the panel to bypass whenever a remote fire mode signal is given to the VFD through th...

Page 12: ...ions are maintained The SMPS converts three phase AC input power to 24 V DC control power Since the SMPS draws power from all three phases it offers immunity protection from most phase loss and brown...

Page 13: ...nly 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 driv...

Page 14: ...able options Non bypass Bypass 130BX363 10 130BX365 10 130BX362 10 130BX364 10 Drive plus both of the following 1 Fuses 2 Disconnect Drive with bypass 1 Fuses 2 Disconnect Circuit Breaker 3 Contactors...

Page 15: ...r Fusing For main panel power fuses only use the specified fuse or an equivalent replacement For drive fuses only use the specified fuse See the fuse ratings label on the inside cover of the unit or T...

Page 16: ...ity 130BX366 10 Figure 2 1 Sample Panel Label Ensure that the model number and power match the order and intended use for the drive 2 1 2 Pre installation Check 1 Compare panel model number to what wa...

Page 17: ...s to limit the exchange of outside air into the option enclosure Extremely harsh environments may require a higher level of protection 2 2 2 Airborne Solids Particles in the air may cause mechanical e...

Page 18: ...can be seen in Table 3 6 208 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 2...

Page 19: ...00 LPJ 70 SP 176F8955 JJN 60 P3 176F8957 JJN 80 20 15 54 P3 34042900 LPJ 90 SP 176F8957 JJN 80 176F8960 JJN 125 25 18 5 68 34043000 LPJ 100 SP 176F8960 JJN 125 P4 176F8960 JJN 125 30 22 80 P4 34043100...

Page 20: ...3 176F8956 JJS 60 30 22 40 P3 34035800 LPJ 60 SP 176F8956 JJS 60 176F8958 JJS 80 40 30 52 176U5037 LPJ 80 SP 176F8958 JJS 80 176F8959 JJS 100 50 37 65 34043000 LPJ 100 SP 176F8959 JJS 100 P4 176F8961...

Page 21: ...P3 176F8954 JJS 50 30 22 32 P3 34035700 LPJ 50 SP 176F8954 JJS 50 176F8956 JJS 60 40 30 41 34035800 LPJ 60 SP 176F8956 JJS 60 176F8958 JJS 80 50 37 52 176U5037 LPJ 80 SP 176F8958 JJS 80 P4 176F8959 J...

Page 22: ...bar for lifting Slide the spreader bar through the two 2 lifting holes on the panel Lifting rings are 0 59in 15mm in diameter see Figure 3 1 If VFD mounting screws interfere with the spreader bar lift...

Page 23: ...quire 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...

Page 24: ...out Failure to run output motor cables separately could result in death or serious injury NOTE Run input power motor wiring and control wiring in three separate metallic conduits or raceways for high...

Page 25: ...pass Mechanical Layout Diagram ID Device Definition ID Device Definition 1 24 V DC Panel 24 V DC SMPS 15 S1 Auto Bypass Selector Switch 2 HPC High Pot Connector 16 TF 120 V AC control transformer 3 F1...

Page 26: ...CK 1 21 8 130BX374 11 27 26 CUST CONNECTION DRIVE CONTROL TERMINALS CUST CONNECTION INPUT AND OUTPUT GROUND Figure 3 6 P2 Non Bypass Mechanical Layout Diagram See Table 3 8 for reference designator de...

Page 27: ...OR 19 2 1 11 13 8 12 4 5 6 10 7 17 130BX375 12 27 26 CUST CONNECTION OUTPUT GROUND CUST CONNECTION DRIVE CONTROL TERMINALS CUST CONNECTION INPUT GROUND Figure 3 7 P3 Bypass Mechanical Layout Diagram...

Page 28: ...NECTION DRIVE CONTROL TERMINALS CUST CONNECTION OUTPUT GROUND 26 27 CUST CONNECTION INPUT GROUND Figure 3 8 P3 Non Bypass Mechanical Layout Diagram See Table 3 8 for reference designator definitions I...

Page 29: ...NLY 18 OR 19 10 11 13 1 8 12 4 5 6 7 17 14 15 CUSTOMER CONNECTION DRIVE CONTROL TERMINALS CUSTOMER CONNECTION INPUT AND OUTPUT GROUND 26 130BX378 12 27 Figure 3 9 P4 Bypass Mechanical Layout Diagram S...

Page 30: ...NNECTION OUTPUT GROUND 26 CUSTOMER CONNECTION DRIVE CONTROLTERMINALS 27 CUSTOMER CONNECTION INPUT GROUND Figure 3 10 P4 Non Bypass Mechanical Layout Diagram See Table 3 8 for reference designator defi...

Page 31: ...6 4 5 6 12 7 17 14 15 EMB2 OPTION ONLY EMB2 OPTION ONLY 130BX381 11 CUSTOMER CONNECTION DRIVE CONTROL TERMINALS CUSTOMER CONNECTION INPUT OUTPUT GROUND 27 26 Figure 3 11 P5 Bypass Mechanical Layout Di...

Page 32: ...DRIVE CONTROL TERMINALS CUSTOMER CONNECTION INPUT GROUND CUSTOMER CONNECTION OUTPUT GROUND 130BX382 12 27 Figure 3 12 P5 Non Bypass Mechanical Layout Diagram See Table 3 8 for reference designator def...

Page 33: ...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 Control wiring should be isol...

Page 34: ...Bypass Bypass 130BX387 11 Figure 3 15 P2 Panel CONTROLWIRES INPUT POWERWIRES OUTPUT POWERWIRES OUTPUT POWERWIRES INPUT POWERWIRES CONTROLWIRES Bypass Non Bypass 130BX388 11 Figure 3 16 P3 Panel Insta...

Page 35: ...RES OUTPUT POWERWIRES CONTROLWIRES INPUT POWERWIRES OUTPUT POWERWIRES Bypass Non Bypass 130BX389 12 Figure 3 17 P4 Panel Installation Vertical Bypass Non Bypass Panel 3 18 MG 13 A1 22 VLT is a registe...

Page 36: ...d these hazards you MUST follow requirements for field wiring installation and grounding as described in the National Electrical Codes NEC and your local state electrical codes All field wiring MUST b...

Page 37: ...0 AWG 6 AWG 75 60 45 169 4 0 AWG 6 AWG 75 230 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 Ground Wiring Size C...

Page 38: ...Temperature Wire Rating Degree C Copper Conductor 15 11 17 P2 P2 10 AWG 10 AWG 60 20 15 22 10 AWG 10 AWG 60 25 18 5 27 P3 8 AWG 10 AWG 60 30 22 32 P3 8 AWG 10 AWG 60 40 30 41 6 AWG 10 AWG 60 50 37 52...

Page 39: ...Panel FC102 202 322 Non Bypass Bypass Panel FC302 Non Bypass Non Bypass Bypass Ground Wire Torque lb in N m Input Output Input Output Drive Disconnect Switch L1 L2 L3 Torque lb in N m Motor T1 T2 T3 T...

Page 40: ...40 4 5 25 18 5 P3 55 6 2 16 1 8 7 0 8 30 3 3 45 5 24 2 7 40 4 5 30 22 P3 55 6 2 40 4 5 18 2 30 3 3 45 5 50 5 6 40 4 5 40 30 55 6 2 40 4 5 18 2 120 13 5 50 5 6 50 5 6 40 4 5 50 37 P4 55 6 2 40 4 5 18 2...

Page 41: ...7 40 4 5 25 18 5 P3 55 6 2 16 1 8 7 79 30 3 3 62 7 24 2 7 40 4 5 30 22 P3 55 6 2 40 4 5 7 79 30 3 3 62 7 50 5 6 40 4 5 40 30 55 6 2 40 4 5 18 2 30 3 3 62 7 50 5 6 40 4 5 50 37 P4 55 6 2 40 4 5 18 2 1...

Page 42: ...ing poses FIRE ELECTROCUTION hazards To avoid these hazards you MUST follow requirements for field wiring installation and grounding as described in the National Electrical Codes NEC and your local st...

Page 43: ...ectronically Controlled Bypass ECB Operation It is recommended that control wiring is rated for 600 V for 480 V and 600 V drives and 300 V for 200 240 V drives Isolate control wiring from high power c...

Page 44: ...program parameter 5 00 for PNP operation Maximum output current is 200 mA total for all 24V loads 18 19 32 33 Digital inputs Selectable for NPN or PNP function in parameter 5 00 Default is PNP 27 29...

Page 45: ...Installation Vertical Bypass Non Bypass Panel 3 28 MG 13 A1 22 VLT is a registered Danfoss trademark 3 3...

Page 46: ...oose connections on terminals 6 CheckTable 3 9 and Table 3 10 for proper ground wire panel to main building distribution ground and panel to motor ground 7 Confirm control connections terminated per c...

Page 47: ...und Check for good ground connections that are tight and free of oxidation Run insulated motor ground wire back to panel in conduit with motor wires Input and output power wiring Check for loose conne...

Page 48: ...o ensure that the motor system and any attached equipment is ready for full speed operation could result in equipment damage 9 Check motor current in drive mode on the motor terminals 9a Put the unit...

Page 49: ...Start Up Vertical Bypass Non Bypass Panel 4 4 MG 13 A1 22 VLT is a registered Danfoss trademark 4 4...

Page 50: ...gs for Common HVAC Applications If the drive is reinitialized be sure that these settings are maintained or reset for proper bypass Name Function Drive Terminals EMB2 X59 EMB2 X55 Remote Drive Start w...

Page 51: ...BLUE 3 4 S105 1 2 ON X2 X1 5 1 4 2 3 7 6 12 8 11 9 10 14 13 1 2 3 4 1 6 2 7 3 8 4 9 5 10 1 6 2 7 3 8 4 9 MK106 5 1 4 2 3 7 6 8 9 11 10 12 4 3 2 1 ON MK107 MK100 MK105 MK103 S105 130B7290 REFERENCE T...

Page 52: ...n This resets the drive and fault timer Auto Bypass Function Setup Enable auto bypass by closing one or more DIP switches on switch S100 located on the bypass control card Times are approximate All OF...

Page 53: ...ly activated overload monitors motor current and trips to remove power to the motor if a sustained over current condition exists A Class 20 overload is standard with a variable setting for motor curre...

Page 54: ...on connector X55 5 1 7 EMB2 Fire Mode General Information Fire mode runs the motor at full speed in bypass and is intended to ignore common safety overload and mode selector switch inputs in emergency...

Page 55: ...tch is used to electrically select whether the motor is controlled by the drive M1 and M2 contactors connected to the full speed bypass M3 contactor or disconnected from both The test position allows...

Page 56: ...drive s local control panel LCP See Figure 6 1 An important feature of the ECB is the ability to accept commands from a building automation system BAS and to report operational status in return Contro...

Page 57: ...n Permissive 5 40 0 Relay 1 off delay Off Delay 0 00 S Run Permissive 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 con...

Page 58: ...ISTIVE 22 CUSTOMER O L RESET BYPASS OVERRIDE BYPASS MODE ENABLE CMS MOTOR SELECTED DRIVE MODE BYPASS MODE 40 mA MAX 24 VDC NC NC CUSTOMER INTERLOCK SUPPLIED SAFETY TB1 100 95 96 M3 M2 OL1 19 20 21 14...

Page 59: ...ad reset User supplied dry contact 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 di...

Page 60: ...ng in drive mode press OK on LCP to activate bypass mode or press CANCEL to remain in drive mode In bypass the motor will run at full speed 130BX235 10 3 When running in drive mode press OK on the LCP...

Page 61: ...130BX238 10 Electronically Controlled B Vertical Bypass Non Bypass Panel 6 6 MG 13 A1 22 VLT is a registered Danfoss trademark 6 6...

Page 62: ...oll through parameter groups A dotted outline surrounds the selected group Bypass options are found in parameter group 31 Bypass 130BX240 10 3 Press OK to enter the selected parameter group 4 Press or...

Page 63: ...t This disables or enables the Off Reset key on LCP 0 disabled 1 enabled 2 password Default value is 1 enabled 00 45 Drive Bypass This disables or enables the Drive Bypass key on LCP 0 disabled 1 enab...

Page 64: ...isplay which shows bypass running hours Table 6 4 Bypass Parameter Functions Bit Description 0 Test Mode The Test Mode bit will be true when the ECB is in Test Mode 1 Drive Mode The Drive Mode bit wil...

Page 65: ...al from the drive activates the auto bypass timer If the fault clears before the time delay is complete the motor remains operating in drive mode This allows temporary faults such as a momentary under...

Page 66: ...ve input terminals selected and program the terminals for run permissive Disable Run Permissive Disable run permissive through the drive parameters and terminal programming 6 1 10 ECB Overload General...

Page 67: ...1 bypass interlock meaning the problem is external to the drive A factory installed jumper between X57 terminals 1 and 2 allows the unit to operate when no safety input is connected This jumper must b...

Page 68: ...ram drive for fire mode If required program a drive output for fire mode status See the drive support materials for programming the fire mode function 6 1 14 ECB Fault Reporting General Information Th...

Page 69: ...Electronically Controlled B Vertical Bypass Non Bypass Panel 6 14 MG 13 A1 22 VLT is a registered Danfoss trademark 6 6...

Page 70: ...contactor that connects the motor to the power line has failed to close The motor can not be operated 227 Bypass Com Error Communication between the main control card and the bypass option has been lo...

Page 71: ...any wrong connections This could potentially cause damage to the panel Operator switches off Verify that operator devices are in operating position per startup procedures Set switches to the correct p...

Page 72: ...d fault Check all control wires for a short to ground Correct any ground faults found This could potentially cause damage to the panel Control short Check control wires for a short in supply voltage C...

Page 73: ...f the same size If readings are not the same or there are visible signs of damage replace the coil or contactor Auxiliary contact binding action Remove auxiliary contacts and test contactor action If...

Page 74: ...5 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 12 99 330 0 12 99 330 0 b 28 80 731 5 41 02 1042 0 32 13 816 0 41 18 1046 0 37 32 948 0 51 89 13...

Page 75: ...k f g A c d D e B C j h SEE DETAIL A SEE DETAIL B 2X DETAIL A SCALE 1 000 2X DETAIL B SCALE 1 000 130BX392 11 Figure 8 1 P2 Bypass Appendix Vertical Bypass Non Bypass Panel 8 2 MG 13 A1 22 VLT is a re...

Page 76: ...h C e SEE DETAIL A SEE DETAIL B 2X DETAIL A SCALE 1 000 2X DETAIL B SCALE 1 000 A 130BX393 10 Figure 8 2 P2 Non bypass Appendix Vertical Bypass Non Bypass Panel MG 13 A1 22 VLT is a registered Danfos...

Page 77: ...A B b a e c d D C SEE DETAIL A 4X DETAIL A SCALE 1 000 130BX394 10 Figure 8 3 P3 P4 P5 Bypass Appendix Vertical Bypass Non Bypass Panel 8 4 MG 13 A1 22 VLT is a registered Danfoss trademark 8 8...

Page 78: ...D b a e c d A B C SEE DETAIL A 4X DETAIL A SCALE 1 000 130BX395 10 Figure 8 4 P3 P4 P5 Non bypass Appendix Vertical Bypass Non Bypass Panel MG 13 A1 22 VLT is a registered Danfoss trademark 8 5 8 8...

Page 79: ...3 153 3CR 2CR 152 1CR 154 BLK 14 AWG GRN YEL 151 T1 600V F13B A1 A2 A1 M1 A1 M2 A2 A2 BLUE 6 4 4 6 4 6 GD 24V GD BLUE BLUE BLUE BLUE BLUE X1 H4 H3 H1 H2 X3 X2 1L3 1L1 1L2 FUSIBLE L1 L3 L2 DISCONNECT D...

Page 80: ...BLUE WHT BLUE BLUE BLUE 3 4 S105 1 2 ON X2 X1 5 1 4 2 3 7 6 12 8 11 9 10 14 13 1 2 3 4 1 6 2 7 3 8 4 9 5 10 1 6 2 7 3 8 4 9 MK106 5 1 4 2 3 7 6 8 9 11 10 12 4 3 2 1 ON MK107 MK100 MK105 MK103 S105 130...

Page 81: ...7 92 20 94 BLU WHT BLU BLK 14 AWG T3 L3 T1 T2 L1 L2 M1 L2 92 L1 91 L3 93 BLUE GD 24V GD BLUE BLUE BLUE BLUE BLUE 1L3 1L1 1L2 GRN YEL 3 2 1 SEE HIGH POT 83 01 84 02 03 BLUE BLUE 04 05 06 12 13 18 19 FA...

Page 82: ...BLUE BLUE BLUE WHT BLUE BLUE BLUE 3 4 S105 1 2 ON X2 X1 5 1 4 2 3 7 6 12 8 11 9 10 14 13 1 2 3 4 1 6 2 7 3 8 4 9 5 10 1 6 2 7 3 8 4 9 MK106 5 1 4 2 3 7 6 8 9 11 10 12 4 3 2 1 ON MK107 MK100 MK105 MK1...

Page 83: ...14 AWG 02 03 01 4 8 MK904 MK901 1 5 100 2 6 3 7 28 24 V DC SMPS MK903 MK902 BLU BLU WHT GD 24V EARTH GROUND GD 1L3 1L2 1L1 12 13 18 19 27 29 32 33 20 37 GRN YEL 3 2 1 SEE HIGH POT FACTORY SAFETY INTE...

Page 84: ...MAXIMUM 1 AMPS DC RESISTIVE 22 CUSTOMER O L RESET BYPASS OVERRIDE BYPASS MODE ENABLE CMS MOTOR SELECTED DRIVE MODE BYPASS MODE 40 mA MAX 24 VDC NC NC CUSTOMER INTERLOCK SUPPLIED SAFETY TB1 100 95 96...

Page 85: ...LU WHT GD 24V EARTH GROUND GD 1L3 1L2 1L1 12 13 18 19 27 29 32 33 20 37 GRN YEL 3 2 1 SEE HIGH POT M3 115VAC TRANSFORMER 149 CONTROL 600V 150 F13A WHT 158 155 153 153 153 3CR 2CR 152 1CR 154 BLK 14 AW...

Page 86: ...VE 22 CUSTOMER O L RESET BYPASS OVERRIDE BYPASS MODE ENABLE CMS MOTOR SELECTED DRIVE MODE BYPASS MODE 40 mA MAX 24 VDC NC NC CUSTOMER INTERLOCK SUPPLIED SAFETY TB1 100 95 96 M3 M2 OL1 19 20 21 14 13 4...

Page 87: ...61 COM RS 485 RS 485 INTERFACE 50 CUSTOMER SUPPLIED START 24 VOLT 130mA ANALOG OUTPUT COMMON ANALOG OUTPUT ANALOG INPUT ANALOG INPUT COMMON ANALOG INPUT 10 VOLT OUT 15 mA RELAY 1 RELAY 2 PROGRAMMABLE...

Page 88: ...www danfoss com drives MG13A122 130R0264 MG13A122 Rev 2011 08 10...

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