Powered by Eaton’s Technology VSD Series Quick Start Guide LIT-1201858 For more information visit: www.johnsoncontrols.com 1 November 2009 VSD Series Quick Start Guide Table of Contents Description Page NEMA Type 1/12 Open Drives (1 – 250 HP) . . . . . . . . . . . . . . 2 NEMA Type 1 IntelliPass/IntelliDisconnect Drive . . . . . . . . . 5 Enclosed NEMA Type 12/3R . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Appendix A — Main Control Board Wiring . . . . . . . . . . . . . 15 Appendix B — Interlock Damper Start Example Using 4 – 20 mA Control Signal . . . . . . . . . . . . . . . . . . . 16 Appendix C — Interlock Damper Start Example Using PID Duct Static Control Signal. . . . . . . . . . . . . . . 17 Appendix D — Bypass Wiring Diagram . . . . . . . . . . . . . . . . 18 Appendix E — Keypad Navigation . . . . . . . . . . . . . . . . . . . . 19 Appendix F — Main Menu Navigation . . . . . . . . . . . . . . . . . 20 Appendix G — Start-Up Wizard . . . . . . . . . . . . . . . . . . . . . . . 21 Appendix H — Static Checking . . . . . . . . . . . . . . . . . . . . . . . 25 Appendix I — Fault and Warning Codes . . . . . . . . . . . . . . . . 27 Technical Support Phone Numbers Branch: 800-281-3792 (Option 1)Third Party (ABCS/DIST): 800-445-4757 (Option 1) General Upon receipt of the unit, verify that the catalog number and unit options stated on the shipping container match those stated on the order/purchase form.Inspect the equipment upon delivery. Report any carton damage to the carrier prior to accepting the delivery. Have this information noted on the freight bill. Johnson Controls is not responsible for damage incurred in shipping. Unpacking Remove all packing material from the unit. Be sure to remove all packing material from lug location. Also, make sure no packing material is left behind that would block the airflow to the fan. Check the unit for any signs of shipping damage. If damage to the product is found after unpacking, report it to the freight company. Retain the packing materials for the carrier to review. Storage It is recommended that the unit be stored in its original shipping box/crate until it is to be installed.The unit should be stored in a location where: • The ambient temperature is between -40°F and 158°F (-40°C and 70°C) • The relative humidity is between 0% and 95%, non-condensing • The environment is dry, clean, and non-corrosive • The unit will not be subjected to high shock or vibration conditions Mandatory Ground Wiring (See Appendix D on Page 18) Be sure to pull low impendance ground wiring from customer power to drive and ground wire from drive to motor. Bypass DriveNEMA Type 12NEMA Type 3ROpen Drive IMPORTANT: This guide is intended to provide a quick reference to the VSD Series drive’s Application Software features for start-up, programming and service. It does not replace the need to thoroughly read and understand the User Manual.UtilityDriveMotor Ground(Inside Motor Conduit Box) VSD Series Quick Start Guide Powered by Eaton’s Technology 2 For more information visit: www.johnsoncontrols.com LIT-1201858November 2009 NEMA Type 1/12 Open Drives (1 – 250 HP) Table 1: Control Wiring Instructions Mounting Drive 1.Mount Drive(See Table below for dimensions.) Figure 1: VSD Series Open Drive Dimensions FrameSizeVoltagehp (VT)Approximate Dimensions in Inches (mm)Weight Lbs. (kg)H1H2H3D1D2D3W1W2R1 dia.R2 dia. FR4230V3/4 – 312.9(327)12.3(313)11.5(292)7.5 (190)2.5 (64)5.0 (126)5.0 (128)3.9 (100).5 (13).3 (7)11 (5)480V1 – 5FR5230V5 – 7-1/216.5(419)16.0(406)15.4(391)8.4 (214)2.7 (68)5.8 (148)5.7 (144)3.9 (100).5 (13).3 (7)17.9 (8.1)480V7-1/2 – 15FR6230V10 – 1522.0(558)21.3(541)20.4(519)9.3 (237)2.7 (68)6.7 (171)7.7 (195)5.8 (148).7 (18).4 (9)40.8(18.5)480V20 – 30575V2 – 25FR7230V20 – 3024.8(630)24.2(614)23.3(591)10.1(257)2.7 (68)7.5 (189)9.3 (237)7.5 (190).7 (18).4 (9)77.2 (35)480V40 – 60575V30 – 40FR8480V75 – 12529.7(755)28.8(732)28.4(721)11.3(288)1.3 (34)11.0(279)11.2(285)10.0(255).7 (18).4 (9)127.8(58)575V50 – 75FR9480V150 – 20045.3(1150)44.1(1120)—14.3(362)5.4 (137)8.8 (224)18.9(480)15.7(400).7 (18).4 (9)321.9(146)575V100 – 150FR10480V250 – 35044(1120)33.5(850)—23.6(600)NANA23.6(600)16.7(425).9(23).47(12)550.7(250)575V200 – 300 Power Wiring NoticeDo not discard the plastic bag containing the wiring plate. 2.Remove the bottom cover by rotating the cover toward you on the base hinges, then lifting the cover away from the base. Power Wiring 3.Locate the plastic bag shipped with the drive containing the wiring plate, and remove the wiring plate.R2W1W2R2R1H1H2D1H3D2D3Knockouts Powered by Eaton’s Technology VSD Series Quick Start Guide LIT-1201858 For more information visit: www.johnsoncontrols.com 3 November 2009 NEMA Type 1/12 Open Drives (1 – 250 HP) Table 1: Control Wiring Instructions (continued) Power Wiring 4.If conduit is being used, attach the wiring plate to it.5.Pass the motor and input power wires/cables through the holes of the wiring plate.6.If shielded cable is used, connect the shields of the input line power cable and the motor cable to the motor and power ground terminals of the VSD Series drive. Power Wiring/Grounding 7.Wire power terminals, motor terminals, and grounding terminals per diagram. Power and Motor leads must be in separate conduit. Note: Do not wire motor loads to B- B+ R-. This will cause damage. • Run motor cables in separate conduit. • DO NOT RUN CONTROL WIRES in same conduit • Cables sized per NEC. • Provide low impedance ground between drive and motor. Control Wiring 8.Wire the control terminals following the details for the specific option boards shown on the following pages. Note: For ease of access, the option board terminal blocks can be unplugged for wiring. Note: If using conduit or Seal Tite for control wiring for Frame 4, you must order NEMA Type 12 kit.GROUND WIRINGUtilityDriveMotor Ground(Inside Motor Conduit Box)IMPORTANT: Improper grounding could result in damage to the motor and/or drive and could void warranty VSD Series Quick Start Guide Powered by Eaton’s Technology 4 For more information visit: www.johnsoncontrols.com LIT-1201858November 2009 NEMA Type 1/12 Open Drives (1 – 250 HP) Table 1: Control Wiring Instructions (continued) Control Wiring 9.Wire control to the OPTA9 Control Board and OPTA2. Note: Drive default is programmed for Damper Interlock. Note: Option Boards OPTC2 (N2/XT/SA Bus) and OPTC4 (LonWorks) are optional. Mandatory Ground Wiring Be sure to pull low impendance ground wiring from customer power to drive and ground wire from drive to motor. I/O Connection • Run 110 Vac and 24 Vdc Control wiring in separate conduit. • Communication wire to be shielded. • RS-232 Keypad cable less than 20 feet. Figure 2: Figure 3: Option Board A9 Location and Settings Start-Up Wizard See Appendix G . UtilityDriveMotor Ground(Inside Motor Conduit Box)Note:+1DVVin+GNDLin+Lin–24VoutGNDDIN1DIN2DIN3CMA24VoutGNDDIN4DIN5DIN6CMBLout+Lout–DO11234567891011121314151617181920Reference OutputI/O GroundControl Voltage OutputI/O GroundStart/StopExternal FaultDIN1-DIN3 CommonControl Voltage OutputI/O GroundSpeed Select 1Fire ModeBypass Overload FaultDIN4-DIN6 CommonOutput FrequencyAnalog OutputDigital Output ReadyAnalog Input Voltage(Range 0-10V DC)X1X2X3ABCDABCDAnalog Input Current(Range 4-20mA)X6ABCDNote: Must pull dedicated ground wire to drive and motor.Run Permisive Damper InterlockNote: See Figure 3 for Dip X1, X2, X3, X6 Switch settings.Optional Communication Cards can besupplied with the Drive or as a Field Option.OptionalCBIncoming PowerCMB and CMA InternallyConnected and Isolatedfrom GroundX1 Jumper SettingAnalog Input 1 (AI1)X2 Jumper SettingAnalog Input 2 (AI2)X6 Jumper SettingAnalog Output 1 (A01)X3 Jumper SettingCMA and CMB Grounding0 to 10V*Voltage Input-10 to 10VVoltage Input0 to 20 mACurrent Input0 to 10V(Differential)Voltage InputCMB Connected to Ground*CMA Connected to GroundCMB Isolated from GroundCMA Isolated from Ground* Designates Default Jumper Settings0 to 20 mA*Current Input0 to 10VVoltage Input0 to 10V(Differential)Voltage Input-10 to 10VVoltage Input0 to 20 mA*Current Output0 to 10VVoltage OutputABCDABCDABCDX1X3X2X6ABCDABCDABCDABCDABCDABCDABCDABCDABCDABCD Powered by Eaton’s Technology VSD Series Quick Start Guide LIT-1201858 For more information visit: www.johnsoncontrols.com 5 November 2009 NEMA Type 1 IntelliPass/IntelliDisconnect Drive Figure 4: Identification of NEMA Type 1 ComponentsFigure 5: VSD Series IntelliPass/IntelliDisconnect Drive DimensionsTable 2: VSD Series NEMA Type 1 IntelliPass/IntelliDisconnect Drive Dimensions If mounting two or more IntelliPass Drives next to each other, make sure to use the proper spacing between the drives for hinged door operation. Optional 3rd Contactor S1 Switch *(provided for drive isolation)Circuit BreakerExtension Bar24V DC Power Supply *RibbonCable HingeOptional 3rd Input Contactor *Output & BypassContactor*Contactor Overload *Manual/Auto Reset *24V DC Motor Overload Terminal Block *Circuit Breaker EndplateCircuit BreakerGround StudsDrive Enclosure Endplate (located at bottom)* IntelliPass only. Drive Horsepower (VT)Frame SizeApproximate Dimensions in Inches (mm)Approx.Weight in lbs. (kg)Distance Between Drives inInches (mm) ABCD 208V, 1 – 3 hp230V, 1 – 3 hp480V, 1 – 7-1/2 hpFR45.04 (128)18.25 (464)13.24 (336)21 (9.5)5.3 (134.6)208V, 5 – 7-1/2 hp230V, 5 – 10 hp480V, 10 – 20 hpFR55.50 (140)23.25 (591)13.24 (336)35 (15.9)5.7 (144.8)208V, 10 – 20 hp230V, 15 and 20 hp480V, 25 – 40 hpFR67.50 (191)29.38 (746)15.25 (387)67 (30.4)7.5 (190.5)208V, 25 and 30 hp230V, 25 and 30 hp480V, 50 – 75 hpFR79.10 (231)37.53 (953)15.25 (387)108 (49.0)9.0 (228.6) VSD Series Quick Start Guide Powered by Eaton’s Technology 6 For more information visit: www.johnsoncontrols.com LIT-1201858November 2009 NEMA Type 1 IntelliPass/IntelliDisconnect Drive Table 3: Bypass Power Wiring Instructions — NEMA Type 1 Mounting Drive 1.Mount drive per dimensions. (See Page 5 .)2.Verify that the main power source is removed upstream.3.Using a flat-blade screwdriver, remove the four screws securing the outer cover of the drive and remove the cover.4.Using the same screwdriver, remove the two center screws securing the side cover.5.Make sure there is adequate room, and open the hinged side cover. Power Wiring 6.Using a flat-blade screwdriver, remove the screws securing the endplate at the bottom of the drive enclosure, and remove the endplate.7.Using a Greenlee conduit cutter (recommended), cut one or more holes in the endplate, located at the bottom of the drive’s enclosure, for the motor and power leads. Note: If bringing the power leads in through the top of the drive’s enclosure, go to step 8. If not, proceed to step 10. Power Wiring 8.Using a flat-blade screwdriver, remove the screws securing the endplate for the circuit breaker enclosure, and remove the endplate.9.Using a Greenlee conduit cutter (recommended), cut one hole in the circuit breaker endplate for the power leads. Power Wiring 10.Calibrate the circuit breaker amperage, so it is 1.25 times the amperage on the motor nameplate, by turning the red set screw located below the circuit breaker extension bar. See the circuit breaker user’s manual supplied with the drive.11.Connect the incoming power leads to circuit breaker terminals labeled L1, L2 and L3. Cables sized per NEC.12.Using the torque wrench, tighten each terminal to the torque value found in the appropriate user’s manual supplied with the drive. • Run cabling in separate metal conduit or wiring tray. • DO NOT RUN CONTROL WIRING with incoming power wiring. • Provide low impedance ground connection to drive chassis. • DO NOT CONNECT to B+, B-, R terminals.Outer CoverTwo Screws on Side CoverBottom EndplateCircuit Breaker EndplatePOWER WIRINGCircuit Breaker Set ScrewCircuit Breaker TerminalsIncoming Power LeadsCircuit Breaker Extension Bar Powered by Eaton’s Technology VSD Series Quick Start Guide LIT-1201858 For more information visit: www.johnsoncontrols.com 7 November 2009 NEMA Type 1 IntelliPass/IntelliDisconnect Drive Table 3: Bypass Power Wiring Instructions — NEMA Type 1 (continued) Motor Wiring 13.Use your first and second fingers and simultaneously push down to release the two orange retaining clips (one on each side of the 24V DC motor overload terminal block).14.If necessary, use a flat-blade screwdriver to carefully remove the terminal block in a straight plane to avoid damaging it. Motor Wiring 15.Connect the motor leads to the motor overload terminals labeled 1TA, 1TB and 1TC.16.Using the appropriate metric Allen wrench (2.5 mm, 3 mm or 4 mm), tighten each overload terminal per the specifications in the contactor user’s manual. An SAE allen wrench will damage the terminals, and the motor overload will need to be replaced (not covered by warranty). 17.Using the torque wrench, tighten each terminal to the torque value found in the appropriate user’s manual supplied with the drive.18.Reinsert the motor overload terminal block. Grounding 19.Use a flat-blade screwdriver to connect the motor ground wire to the ground stud (located at either the top or bottom of the drive’s enclosure). (Mandatory) Ground connection main power ground must be connected to other ground screws. • Run motor cables in separate conduit. • DO NOT RUN CONTROL WIRES in same conduit • Cables sized per NEC. • Provide low impedance ground between drive and motor. MOTOR WIRINGMotor LeadsMotor Overload TerminalsGROUND WIRINGUtilityDriveMotor Ground(Inside Motor Conduit Box)IMPORTANT: Improper grounding could result in damage to the motor and/or drive and could void warrantyMotor Ground Stud VSD Series Quick Start Guide Powered by Eaton’s Technology 8 For more information visit: www.johnsoncontrols.com LIT-1201858November 2009 NEMA Type 1 IntelliPass/IntelliDisconnect Drive Table 3: Bypass Power Wiring Instructions — NEMA Type 1 (continued) Setting Overload 20.Lift to open the cover on the motor overload, and use a1/8" flat-blade screwdriver to set the overload amperage to match the value on the motor nameplate.21.Turn the auto/manual reset (factory default is manual) on the motor overload 90° to the auto position. Control Wiring 22.Use a flat-blade screwdriver to carefully remove the low- voltage I/O terminal block.23.Insert the incoming control leads into the terminal block. Refer to the electrical schematic supplied with the drive.24.Reinsert the I/O terminal block into the control board.25.Verify that all other wires to the terminal block are connected.26.Terminate control wiring to the OPTA9 and OPTA2 board (Terminals 1 – 26). • Run 110 Vac and 24 Vdc control wiring in separate conduit. • Communication wire must be shielded. • RS-232 keypad cable must be less then 25 feet. Figure 6: VSD Series IntelliPass with Three ContactorsAuto/Manual ResetCONTROL WIRINGDriveGroundMotorGroundNote: Optional COMM cards can be suppliedNote: with the drive or as a field option.CustomerGroundDriveGroundSpeed Select 1Fire ModeBypass Overload FaultStart/StopNote: See Figure 3 for Dip X1, X2, X3, X6 Switch settings.OptionalOptional Powered by Eaton’s Technology VSD Series Quick Start Guide LIT-1201858 For more information visit: www.johnsoncontrols.com 9 November 2009 NEMA Type 1 IntelliPass/IntelliDisconnect Drive able 3: Bypass Power Wiring Instructions — NEMA Type 1 (continued) Static Check 27.Make sure power is off, and perform static checks as described in Table 7 (for the converter) , Table 8 (for the inverter) and Table 9 (for the DC bus). Refer to Page 25, Appendix H. Note: Static check shown is for L3 and B+ terminals. 28.Once the pre-power static checks are completed, reinstall the drive’s outer and side covers, tightening all the screws.High Voltage is present on L1, L2, L3, B-, B+, BT, T1, T2, T3.Starting Drive29.Make sure that the drive’s 3rd contactor S1 switch, if present, is in the ON position (shown in OFF position).Note: The bypass mode operates with the switch in the OFF position, however the drive will not run. Yet the keypad will operate.Starting Drive30.Turn the circuit breaker handle in a clockwise direction.High Voltage•Always work with another person.•Be sure equipment is properly grounded.•Wear safety glasses.Start-Up WizardSee Appendix G. WARNINGL1, L2, L3B-, B+, BTT1, T2, T3WARNINGCircuit Breaker HandleNext >