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Electronic Bypass Controller Installation and Commissioning Guide

9

2.4 Mounting & Clearances

Install the electronic bypass package on a vertical surface and allow the following
minimum clearances for normal heat dissipation.

Industrial Automation

TM

WARNING

WARNING

Potentially hazardous voltage

can exist within this device. Only fully trained, qualified personnel should
service this equipment.
Pressing the stop button will not remove power from this equipment.
Never service this equipment without first being sure all power is safely
removed. Hazardous voltage levels may exist for up to 5 minutes after

power is disconnected!

Industrial Automation

TM

WARNING

WARNING

Potentially hazardous voltage

can exist within this device. Only fully trained, qualified personnel should
service this equipment.
Pressing the stop button will not remove power from this equipment.
Never service this equipment without first being sure all power is safely
removed. Hazardous voltage levels may exist for up to 5 minutes after

power is disconnected!

12 in

6 in

12 in

6 in

TOP

SIDE-TO-SIDE

Air Flow

Notes:

•  Ambient operating temperature; 32 °F to 104 °F (0 °C to 40 °C)
•  Install the unit in a dry environment free from oil mist and dust
•  Install the unit in a location free from radioactive materials, combustible materials,

harmful gases 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 these notes could void the warranty

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Summary of Contents for HVAC Drive H300

Page 1: ...Electronic Bypass Controller HVAC Drive H300 Unidrive M200 and Unidrive M400 Installation and Commissioning Guide Part Number PSD H300BP ICG Issue 4 1 ...

Page 2: ...5 4 Control Circuit Wiring 12 2 5 4 1 Analog Output 12 2 5 4 2 Digital Input 12 2 5 4 3 Digital Relay Outputs 12 2 5 5 4 Internal Control Wire Connections 13 2 5 6 Grounding 13 2 6 Inspection 14 2 7 Checking Motor Rotation 14 2 7 1 Check 1 Rotation on VFD power 14 2 7 2 Check 2 Rotation on Bypass power 15 Section 3 Operation 16 3 1 Keypad Operation 16 3 1 1 VFD Keypad 17 3 1 2 Electronic Bypass Ke...

Page 3: ...26 4 7 1 TEST mode 26 4 7 2 VFD mode 27 4 7 3 Bypass Mode 27 4 7 4 Hand Mode 27 4 7 5 Auto Mode 28 4 8 Bypass Modes of the Electronic Bypass 28 4 8 1 MANUAL Bypass 28 4 8 2 Automatic Bypass on VFD Fault 29 4 8 3 Emergency Bypass 29 Section 5 Programming 30 5 1 Required Programming 30 5 2 Recommended Programming 31 Section 6 Alarm Faults 32 6 1 Electronic Bypass Keypad Alarms and Faults 32 Section ...

Page 4: ...d control board while the power supply is turned ON 6 The electronic bypass is suitable for use on a circuit capable of delivering not more than 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 Electrostatic Discharge ESD DO N...

Page 5: ...lete 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 instru...

Page 6: ...nd your Emerson Control Techniques representative immediately 3 3 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 ...

Page 7: ...als Serial number Output voltage Input voltage Key to approvals CE approval Europe C Tick approval Australia UL cUL approval USA Canada RoHS compliant Europe R Large label This label is only applicable to size 7 and above Refer to Figure 2 2 Model number on page 9 for further information relating to the labels Refer to User Guide Model Frame size Voltage Current rating Drive format H300 084 01840 ...

Page 8: ...GISTER G 16 kW 0010 10 HP 0250 250 HP 3 RFI Filter W SI I O H 17 kW 0015 15 HP 0300 300 HP 4 Input Reactor 3 RFI Filter Y AI 485 ADAPTOR I 18 kW 0020 20 HP 0350 350 HP 5 Input Reactor 5 RFI Filter Z KI 485 ADAPTOR J 19 kW 0025 25 HP 0400 400 HP 6 Matrix AP Filter 1 SI PROFIBUS K 20 kW 0030 30 HP 0450 450 HP Enclosure size considerations Addition of one or multiple filtering options may change the ...

Page 9: ...voltage can exist within this device Only fully trained qualified personnel should service this equipment Pressing the stop button will not remove power from this equipment Never service this equipment without first being sure all power is safely removed Hazardous voltage levels may exist for up to 5 minutes after power is disconnected 12 in 6 in 12 in 6 in TOP SIDE TO SIDE Air Flow Notes Ambient ...

Page 10: ...nd conductors DO NOT use conduits as ground 7 Control wiring must be 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 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 covere...

Page 11: ...may exist for up to 5 minutes after power is disconnected Recommended conduit entrance control wire Recommended conduit entrance motor connection 2 5 3 Output Wiring The electronic bypass package is always supplied with a Class 10 motor O L on its output However the unit may be supplied with several different output options The following output options are available Single motor O L Terminals T1 T...

Page 12: ...rd to allow maximum flexibility As per the following 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 T...

Page 13: ...drive M200 M400 Wire Number J11 1 Motor overload relay Motor overload relay 12 J11 2 22 10 10 11 J11 3 28 1 6 16 J11 4 27 14 14 10 J11 5 N C N C N A J11 6 24 12 12 8 J11 7 23 13 11 9 J10 1 Input Contactor 5 5 J10 2 Bypass Contactor 4 4 J10 3 Output Contactor 3 3 J10 4 115 Vac Neutral 2 2 J10 5 115 Vac Hot 1 1 2 5 6 Grounding Never ground the electronic bypass package in common with welding machine...

Page 14: ... of an induction motor based on the motor lead markings This plus the uncertainty of the phase rotation of the utility power being applied to the electronic bypass package terminals requires that the motor rotation direction be checked and be correct in both VFD and Bypass Modes Failure to confirm rotation may cause severe damage to the electronic bypass package motor or the driven equipment 2 7 1...

Page 15: ...te leads as noted in the following table Motor Rotation Correction VFD Correct Correct Incorrect Incorrect Bypass Correct Incorrect Correct Incorrect Action No Action Change any two power leads at input disconnect Change any two leads at input at input disconnect and change any two leads at the output of the motor overload Change any two leads at output of motor overload There is no standard for t...

Page 16: ...tory set for operation in the electronic bypass package DO NOT change these settings as this will result in improper operation Failure to observe these precautions may result in equipment damage serious personal injury or death 3 1 Keypad Operation The electronic bypass package utilizes two keypads in its operation The VFD keypad controls the speed in the Hand Mode using the up and down arrow keys...

Page 17: ...ctronic bypass See the HVAC Drive H300 Installation Commissioning Guide Unidrive M200 M201 User Guide or the Unidrive M400 User Guide for detailed programming information 3 1 2 Electronic Bypass Keypad Operation of the electronic bypass package is controlled by the electronic bypass keypad located on the door of the lower enclosure 3 1 3 Electronic Bypass Keypad Layout There are four 4 main sectio...

Page 18: ... system status LEDs represents a one line power diagram with a total of five 5 LEDs located on the keypad 1 Main power on LED 2 VFD power LED 3 Input Contactor status LED 4 Output Contactor status LED 5 Bypass Contactor status LED The operating status of the electronic bypass can easily be seen from the illuminated LEDs which indicate power ON operation mode and run conditions 3 1 5 HAND OFF AUTO ...

Page 19: ...re are four 4 LEDs on the electronic bypass keypad indicating the various application specific faults that may occur They are as follows 1 Motor Overload 2 Safety 3 Fire Alarm 4 VFD Fault 3 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 pres...

Page 20: ...ied run contact closes between terminals TB2 5 and TB2 8 AUTORUN and 24V common The RUN LED will illuminate when the contact closes Incoming Power Power On 1 Select Operation Mode RUN 1 Rest mechanical overload inside enclosure Alarm Display 2 Select Run Mode Input Contactor Bypass Contactor Output Contactor Motor 1 Overload External Safety Fire Alarm VFD Fault Press OFF RESET once to cancel RUN m...

Page 21: ...s OFF RESET button twice Cancels the operation mode Incoming Power Power On 1 Select Operation Mode RUN 1 Rest mechanical overload inside enclosure Alarm Display 2 Select Run Mode Input Contactor Bypass Contactor Output Contactor Motor 1 Overload External Safety Fire Alarm VFD Fault Press OFF RESET once to cancel RUN mode Press OFF RESET twice to cancel OPERATION mode TEST HAND VFD AUTO OFF RESET ...

Page 22: ...lectronic bypass control 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 4 2 Electronic Bypass Keypad Function Summary refer to table on next page The electronic bypass keypad has 6 buttons labele...

Page 23: ...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 Override 5 N A 6 N ...

Page 24: ...uses the opening of the fire alarm input TB2 6 to stop the motor independent of whether it was being run by 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 removing the fire alarm signal and cycling the customer reset input It is recommended that VFD parameter Catch a Spinning Motor be set to 1 if the...

Page 25: ...FD Auto Mode With 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 customer supplied 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 will begin to flash indicating the Damper Close...

Page 26: ...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 An interlock prevents the closing of the 3 contactors at once In the event the bypass control board ...

Page 27: ...nd Test Mode can be operated 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 4 7 4 Hand Mode In the Hand Mode starting and stopping is controlled entirely from the drive keypad Hand Mode can control both VFD and Bypass operation modes To place in VFD Hand Mode press...

Page 28: ...ton 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 4 8 Bypass Modes of the Electronic Bypass There are three modes of operation for bypassing the VFD and operating on full line power 1 MANUAL Bypass Manual bypass operation 2 AUTOMATIC Bypass Automatic bypass on VFD fault 3 EMERGENCY bypass ...

Page 29: ...ge this 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 With the component side facing you move jumper J6 from the open position normal to the emergency position When the enclosure door is closed and the disconnect is in the ON position the bypass contactor coil will be...

Page 30: ...erence selector A1 A2 A1 A2 01 051 Power up keypad reference LASt 1 LASt 1 01 052 Enable hand off auto keypad mode 1 1 02 006 S ramp enable On 1 On 1 02 007 Maximum Rate of Change of Acceleration 60 10 s Max Hz 06 012 Enable stop key On On 07 010 00 026 Analog input 1 destination 0 0 menu param 07 014 00 028 Analog input 2 destination 01 036 01 036 menu param 08 022 Digital I O 2 source destinatio...

Page 31: ...alent Description Setting Units Fan Pump 01 006 00 011 Max Speed Hz 60 60 Hz 01 007 00 010 Min Speed Hz 15 6 Hz 02 011 00 012 Acceleration rate 1 100 16 6 s 100 Hz 02 021 00 013 Deceleration rate 1 100 16 6 s 100 Hz 05 007 00 020 Motor rated current From Motor A 05 008 00 019 Motor load rpm rated speed From Motor RPM 05 009 00 018 Motor rated voltage From Motor V 05 013 00 015 Dynamic V F flux opt...

Page 32: ...ors full load Ampere rating Check for excessive motor current and load 2 Safety Indicates that an external 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 Incoming Power Power On 1 Select Operation Mode RUN 1 Rest mechanical overlo...

Page 33: ...ternal safeties and motor overloads are disabled The unit will run to destruction in this mode If fire alarm is set for Stop Mode the VFD package will disable the motor and prevent it from being operated in either VFD or Bypass Mode 4 VFD Fault Indicates that the VFD has had a fault The VFD fault code will be displayed on the VFD keypad See the Affinity User Guide for detailed fault information in...

Page 34: ... panel 32 bit microprocessor MODBUS BACnet Metasys N2 standard with H300 only HAND OFF AUTO pushbuttons TEST VFD BYPASS pushbuttons Auto transfer to bypass on fault selectable Damper Mode programmable Damper actuator control 5 A 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 10 ...

Page 35: ...t least ten 10 minutes after the power supply is disconnected and all LEDs are extinguished The electronic bypass will function longer if kept clean 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 Co...

Page 36: ...ring shipping Input wiring to drive in separate conduit YES NO Output wiring to drive in separate conduit YES NO Ground wire from AC mains ground to drive YES NO Ground wire to motor from drive YES NO 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 ...

Page 37: ... terminals and pull apart terminal blocks fully engaged YES NO Physical installation and wiring conform to factory drawings or manuals as required YES NO Control devices contactors overloads breakers switches operating mechanisms interlocks OK YES NO Separate AC line reactor dc link reactor or dynamic brake module resistor if supplied properly installed YES NO Basic settings application specific s...

Page 38: ...Only raise if there is an audible noise issue Catch a spinning motor 6 009 0 023 1 1 Press M Detects Positive and Negative Frequencies T7 Analog input 2 7 011 0 027 20 Apr 20 Apr Press M Factory default is 4 20 ma If 0 10 VDC change default Change Security Status 11 044 0 031 L2 L2 PressOff reset This allows access to advanced Menu Parameters Save parameters to Smart Card 11 042 0 033 Prog Prog Se...

Page 39: ...Electronic Bypass Controller Installation and Commissioning Guide 39 ...

Page 40: ...ou go to the website or send an Email to info us emersonindustrial com 2016 Emerson Electric Co The information contained in this document is for guidance only and does not form part of any contract The accuracy cannot be guaranteed as Emerson have an ongoing process of development and reserve the right to change the specification of their products without notice ...

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