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3.8.2 AUTOMATIC Bypass on VFD Fault

 

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19

 

3.8.3 EMERGENCY Bypass

 

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Chapter 4 - Programming

 

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4.1 Commander HSK Required Programming

 

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4.2 Affinity BA Required Programming

 

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4.3 Commander HSK Recommended Programming

 

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4.4 Affinity Recommended Programming

 

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Chapter 5 - Operation

 

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5.1 Keypad Operation

 

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5.1.1 VFD Keypad

 

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5.1.2 Electronic Bypass Keypad

 

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5.1.3 Electronic Bypass Keypad Layout

 

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5.1.4 System Status LEDs

 

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5.1.5 HAND / OFF / AUTO Buttons

 

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5.1.6 TEST / VFD / BYPASS Buttons

 

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5.1.7 LED Alarm Display

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5.2 Starting Operation

 

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5.3 Ending Operation

 

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Chapter 6 - Alarm & Faults

 

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6.1 Electronic Bypass Keypad Alarms and Faults

 

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Chapter 7 - Appendix

 

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7.1 Specifications

 

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7.1.1 Electronic bypass

 

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7.2 Maintenance & Inspection

 

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7.3 Start-up Checklist – Electronic Bypass

 

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7.4 Startup Checklist – VFD

 

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Chapter 8

 

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34

 

8.1 FPCSK Schematic 

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8.2 FPCBA Schematic

 

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Summary of Contents for FPCBA

Page 1: ...FPCSK and FPCBA Electronic Bypass Controller INSTRUCTION MANUAL START UP GUIDE Part Number 027 2201 Issue 1 1 ...

Page 2: ...on 6 The Electronic bypass is suitable for use on a circuit capable of delivering not more that 100 000 RMS symmetrical amperes 480 Volts maximum 460 Volt Class units 240 volts maximum 230 Volt class units 7 Static sensitive printed circuit boards are installed in the Electronic bypass package Damage may occur due to ESD Electrostatic Discharge DO NOT handle any components without following proper...

Page 3: ... Rotation 10 2 7 1 Check 1 Rotation on VFD power 11 2 7 2 Check 2 Rotation on Bypass power 11 Chapter 3 Overview of the Electronic bypass 12 3 1 Control Board 12 3 2 Electronic Bypass Keypad Function Summary 12 3 3 Using the Electronic Bypass Configuration Switches 14 3 4 Using the Additional Customer Inputs 15 3 5 Alarm Displays 16 3 6 Failure and Power Off Conditions 16 3 7 Control Modes of the ...

Page 4: ...nic Bypass Keypad 24 5 1 3 Electronic Bypass Keypad Layout 25 5 1 4 System Status LEDs 25 5 1 5 HAND OFF AUTO Buttons 25 5 1 6 TEST VFD BYPASS Buttons 26 5 1 7 LED Alarm Display 26 5 2 Starting Operation 26 5 3 Ending Operation 27 Chapter 6 Alarm Faults 28 6 1 Electronic Bypass Keypad Alarms and Faults 28 Chapter 7 Appendix 30 7 1 Specifications 30 7 1 1 Electronic bypass 30 7 2 Maintenance Inspec...

Page 5: ...ete integrated HVAC control system which employs the latest Variable Frequency Drive VFD technology and incorporates a dedicated micro processor based controller for HVAC applications The Electronic bypass package uses a dedicated Electronic bypass keypad that clearly shows the system operating status The Electronic bypass is designed for ease of installation and startup Please follow this instruc...

Page 6: ...representative immediately Verify that all internal hardware i e components screws etc is properly seated and fastened securely 2 2 Nameplate Information The Electronic bypass package has two nameplates for identification The main label is located on the inside of the enclosure This nameplate provides information on the entire package The second nameplate is located on the VFD This nameplate conta...

Page 7: ...1 VFD Labels Typical Standard VFD Rating Label Typical VFD Approvals Label ...

Page 8: ...2 2 3 Part Number Identification ...

Page 9: ... unit in a dry environment free from oil mist and dust Install the unit in a location free from radioactive materials combustible materials harmful gasses or liquids Do not install the unit in a location susceptible to excessive vibrations Do not install in direct sunlight During installation protect the unit from foreign particles such as metal shavings produced by drilling Failure to follow thes...

Page 10: ...in conduit separate from both power supply and motor wiring 8 Tighten the screws on the main circuit disconnect if provided and control circuit terminals 9 Please observe National and Local codes when wiring electrical devices Failure to observe these precautions may result in equipment damage or improper operation and may not be covered under warranty 2 5 2 Input Wiring The Electronic bypass pack...

Page 11: ...t However the unit may be supplied with several different output options The following output options are available Single motor O L Terminals T1 T2 and T3 Dual motor O L Terminals Motor 1 T1 T2 and T3 Motor 2 T4 T5 and T6 Output reactor Connect the motor leads using the following recommended conduit locations ...

Page 12: ...ressed with R C snubbers If adding additional inductive loads i e magnetic contactors magnetic relays magnetic valves solenoids magnetic brakes etc in or near the Electronic bypass package use an appropriate surge suppressor across the coils to limit the transients on the supply lines ...

Page 13: ...ollowing table the Electronic bypass control board provides eight 8 digital inputs Terminal No Description TB2 3 Safety NC TB2 4 Reset TB2 5 Automatic Run TB2 6 Fire NC TB3 1 Remote Bypass TB3 2 Remote VFD TB3 3 Damper Feedback TB3 4 Fireman s Override TB2 8 TB4 1 2 3 Common All digital inputs are dry contacts voltage free 2 5 4 3 Digital Relay Outputs There are four 4 Form A relay outputs rated 1...

Page 14: ...actor 3 J10 4 115 Vac Neutral 2 J10 5 115 Vac Hot 1 2 5 5 Control Circuit Wiring FPCBA 2 5 5 1 Analog Output A 0 10 Vdc analog output signal is available by connecting to Affinity control terminals 9 and 11 The default is output frequency 2 5 5 2 Digital Input The Electronic bypass combines digital inputs from the Affinity inverter and the Electronic bypass control board to allow maximum flexibili...

Page 15: ...nnections between the Electronic bypass control board and the Affinity inverter These connections are made at the factory and are for reference only Do not change this wiring as it will cause the Electronic bypass to operate improperly or not at all Electronic bypass control Board FPCBA Wire number J11 1 Motor overload relay 12 J11 2 41 11 J11 3 11 16 J11 4 29 10 J11 5 N C N A J11 6 26 8 J11 7 25 ...

Page 16: ...ion of the Electronic bypass package insure that the enclosure door is securely closed Also insure all personnel are clear of the connected load as this operation will energize and rotate the motor After applying 3 phase power to the Electronic bypass package insure that the MAIN POWER LED is illuminated If any alarms are illuminated refer to chapter 6 for explanation There is no standard for the ...

Page 17: ...nic bypass keypad This will start the motor across the line Check motor rotation Quickly stop the motor by pressing the OFF RESET push button Note the direction of rotation as the motor shaft begins to rotate as compared to the required rotation direction Change the appropriate leads as noted in the following table Motor Rotation Correction VFD Correct Correct Incorrect Incorrect Bypass Correct In...

Page 18: ...ntrol board DIP switch and jumper settings required to properly configure the Electronic bypass All jumpers and switches are located on the door mounted control board 1 Option Enable Disable SW1 2 Digital Inputs J13 3 Digital Outputs J14 4 Relay Outputs J12 3 2 Electronic Bypass Keypad Function Summary The Electronic bypass keypad has 6 buttons labeled TEST VFD BYPASS HAND AUTO and OFF RESET Each ...

Page 19: ...Damper Solenoid 6 Damper 7 Auto Closes when placed in Auto 8 Auto Digital Inputs TB2 1 Safety Tie 1 2 Safety Tie 2 3 Safety NC Contact 4 Customer Reset NO Contact 5 Auto Run NO Contact 6 Fire NC Contact 7 Fused 24 Vdc 8 24 Vdc Common Digital Input Common Digital Inputs TB3 1 Remote Bypass Remote Bypass Command 2 Remote VFD Remote VFD Command 3 Damper Feedback Feedback from end switch 4 Fireman s O...

Page 20: ...y the VFD or the line When the motor is stopped in this situation the previous operating state of the electronic bypass package will be restored by re closing the fire alarm signal It is recommended that VFD parameter 6 09 Catch a Spinning Motor be set to 1 if the fire alarm input is used With the Fire Alarm switch 2 OFF the bypass will attempt to run the system to destruction in the event of fire...

Page 21: ...h Damper Control switch 3 OFF For normal operation mode a start command is given closing the Damper relay contacts The unit then waits for a contact closure from the Damper end switch indicating the Damper is fully open If the Damper feedback does not occur within 120 seconds then one or more of the LEDs on the board begin to flash indicating the damper close timer has timed out without feedback b...

Page 22: ...J5 J6 and J7 control the input bypass and output contactors respectively Moving any of these jumpers from the default open position to the emergency position will force the associated contactor to be energized This will happen irrespective to any logic damage on the bypass board See section 3 8 3 for details In the event the bypass control board should lose power its EEPROM memory retains the last...

Page 23: ...ated simultaneously if desired To exit the BYPASS mode press the OFF RESET button on the Electronic bypass keypad The BYPASS contactor will open and its respective keypad LED will go out 3 7 4 HAND mode In the HAND mode starting and stopping is controlled entirely from the door mounted pushbuttons HAND mode can control both VFD and BYPASS operation modes To place in VFD HAND mode press the VFD but...

Page 24: ...on once on the Electronic bypass keypad The AUTO and RUN LEDs will turn off Pressing the OFF RESET button again will turn off the VFD or BYPASS operation LEDs 3 8 Bypass Modes of the Electronic bypass There are three modes of operation for bypassing the VFD and operating on full line power MANUAL Bypass Manual bypass operation AUTOMATIC Bypass Automatic bypass on VFD fault EMERGENCY bypass Emergen...

Page 25: ...is jumper use the door interlocked disconnects to remove power from the Electronic bypass before opening the enclosure door Remove the four 4 mounting screws from the control board Turn the board so that the component side is facing you Move jumper J6 from the open position normal to the emergency position When the enclosure door is closed and the door interlock in the ON position the bypass conta...

Page 26: ...5 Terminal B7 digital input destination 0 00 menu param 9 04 Logic function 1 source 1 8 03 menu param 9 06 Logic function 1 source 2 8 05 menu param 9 10 Logic function 1 destination 1 43 menu param 6 40 Enable sequencer latching Off 4 2 Affinity BA Required Programming The following Affinity BA parameters must be set to the values shown in order to ensure proper operation of the Electronic bypas...

Page 27: ...valent Description Setting Units 1 06 02 Maximum set speed 60 Hz 1 07 01 Minimum set speed 0 Hz 2 11 03 Acceleration rate 1 50 0 s 100 Hz 2 21 04 Deceleration rate 1 75 0 s 100 Hz 5 07 06 Motor rated current From Motor A 5 08 07 Motor rated speed From Motor RPM 5 09 08 Motor rated voltage From Motor V 5 13 32 Dynamic V to f select OFF 6 09 33 Catch a spinning motor select 1 7 33 36 Analog output c...

Page 28: ... rpm rated speed From Motor RPM 5 09 0 44 Motor rated voltage From Motor V 5 13 0 09 Dynamic V F flux optimise select OFF OFF 6 09 0 33 Catch a spinning motor 1 1 7 19 T9 analog output 1 source 5 01 5 01 menu param 7 33 T9 analog output 1 control Adv Adv 8 21 T24 digital I O source destination 10 02 10 02 menu param 11 44 0 49 Security status L2 L2 Note If the analog speed reference into VFD termi...

Page 29: ...FD heatsink which operates at a very high temperature 4 Since it is easy to change operation from low to high speed verify the safe working range of the motor and connected load before operation 5 DO NOT check signals during operation 6 VFD parameters have been factory set for operation in the Electronic bypass package DO NOT change these settings as this will result in improper operation Failure ...

Page 30: ...l Fireman s Override auto transfer to bypass on VFD fault and other features and functions detailed in this guide The following photo shows the respective keypad locations VFD Keypad 5 1 1 VFD Keypad The keypad on the VFD is primarily used for speed control in hand mode and monitoring purposes as limited programming is required to operate the Electronic bypass See the Commander SK Advanced User Gu...

Page 31: ... ypass Cont ating status d LEDs w F AUTO Butt t Start Mod e 3 button ad Layout ain sections us LEDs F AUTO bu BYPASS b display EDs represe on the key On LED LED ctor status L actor status tactor statu of the Ele which indica tons de section o ns 25 s of the Elec uttons buttons ents a one ypad LED s LED s LED ectronic byp ate power offers simp ctronic bypa line power pass can ea ON ope le control o...

Page 32: ...re Alarm 4 VFD Fault 5 2 Starting Operation There are two 2 basic steps required to begin operation Step 1 Select the operation mode by pressing the TEST VFD or BYPASS buttons You must select one of these modes For VFD operation press the VFD button For Bypass operation press the BYPASS button For Test operation press the TEST button The BYPASS and TEST buttons may be pressed together Step 2 Selec...

Page 33: ...27 5 3 Ending Operation There are two 2 options available for ending operation 1 Press OFF RESET button once Cancels the start mode of operation 2 Press OFF RESET button twice Cancels the operation mode ...

Page 34: ...ernal safety interlock is in the open position If a safety input is not used check the bypass terminal block for a jumper between terminals TB2 3 and TB2 8 If a safety input is used verify that the Safety contact is closed 3 Fire Alarm Indicates that a Fire condition exists If fire alarm is set for purge mode the VFD package will operate the motor at full speed Note In purge mode all external safe...

Page 35: ...29 Commander SK Advanced User Guide or the Affinity User Guide for detailed fault information including possible causes and remedies ...

Page 36: ...mper actuator control 5 Amps 125 Vac relay contact Smoke fire alarm programmable to Purge mode Zero speed mode Four 4 relay outputs Dry contact digital inputs Narrow footprint PID controller Class 20 motor overload relay One 1 analog output 0 10 Vdc scalable Two 2 analog inputs programmable for 0 10 Vdc scalable 4 20 mA scalable default auto speed input Speed search function Digital manual speed c...

Page 37: ... cool and dry and if all precautions highlighted in this manual are observed Periodically inspect the Electronic bypass package as described in the table below to prevent accidents and to ensure high performance with high reliability Component Check Corrective Action External terminals connectors mounting screws etc Loose screws or connectors Secure tighten Heat sink Build up of dust and dirt Blow...

Page 38: ...Power ready to be energized to drive YES NO Motor and load ready for operation YES NO Control Wiring Automatic Run connected between TB2 5 TB2 8 YES NO Automatic Speed reference 4 20 mA connected to Affinity terminals 7 11 or HSK terminals T2 T1 YES NO Normally Closed Safety contact or Jumper connected between TB2 3 TB2 8 YES NO Normally Closed Fire contact or Jumper connected between TB2 6 TB2 8 ...

Page 39: ...sure inspected for shipping damage physical integrity door latch and lock operation Line and motor power connections tight and made to proper terminals with satisfactory clearances Control wiring present and made to proper terminals and pull apart terminal blocks fully engaged Physical installation and wiring conform to factory drawings or manuals as required Control devices contactors overloads b...

Page 40: ...34 Chapter 8 8 1 FPCSK Schematic ...

Page 41: ...35 8 2 FPCBA Schematic ...

Page 42: ...36 NOTES ...

Page 43: ...37 Part Number 027 2201 Issue 1 1 Control Techniques Americas LLC 2009 ...

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