JC-VSD FP Series II Engineering Guide0.5 - 50 HP 208 - 240 VAC0.5 - 125 HP 380 - 480 VACCode No. LIT-12012112Updated May 2017DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITYThe information, recommendations, descriptions and safety notations in this document are based on Johnson Controls (“JCI”) experience and judgment and may not cover all contingencies. If further information is required, an JCI sales office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in appropri-ate JCI selling policies or other contractual agreement between JCI and the purchaser.THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES. In no event will JCI be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other-wise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recom-mendations and descriptions contained herein. The information contained in this manual is subject to change without notice. iiJC-VSD FP Series II Engineering Guide LIT-12012112 May 2017 www.johnsoncontrols.comiiiLIT-12012112JC-VSD FP Series II Engineering Guide LIT-12012112 May 2017 www.johnsoncontrols.comContentsIINTRODUCTION ...................................................1JC-VSD Series II FP ....................................................1PRODUCT DISCRIPTION .............................................2JC-VSD FP Series II ....................................................2JC-VSD Series II (Base Drives) ...........................................2JC-VSD FP Series II (Drive with Input Disconnect) ...........................................2JC-VSD FP Series II (Drive with Classic Bypass) ..................................2APPLICATION ......................................................4General Application Considerations ........................................4Fan Applications ......................................................5Retrofit Fan Applications ................................................6Pump Applications .....................................................7Pump and Fan Control ..................................................8Cooling Tower Applications ..............................................8JCI-VSD Series II Base Drive .............................................9JCI-VSD Series II Drives ................................................9Nomenclature Base Drive Only ..........................................10Product Selection JC-VSD Series II Drives—230 Vac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Product Selection JC-VSD Series II Drives—460 Vac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Onboard Network Communications ......................................13Accessories .........................................................14Keypad Accessories ...................................................14Replacement Parts ...................................................14Technical Data and Specifications ........................................14JC-VSD FP Series II Enclosed Drives .....................................16JC-VSD FP Series II Enclosed Drives .....................................16FP Series II Base Drive with Bypass .....................................16Nomenclature .......................................................17DIMENSIONS .....................................................25FP Series II Size Chart .................................................25Outside Dimensions - Base Drive ........................................26FP Series II: Type 1 Disconnect Outside Dimensions .........................27Knockout Dimensions (A1-4 through A3-6) .................................28Knockout Dimensions (A4-6 through A6-8) .................................29FP Series II: Type 1 Bypass Outside Dimensions ............................30Type 1 Bypass Knockout Dimensions .....................................31FP Series II: Type 1 Micro Disconnect Outside Dimensions ....................32FP Series II: Type 3R Disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33ivLIT-12012112JC-VSD FP Series II Engineering Guide LIT-12012112 May 2017 www.johnsoncontrols.comFP Series II: Type 3R Disconnect Knockout .................................34FP Series II: Type 3R Bypass ............................................35FP Series II: Type 3R Bypass Knockout ....................................36FEATURES .......................................................37Standard Features (JC-VSD Series II) Base Drives ........................................................37Standard Features Drive with Input Disconnect or Classic Bypass (JC-VSD FP Series II) ................................................38SPECIFICATIONS ..................................................39JC-VSD Series II Base Drives ...........................................39JC-VSD FP Series II Drive with Input Disconnect or Classic Bypass .............42Definition of NEMA and IEC Environmental Ratings .........................45GUIDE SPECIFICATIONS ............................................46Part 1 - General ......................................................461.01 Description .....................................................461.02 Quality Assurance ................................................461.03 Submittals ......................................................46Part 2 – Products .....................................................472.01 Variable Frequency Base Drives .....................................47Part 3 – Execution ....................................................4911.01 Installation .....................................................4911.02 Start-Up .......................................................4911.04 Warranty ......................................................49GLOSSARY .......................................................50APPENDIX A - WIRING DIAGRAMS ...................................56APPENDIX B - POWER CABLE WIRE SIZES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611IntroductionJC-VSD FP Series II Engineering Guide LIT-12012112 May 2017 www.johnsoncontrols.comIntroductionJC-VSD Series II FPJohnson Controls has led the HVAC industry in variable speed drive (VSD) technology since 1979 with the intro-duction of the Turbo-Modulator – the variable speed drive specifically designed for centrifugal chiller application. The Johnson Controls involvement in applying electronics to HVAC technology exceeds that of any other company either in the HVAC industry or the electronics industry. Since 1983, when the Air-Modulator was introduced, Johnson Controls has successfully applied thousands of these drives to fans, pumps, and cooling towers providing exceptional energy savings, high-reliability, and performance.This JC-VSD Series II FP guide is intended as a reference to application and installation information for the HVAC design engineer. The content of this guide provides general theory of operation, application information, key design parameters, and complete specifications.Why Variable Speed?Centrifugal fans and pumps are commonly used in HVAC equipment. Because of their centrifugal design, any reduc-tion in the speed at which the fan or pump operates causes a cubic reduction in the horsepower the motor requires. This is represented by the following equation: (RPM2)3 (HP2) (RPM1)3 = (HP1)This shows that a 10% reduction in the RPM of the fan or pump results in a 27% reduction in horsepower required. Therefore, a means by which the RPM or speed of the fan or pump could be reduced would produce significant energy savings. The JC-VSD FP Series II provides such a means by varying the speed of the fan or pump motor.What is a Variable Speed Drive?A variable speed drive is an electronic device which changes the speed of a motor by changing the frequency and voltage fed to the motor. An AC motor runs at a speed proportional to the frequency applied, as described in the following for-mula:120 x frequencySynchronous motor speed =Number of motor polesThe speed is dependent on the frequency; a change in fre-quency will change the motor speed. The AC motor, howev-er, must also have the voltage vary in the same proportion as the frequency to maintain full torque capabilities through-out the speed range. Therefore, a variable speed drive must change both the frequency and the voltage of the power fed to the motor to vary speed while maintaining torque for the required load.ExampleSPEED%HP%100% 100%90% 73%80% 51%70% 34%60% 22%50% 13%40% 7%30%3%Fan Power with Different Air Volume Control Methods2Product DiscriptionJC-VSD FP Series II Engineering Guide LIT-12012112 May 2017 www.johnsoncontrols.comJCI-VSD FP Series IIThe FP Series II is Johnson Controls Low-Voltage AC Drive for the control of three-phase AC motors. Johnson Controls applies this product regularly on YORK® Air Handlers. These AC Drives are also available through YORK® for sale on other HVAC Drive applications. This affords users with the oppor-tunity to have one feature rich AC drive applied throughout a facility for HVAC requirements, with minimal familiarization training, parts and service, allowing Johnson Controls to provide for your total service needs.The FP Series II is an adjustable frequency AC drive designed specifically for the HVAC market that achieves the ultimate in flexible motor control performance. With drives ranging from 1 to 125 HP, the FP Series II fea-tures an ‘intuitively obvious’ multi-lingual, full graphic display panel that also provides an assistant to aid users in start-up. The control panel can be mounted on the cover of the drive, or remotely, and can upload, store, and download param-eters.The FP Series II can be used for the simplest to the most demanding HVAC applications. Two integral option slots can be configured with additional relay outputs as well as a host of different communication bus adapters.The FP Series II has a 110% short term overload rating for one (1) minute out of ten (10) and is capable of 150% short-term overload rating for 2 seconds out of each minute.Our Active Energy Control algorithm provides best-in-class energy efficiency utilizing patented dynamic V/Hz energy optimization software.JCI-VSD Series II (Base Drives)The JCI-VSD Drive is available from 1 to 50 HP in 208/230/240V, and 1 to 125 HP in 380/400/415/440/460/480V, input voltages. The JCI-VSD Drive has six frame sizes (FR4 to FR9) designed for wall mounting. The JCI-VSD Drive has a control panel for user interface, parameter adjustment and drive operation mount-ed on the front of the drive.The front section of the JCI-VSD contains the electronics, power and control wire terminals. The rear section forms a cooling channel. The two section construction allows the unit to be installed protruding through a wall, or through the rear wall of a customer supplied enclosure using additional hardware, placing the rear section in a cooling air duct to minimize the heat inside the cabinet. In standard installa-tions, the drive is mounted directly onto a wall. Conduit openings (knock-outs) are provided for bottom and side conduit entry. When mounting inside a customer-supplied cabinet, the conduit box plate is not required.JCI-VSD FP Series II (Drive with Input Disconnect)The FP Series II Drive provides an enclosed disconnect with door-mounted operator (padlock-able in the OFF position), electronic motor overload protection (provided from the base drive), and provisions for external control connections. Conduit open-ings (knock-outs) are provided for bottom rear conduit entry. Complete, pre-engineered packages reduce time, effort and the cost of installing the popular drive disconnect option.When supplied with the UL Type 3R/NEMA 3R Outdoor duty package, the disconnect options and features remain the same as the NEMA 1 unit except for the following:The NEMA 3R FP Series II is provided in a wall mounted YORK® champagne brown enclosure from 1 to 50 HP at 208/230V, and 1 to 125 HP at 460V. The FP Series II NEMA 3R is provided with control panel for user interface, param-eter adjustment and drive operation mounted on the front of the drive protected by a control panel door. The control panel is not visible with the control panel door closed. Conduit openings (knock-outs) are provided for at the bot-tom and rear of the enclosure. Complete, pre-engineered package drives reduce time, effort and the cost of installing the popular drive disconnect option.JCI-VSD FP Series II (Drive with Classic Bypass)The FP Series II Drive with classic bypass is packaged with a fused or nonfused input disconnect switch and a two contactor bypass function that allows the motor to be run at full voltage in the event the drive is shut down for ser-vice. The bypass function is configured entirely of standard industrial control components. It includes two mechanically interlocked contactors, a motor overload relay, a control power transformer with primary and secondary fusing, and cover mounted Hand-Off-Auto switch and Drive-Off-Bypass selector switch. Bypass is accomplished by means of the two contactors. One is the bypass contactor used to con-nect the motor directly to the power line. The other is the drive output contactor that disconnects the motor from Product DescriptionThe FP Series II Drive input disconnect is either a fused or non-fused input disconnect switch. The FP Series II is available in a wall mounted enclosure from 1 to 50 HP at 208/230V, and 1 to 125 HP at 460V input voltages. The FP Series II Packaged Drive comes in a standard NEMA 1 galvanized steel enclosure or a NEMA 3R painted product. The FP Series II Packaged Drive has the NEMA 1 base drive mounted on the top of a back panel allowing access to the drive control panel for user interface. When applying the NEMA 3R enclosure for outdoor duty, keep in mind the package is rated for operation in the direct sunlight from 0°F to 104°F. With the standard derate it may be applied up to 124°F. Note that power must be applied for the space heater for Low Temperature Option to operate and keep the drive warm to allow it to start in cold condi-tions.3Product DiscriptionJC-VSD FP Series II Engineering Guide LIT-12012112 May 2017 www.johnsoncontrols.comthe drive output when operating in the bypass mode. This prevents the “back feeding” that would occur if line voltage were applied to the drive output terminals. The drive output contactor and the bypass contactor are mechanically inter-locked to prevent simultaneous operation. Motor overload protection in the bypass mode is provided by a Class 20 motor overload relay. FP Series II Drive W/ Bypass Packages include either a fused or non-fused input disconnect switch with a door mounted external operating handle that is inter-locked with the enclosure door and lockable in the OFF posi-tion with up to three padlocks. The multi-lingual, alphanu-meric drive control panel is mounted on the enclosure door. The drive service switch isolates the drive from the power source for service and provides superior functionality to a three-contactor arrangement. Drive with Bypass Packages are available in NEMA 1 gal-vanized steel 1 to 50 HP at 208/230V, and 1 to 125 HP at 460V. Conduit openings (knock-outs) are provided for top/bottom/ rear conduit entry. Complete, pre-engineered pack-ages reduce time, effort and the cost of installing the popu-lar drive bypass option. When the FP Series II is provided with the NEMA 3R enclo-sure option, it is provided in a YORK® champagne brown enclosure. The multi-lingual, alphanumeric drive control panel is mounted on the enclosure door behind a control panel door to protect it from the elements. Application ConsiderationsBecause of the variety of uses for the FP Series II, those responsible for the application and control of these drives must satisfy themselves that all necessary steps have been taken to insure that they meet all performance and safety requirements regarding national and local laws, regulations, codes and standards. Unless otherwise noted, FP Series II products found in this Engineering Guide are designed to meet NEMA (National Electrical Manufacturers Association) standards. FP Series II products also carry third party approvals through UL and cUL. Approval for installation in a CE first environment, restricted distribution is also provided with the FP Series II base drive and these products carry the CE mark. The FP Series II Drive with input disconnect or classic bypass are supplied for UL/cUL and are not provided with a CE mark. These listings are based on standard prod-uct and any exceptions to this will be noted in the appropri-ate section.Branch Circuit Protection (Series II Base Drive)The Series II base drive does not include a disconnect device. A means to disconnect input power must be installed between the AC power source and the Series II base drive. This branch circuit protection must:●●Be sized to conform to applicable safety regulations,including, but not limited to, both National and local elec-trical codes.●●Be locked in the open position during installation andmaintenance work.The disconnect device must not be used to control the motor. Instead use the control panel, or commands to the I/O terminals for motor control. Cycling the disconnect device cycles power to the drive’s DC capacitors. These capacitors have a maximum limit of 5 cycles in ten minutes.FusesSee JC-VSD FP Series II Installation Manual (LIT-12012114) for fuse recommendations for short circuit protection on the drive’s input power. These recommendations are not requirements if branch circuit protection is otherwise pro-vided per NEC. UL508A manufacturers are not required to use the recommended fuses for the purpose of UL listing a panel that includes the FP Series II.Branch Circuit Protection (JCI-VSD Drive with Input Disconnect or Classic Bypass)The FP Series II Drive with Fused Disconnect or Fused Disconnect and classic bypass is supplied with a means to disconnect input power sized per UL508A, and the discon-nect is lockable in the open position. The FP Series II Drive with Non-Fused Disconnect or Non-Fused Disconnect and classic bypass is supplied with a means to disconnect input power sized per UL508A, and has not been provided with branch circuit fusing. To main-tain the 100 KA UL short circuit rating, class J or RK1 fuses must be supplied electrically ahead of the enclosed drive and sized to conform to applicable safety regulations, includ-ing, but not limited to, both National and local electrical codes.Selecting the Correct Drive CapacityAll FP Series II drives are current rated devices. The HP rat-ings provided are for reference only and are based on typical 4-pole motors at nominal voltages (NEC Table 430-150). Iffull motor torque is required, ensure the drive has a continu-ous current rating equal to, or greater than, the full loadamp rating of the motor.The control panel is not visable with the control panel door closed. Conduit openings (knock-outs) are provided for at the bottom and rear of the enclosure.4ApplicationJC-VSD FP Series II Engineering Guide LIT-12012112 May 2017 www.johnsoncontrols.comApplicationGeneral Application ConsiderationsHorsepower RangeThe Johnson Controls VSD FP Series II is a complete prod-uct line covering the nominal horsepower sizes from 0.5 HP to 125 HP for 380 to 480V/3-Phase, and 0.5 HP to 50 HP for 208V to 240V/3-Phase. This one product line can be used for the smallest return fan or the largest chilled water pump. The critical sizing parameter is the output current rating of the drive (listed on pages 23- 26). The nameplate FLA rating of the motor(s) should not exceed the output current rating of the drive at 208, 230, 380, or 460-480VAC.FP Series II are designed with sufficient current capacity to be applied to high efficiency motors. The current capac-ity complies with the industry’s Energy Policy Act (EPACT) motor full load amp ratings. FP Series II FLA output ratings meet or exceed Table 430-150 of the National Electric Code® 1993.Power SupplyThe FP Series II is designed for nominal 380V to 480V (+10%), 48-63 Hz input power, or 208V to 240V (-15%), 48-63 Hz. For other power supply systems, a step trans-former should be used. The minimum required kVA rating ofthe transformer must be calculated as follows:Transformer kVA =1.732 x Line to Line Voltage x VFD Input Amps1000Power factor correction capacitors are not required as the FP Series II maintains a .98 power factor at nominal load.Example:399.05 kVA =1.732 x 480 x 4801000In this example the drive is supplied with 480V AC and rated for 480 amps. Based upon the calculation a 400 KVA isola-tion transformer would be required for the example above. When requesting information from the transformer vendor let them know that 100% of the transformer load will be a variable speed drive.LocationFP Series II are designed for indoor location, in a NEMA-1 classification area, having 5°F to 104°F (-15°C - 40°C) ambi-ent temperature limits. The relative humidity of the area should be between 0% to 90% non-condensing.Sufficient clearance (as noted in the dimensional section) to permit normal servicing and maintenance should be pro-vided around the entire unit.Power WiringThe FP Series II is equipped with power lugs for easy con-nection of power wiring. Maximum wiring size for each FP Series II is listed in the power and control wiring drawing, Form 100.04-PA1.2. A single point ground connection is provided in the FP Series II. Power wiring should be sized and installed in accordance with the National Electrical Code (N.E.C.). Copper wire is required for all power wiring con-nections to the FP Series II. WARNING DO NOT USE ALUMINUM WIRE. VSD FP Series II Terminals Are Not Rated for Use with Aluminum WireFor wiring and fuse sizing purposes, follow the guidelines for Rated Input Current and Max Prefuse Amps listed in Performance Data.Control Wiring / InterfaceJohnson Controls provides as standard on FP Series II a single point control interface which accepts standard control signals (4-20mA, 0-10VDC) mounted in the unit. Also avail-able for factory mounting is a pneumatic control interface which accepts a standard 3-15 PSIG control signal.NOTE For 380V, 50Hz applications size VFD for FLA that meet or exceed motor FLA. 5ApplicationJC-VSD FP Series II Engineering Guide LIT-12012112 May 2017 www.johnsoncontrols.comFan ApplicationsTheory of OperationVariable Air-Volume (VAV) systems have long been accepted as the energy efficient air distribution method. Johnson Controls and other HVAC suppliers have, traditionally, offered Variable Inlet Vanes (VIV) on air handling units to pro-vide this variable air volume capability. VIVs unload the fan by adding a pre-swirl to the air as it enters the fan in such a way as to provide a reduction in head pressure across the fan and a decrease in air flow rate. This causes a change in the operating point of the fan on the system curve (Figure 1)and a subsequent reduction in the horsepower drawn bythe fan motor.Alternatively, the FP Series II unloads the fan by slowing it down. This shifts the RPM curve on which the fan oper-ates. By reducing the RPM curve, the operating point now requires significantly less brake horsepower than a system using VIVs. This is shown in Figure 2. The part load perfor-mance comparison is shown in Figure 3.ApplicationVariable speed drives can be applied to forward-curved, air-foil or backward-inclined centrifugal fans. When retrofitting the FP Series II to a fan with existing VIVs, the VIVs Figure 1. Fan Curves with Inlet Vane ControlFigure 2. Fan Curves with Variable Speed ControlLD00894should either be removed or locked into the wide open posi-tion. Leaving the vanes on the fan will require the fan to use more power than if they were removed. The power penalty can range from 5% to 25% of FLA depending on fan size and velocity of air across the vanes. The smaller the fan, the higher the penalty.Sequence of OperationThe typical variable speed air system is depicted in Figure 4.It consists of an air handling unit being controlled by anFP Series II, duct work, and standard temperature controls.Under full load conditions, the fan is running at full speedand the discharge dampers are fully open, allowing themaximum amount of cooling into the space. As the coolingdiminishes, the temperature controls send a signal to thedampers to close; this increases the static pressure in theduct work. A static pressure sensor in the duct work sendsa signal through a receiver/controller to the FP Series II, tell-ing it to slow down the motor proportionally.The reduced motor and fan speed matches the air flow to the space temperature. As the space temperature rises, the dampers open lowering the duct static pressure. A reduc-tion in static pressure will cause the FP Series II to increase the speed of the motor, again matching the air flow to the space temperature.Figure 3. Air-Mod Part Load PerformanceFigure 4. Typical VAV SystemFan Power with Different Air Volume Control MethodsFan Power with Different Air Volume Control MethodsVAV Variable Speed Fans - ControlNext >