Trane Vertical Bypass/Non Bypass Panel manual

Rev . 2011-08-12 177R0253 MG14D122 *MG14D122* A ugust 2011 B AS-SVX49A-EN Operator s Guide TR200 V ertical Bypass/Non Bypass P anel SAFETY W ARNING Only qualified per sonnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazar dous and requires s[...]

Safety WARNING EQUIPMENT HAZARD! The vertic al bypass/ non bypass panel contains dangerous voltages when connected to mains voltage. It is strongly recommended that all electrical work conform to the National Electrical Code (NEC) and all national and lo cal regulations. Installation, start-up and maintenance should be p erformed only by qual ified[...]

Contents 1 Introduction 2-1 1.1.1 Purpose of the Manual 2-1 1.1.2 Overview 2-1 1.1.3 Typical Bypass Opera tion 2-1 1.2 Bypass Circui ts 2-1 1.2.1 Three-contactor Bypass 2-1 1.3 Bypass Options 2-2 1.3.1 Common Run/Stop with Bypass 2-2 1.3.2 Automatic Bypass 2-2 1.3.3 Run Permissive in Bypass 2-2 1.3.4 Basic Fire Mode in Bypass 2-2 1.3.5 Advanced Fir[...]

3.2.1 Lifting 4-3 3.2.2 Hoist or Overhead Lift 4-3 3.2.3 Forklift 4-3 3.2.4 Shipping Weights 4-3 3.3 Cooling 4-4 3.4 Electrical Installation 4-5 3.4.1 Component Identification & Customer Connection 4-7 3.4.2 Wire and Cable Access 4-15 3.4.3 Wire Size 4-19 3.4.4 Wire Type Rating 4-20 3.4.5 Terminal Tightening Torques 4-20 3.4.6 Input Line Connec[...]

6.1.5 ECB Hand/OFF/Auto 7-8 6.1.6 ECB Mode of Operation 7-8 6.1.7 Bypass Status Word Bit Exa mples 7-10 6.1.8 ECB Auto Bypass 7-10 6.1.9 ECB Run Permissive 7-11 6.1.10 ECB Overload 7-11 6.1.11 ECB Safety Int erlock 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 [...]

Contents BAS-SVX49A-EN[...]

1I n t r o d u c t i o n 1.1.1 Purpose of the Manual This manual is intended to pr ovide detailed information for the install ation and operation of the option panel used in conjunction with a Trane variable frequency drive (VFD or drive). To enable efficient handling of the equipment, requirements are provided for installation of mechanical, elect[...]

Contactor Drive Mode OFF Bypass Mode Test Mode M1 Closed O pen Open Closed M2 Closed O pen Open Open M3 Open Open Closed C losed Table 1.1 Contactor Operation Figure 1.1 Basic Non Bypass Circuit 1.3 Bypass Options 1.3.1 Common Run/Stop with Bypass Allows a remote signal to initiate operation in either drive control or bypass depending upon the posi[...]

1.4 Bypass Platform Configurations The two bypass platform configurations are ECB and EMB2. The features available as options with each platform are listed in Table 1.2 . The ECB, also listed below, has all option features available. See 5 Electromechanical Bypass (EMB2) Operation for additional details on the EMB2 and 6 Electronically Controlled B[...]

the option panel door can be op ened. (Bypas s panel only.) • Disconnect without fuses. For user-supplied fuses option. (Bypass pa nel only .) • Main circuit breaker. A thermal/ magnetic current interrupt device using an ON/TRIP/OFF/RESET switch. When in the ON position, a trip fault removes power from the dr ive/bypass c ircuit and t h e s w i[...]

1.6.3 Panel Configurations The TR 200 Drive Series comes in two panel enclosure types. One is the non b ypass and the other is the bypass. S ee Table 1.3 for descriptions and avail able options. Non bypass Bypass Drive plus both of the following: 1. Fuses 2. Disconnect Drive with bypass: 1. Fuses 2. Disconnect/Circuit Breaker 3. Con tactors 4. Powe[...]

1.6.4 Panel Voltage and Frame Ratings Table 1.4Table 1.4 d e f i n e s t h e v o l t a g e a n d h p r a t i n gs o f t h e f r a m e s s i z e s f or t h e p a n e l . S e e 8 Appendix for overall and mounting dimens ions. Panel P2 (B3 - Drive) Bypass Non Bypass TR200 TR200 Volts VAC HP (KW) 208 & 230 7.5 (5.5) - 15 (11) 7.5 (5.5) - 15 (11) 46[...]

2 Pre-installation 2.1.1 Receiving Inspection Inspect the packaging and equipm ent closely when received. Any indication of careless handling by the carrier should be noted on the delivery receipt, especially if the equipment will not be immediately uncrated. Obtain the delivery person’s signed agreement to any noted damages for any future insura[...]

dirt. If the unit does not have power app lied to it, supply a protective covering. It is important to ensure that the components stay as clean as possible. It may be necessary to clean the interior once construction is completed. • Keep drawings and manuals access ible for detailed installation and operation instructions. It is imp ortant that t[...]

3 Installation 3.1.1 Tools Required In addition to the standard tool kit, the tools in Table 3.1 are reco mmended for installation of the option pa nel. TOOLS Spreader bar capable of lifting up to 750 lbs. Max diameter 0.5 in. Forklift, crane, hoist o r other lifting device capable of handling up to 750 lbs. (Qualified device operator available for[...]

230 V AC HP (KW) UL Mo tor Current Panel (TR200) Non Bypass & B y p a s s Main Fuse (TR200) Bussman Drive F use (TR 200) Bussman Transformer Fuse (TR200) Bussman 7.5 (5.5 ) 22 P2 LPJ-35-SP JJN -50 10 (7.5) 28 LPJ-45-SP JJN-50 15 (11) 42 LPJ-70-SP JJN-60 20 (15) 54 P3 LPJ-90-SP JJN-80 25 (1 8.5) 68 LPJ-100-SP JJN- 125 30 (22) 80 P4 LPJ-125-SP JJ[...]

3.1.3 Internal Main Panel Fuses Use only the specified fuse or an equivalent replacement for th e internal main fuses. See the specifications label inside the c o v e r o f t h e u n i t f o r a c c e p ta b l e r e p l a c e m e n t m a i n f u s e s . A s a mp l e o f t h i s c a n be s e e n i n Table 3.6 . Fuse Description Manufacturer Part Num[...]

Figure 3.1 Proper Lifting Method 3.3 Cooling • Only m ount the drive and p anel vertical ly. • Panels rely on the am bient air for coo ling. It is important to observe the li mitations o n ambient air te mperature. The maximum a mbient temperature for all bypass panels is 40 ° C a n d 45 ° C for non by pass panels. Derating concerns start abo[...]

3.4 Electrical Installation WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadverten tly energized. Failure to disconnect power before servicing could result in death or serious injury. WARNING P r o p e r F i e l d W i r[...]

Figure 3.4 Power Connections Installation 3-6 BAS-SVX49A-EN[...]

3.4.1 Component Identification & Customer Connection Mechanical l ayout drawings are intende d to provide the installer or equipment user with component identification and location for that specific unit. Figure 3.5 represent s a typical layout drawing. Table 3.8 provides definitions for drawing reference des ignators. (Not all reference design[...]

Figure 3.6 P2 Non Bypass Mechanical Layout Dia gram. See Table 3.8 for reference designator definitions. Installation 3-8 BAS-SVX49A-EN[...]

Figure 3.7 P3 Bypass Mechanical Layout Diagram. See Table 3.8 for reference designator definitions. Installation BAS-SVX49A-EN 3-9[...]

Figure 3.8 P3 Non Bypass Mechanical Layout Dia gram. See Table 3.8 for reference designator definitions. Installation 3-10 BAS-SVX49A-EN[...]

Figure 3.9 P4 Bypass Mechanical Layout Diagram. See Table 3.8 for reference designator definitions. Installation BAS-SVX49A-EN 3-11[...]

Figure 3.10 P4 Non Bypass Mechanical Layout Diag ram. See Table 3.8 for reference designator definitions. Installation 3-12 BAS-SVX49A-EN[...]

Figure 3.11 P5 Bypass Mechanical Layout Diagram. See Table 3.8 for reference designator definitions. Installation BAS-SVX49A-EN 3-13[...]

Figure 3.12 P5 Non Bypass Mechanical Layout Diag ram. See Table 3.8 for reference designator definitions. Installation 3-14 BAS-SVX49A-EN[...]

3.4.2 Wire and Cable Access WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadverten tly energized. Failure to disconnect power before servicing could result in death or serious injury. • Refer to through for wire routi[...]

Figure 3.15 P2 Panel Figure 3.16 P3 Panel Installation 3-16 BAS-SVX49A-EN[...]

Figure 3.17 P4 Panel Installation BAS-SVX49A-EN 3-17[...]

Figure 3.18 P5 Panel Installation 3-18 BAS-SVX49A-EN[...]

3.4.3 Wire Size WARNING ELECTROCUTION AND FIRE HAZARDS WITH IMPROPERLY INSTALLED AND GROUNDED FIELD WIRING! Improperly installed and grounded field wiring poses FIRE & ELECTROCUTION haz ards. To avoid these hazards, you MUST follow requirements for field wi ring installation and grounding as described in the National Electrical Codes (NEC) and [...]

460 VAC HP (KW) UL Motor Current Pa nel (TR200) Non Bypass & B y pa s s Maximum Field Wiring Size Class B or C Field Grou nd Wiring Size Class B or C Minimum Temperature Wire Rating " ° C" Copper Conductor 15 (1 1) 21 P2 10 AWG 10 AWG 60 20 (1 5) 27 8 AWG 10 AWG 60 25 (18.5) 34 6 AWG 10 AWG 60 30 (2 2) 40 P3 6 A W G 1 0 A W G 6 0 40 [...]

208 VAC HP (KW) Panel (TR200) Non Bypass & B y p a s s Non Bypass Bypass Ground Wire Torque lb- in (N-m) Input Output Input Output Drive Disconnect S w i t c h L 1 , L 2 , & L 3 Torque lb-in (N-m) Motor T1 , T2, & T3 Torque lb-in (N-m) Disconnect Switch (w/o Fuses) UL508A L1, L2, & L 3 Torq ue lb-in (N-m) Disconnect Switch Fusible U[...]

2 3 0 V A C HP (KW) Panel (TR200) Non Bypass & Bypass Non Bypass Bypass Ground Wire Torque lb-in (N-m) Input Output Input Outp ut Drive Disconnect S w i t c h L 1 , L 2 , & L 3 Torque lb- in (N-m) M o t o r T 1 , T 2 , & T 3 Torque lb-in (N-m) Disconnect Switch (w/o Fuses) UL508A L1, L2, & L3 Torque lb-in (N-m) Disconnect Switch Fus[...]

460 V AC HP (KW) Panel (TR20 0) Non Bypass & B y pa s s Non Bypass Bypa ss 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 Torque lb-in (N-m) Disconne ct Switch (w/o Fuses) UL508A L1, L2, & L3 Torque lb-in (N-m) Disconne ct Sw itch Fusible U L98 L1, [...]

600 VAC HP (KW) Panel (TR200) Non Bypass & Bypass Non Bypass Bypass Ground Wi re Torque lb-in (N-m) Input Output I nput Output Drive Disconnect S w i t c h L 1, L 2 , & L 3 Torque lb- in (N-m) Motor T1, T2, & T3 Torque lb -in (N-m) Disconnect Switch (w/o Fuses) UL508A L 1 , L 2 , & L 3 T o r q u e lb-in (N-m) Disconnect Switch Fusib[...]

Field Connection Tightening Torque lb-in (N-m) Temperature & Type Rating L1, L2, L3/Ground 25 (2.8) 25 (2.8) Use 75 ° C Copper Conductor 2T1, 2T2, 2T3/Ground 25 (2.8) 25 (2.8) Use 75 ° C Copper Conductor TB1 25 (2.8) 25 (2.8) Use 75 ° C Copper Conductor Table 3.15 Sample Tightening Torq ue and Wire Rating Label 3.4.6 Input Line Connection WA[...]

• C o n n e c t t h e 3 - p h a s e m o t o r w i r i n g t o b y p a s s terminals T1 (U), T2 (V), and T3 (W). Se e the connection drawing inside the cover of the unit. • Depending on the configuration of the equipment, motor wiring may be connected to overload or terminal block. • Torque terminals in accordance with the information provided[...]

130BX224.10 2 3 4 1 Figure 3.19 Con trol Terminals Location 1. EIA-485 terminal 2. Jumper wire 3. Control terminals 4. Grounded restraining clips 3.4.10 Serial Communication Bus Connection The ECB reports serial communica tion data to host systems through the drive. Connection to the serial communication network is made either through the EIA-485 t[...]

3.4.11 Drive Control Terminals Definitions of the drive terminals are summarized in Table 3.16 . • Connector 1 provides four digita l inputs; two selectable digital inputs or outputs , 24 V DC terminal supply voltage, and a common for optional cus tomer supp lied 24 V DC voltage. • Serial communication s use EIA-485 connector 2 with terminal 68[...]

4S t a r t U p 1. Input power to the unit must be OFF and locked out per OSHA requirements. Do not r ely on panel disconnect switches. WARNING HAZARDOUS VOLTAGE! if inpu t and output conn ections hav e been connected improperly, there is potential for high voltage on these terminals. If power leads for multiple motors are improperly run in same con[...]

4.1.1 Inspection Prior to Start Up Before applying power to the unit, inspect the entire installation as detailed in Table 4.1 . Inspect For Description Auxilia ry equip ment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on input power side of driv e or output side to motor. Examine their opera[...]

CAUTION MOTOR START! Ensure tha t motor, system, and any attached equipment is r e a d y f o r s t a r t . F a i l u r e to d o s o c o ul d r e s u l t i n p e r s o n al injury or equipment damage. 5. If a bypass is connected, place the Mode Selector Switch in drive mode . Apply power by turning the main disconnect switch to the ON position. 6. E[...]

Start Up 4-4 BAS-SVX49A-EN[...]

5 Electromechanical Bypass (EMB2) Operation 5.1.1 Typical Control Connections for Common HVAC Applications Drive Termi nal Parameter Number Parameter Name Value Number Value Name Function 27 500 D igital I/O Mo de 0 PNP External Interlock 27 501 Term 27 mode 0 I nput External Interlock 29 502 Term 29 Mode 1 Output Auto Bypass 18 510 Term 1 8 digita[...]

Figure 5.1 Customer Side EMB2 Control Card Terminal Connections Electromechanical Bypass (E... 5-2 BAS-SVX49A-EN[...]

5.1.2 EMB2 Auto Bypass General Information Auto bypass allows a faul t condition in the drive to activate running the motor in bypass without op erator interventi on. Activation of th e function is through setting DIP switches (S100) located on the EMB2 by pass control card (see Figure 5.1 ). A fault condition enables a delay timer prior to trippin[...]

5.1.4 EMB2 Run Permissive General Information Run p ermissive all ows a remote signa l to notify the drive to sta rt, indica ting the system is saf e to operate. Run permissive works in drive or bypass mode. Run permissive is enab led by factory default a nd can be dis abled by switching dip switch #4 on S105 to the on position or placing a jumper [...]

trip when pressed. Use the reset pushbutton to reset the overload after the te st. • Reset is used to reset the overload after it trips. If the overload is still hot, wait until the motor reaches normal operating temperature before r e s e t t i n g . T h e o v e r l o a d o f f e r s a m a n u a l ( h a n d ) o r auto reset selection. It is high[...]

Fault Re porting Function Setup • Fault reporting status is connected to connecto r X55, output terminals 5, 6, and 7. 5.1.9 EMB2 Switches Mode selector switch. A panel mounted Drive/OFF/Bypass/Test selector switch is used to electrically select whether the motor is controlled by the drive (M1 and M2 contactors), connecte d to the full-speed bypa[...]

6 Electronically Controlle d Bypass (ECB) Operation 6.1 Electronically Controlled Bypass (ECB) Operation 6.1.1 Overview Information provided in this section is intended to enable the user to conn ect control wiring, program functions, and operate the ECB and its op tional features. The ECB contains a local processor located on the ECB control card,[...]

Parameter Parameter name Setting title Setting Function 5-01 Term 27 Mode Input 0 Customer Interlock 5-02 Term 29 Mode Output 1 Auto bypass 5-10 Term 18 digital input Start 8 Common run/stop 5-11 Term 19 digital input Run Permissive 52 Run Permissive 5-12 Term 27 digital input E xternal Interlock 7 Customer Interlock 5-31 Term 29 digital output No [...]

Figure 6.2 ECB Control Card Terminal Connections Electronically Controll ed Bypass (ECB) Opera- tion BAS-SVX49A-EN 6-3[...]

Input Conn. Term. Function Type X57 1 Digital input for safety stop User supplied dry contact 2 Common User supplied dry contact 3F a c t o r y u s e o n l y 4N o f u n c t i o n 5F a c t o r y u s e o n l y 6F a c t o r y u s e o n l y 7F a c t o r y u s e o n l y 8 Digital input for remote bypass enable User supplied dry contact 9 Digital input o[...]

6.1.3 ECB Drive or Bypass Selection Use the keypad and display to s w i t c h b e t w e e n t h e mo t o r r u n n i ng i n d r i v e m o d e o r b y p a s s w h e n o p e r a t i n g i n l o c a l c o n t r o l . The display in operating mode is shown below. 1. Press [Drive Bypass]. Display changes to show bypass and drive mode options (shown in S[...]

NOTE! P r e s s i n g [ I n f o ] a t a n y t i m e d i sp l a ys t i p s a n d g u i d e l i n e s f o r performing the function currently activated. 130BX238.10 Electronically Controlled B... 6-6 BAS-SVX49A-EN[...]

6.1.4 ECB Programming Use the keypad a nd display for programming ECB functional options . All programming options a ppear in numbered parameters. Parameters are arranged in groups by relate d functions. Programming is performed b y accessing the parameters through a menu and se lecting fr om display ed options or entering nu merical val ues. See t[...]

6.1.5 ECB Hand/OFF/Auto General Information The [Hand on], [Off Reset], an d [Auto on] keys on the keypad control both the drive and bypas s (see Figure 6.1 ). [Drive Bypass] allows the user to locally select drive or bypass mode of operation. It does not necess arily start or stop the motor. Prior to Enabling Hand/Off/Auto • Complete the s tart-[...]

• Auto bypass mode: When in drive mode, auto bypass is a timed inte rval that allows a fault condition in the drive to activate running the motor in by pass without op erator intervention. Mode of Operation Select • Mode of operation is program med through parameter group 31-** . See Table 6.4 . Par. No. Selection Function 31-00 Bypass Mode Sel[...]

6.1.7 Bypass Status Word Bit Examples 1. Motor running and bypass in drive mode. Status word 22 hexadecimal converts to 00000100010 binary. B i t 1 0 9 8765 43 2 1 0 B i n a r y 00 0001 00 0 1 0 1. External interlock fault (open) and bypass in bypa ss mode. Status word 208 hexadecimal converts to 01000001000 binary. B i t 1 0 9876 5432 10 B i n a r[...]

130BX244.10 Figure 6.4 Drive Display with Bypass Start Time Delay Active 6.1.9 ECB Run Permissive General Information With run permissive active, t h e d ri v e s e n d s a r u n r e q u e s t and waits for a remote resp onse before notifying the motor to sta rt. The response indicates the system is safe to operate. Run permissive operates from the[...]

Operation Overloads and motors ar e both rated by class. The class is defined by the NEC to dete rmine the maximum time to trip. A Class 20 overload, for example, ha s a typical trip delay of 20 sec. or less at 600% current and normal operating temperature. This al lows for high motor inrush current for 20 sec. while the motor is ramping up to sync[...]

6.1.13 ECB Advanced Fire Mode General Information Drive oper ation in advanced fire mode is programma ble. In the event the drive does not function, the motor is operated in bypass at full speed. Fire mode is intended to ignore com mon safety and ov erload inputs in emergency situations. The fire m ode function is built-in. See the drive support ma[...]

Electronically Controlled B... 6-14 BAS-SVX49A-EN[...]

7 Start Up Troubleshooting 7.1.1 Option Panel Alarm and Warnings Code Number Title De finition 220 Overload Trip M otor overload has tripped. Indicates ex cess motor load. Check motor and driven load. To reset, press [Off Reset]. Then, to restart the system, press [Auto on] or [Hand on]. 221 Bypass Interlock Bypass interlock has opened and caused t[...]

Symptom Possible cause Test Solution No function Missing input power See startup guide for voltage checks. Correct voltage at source. Missing or open fuses or circuit breaker tripped S e e o p e n f u s e s a n d t r i pp e d c i r c u i t breaker in this section for possible causes. Reset circuit breaker. If fuses, check for opens with power remov[...]

Symptom Possible cause Test Solution Repeated fuse or circuit breaker fault. Application problem Perform startup proced ures. Check panel output motor current at full speed and check for excessive over current. If current is too high, reduce the load on the motor. Panel problem Perform startup proced ures. Check panel input current at full load and[...]

Symptom Possible cause Test Solution Overload trips Motor overloaded Motor is drawin g too much cu rrent for the application. Perform startup and verify mo tor curren t is within specifications. If not, reduce the load on the motor. Loose connections Look for signs of overheating on connections to OL. Perform pre-st artup check for loose connection[...]

8A p p e n d i x 8.1.1 Dimensions P2 NON- BYPASS P2 BYPASS P3 NON- BYPASS P3 BYPASS P4 NON- BYPASS P4 BYPASS P5 NON- BYPASS P5 BYPASS A 8.86 [225.0] 9.1 1 [231.4] 9 .57 [243 .0] 9.57 [243.0] 12. 69 [322.3 ] 12.69 [322.2] 15.13 [384.3] 1 5.13 [38 4.2] A 1 6 . 6 6 [ 1 6 9 . 1 ] ------- B 29.92 [759.9] 41.77 [1061.0] 34.33 [872.0] 43.23 [1098.0] 39.58[...]

8.1.2 Mechanical Diagrams Figure 8.1 P2 B ypass Appendix 8-2 BAS-SVX49A-EN[...]

Figure 8.2 P2 Non-bypass Appendix BAS-SVX49A-EN 8-3[...]

Figure 8.3 P3 P4 P5 Bypass Appendix 8-4 BAS-SVX49A-EN[...]

Figure 8.4 P3 P4 P5 Non-bypass Appendix BAS-SVX49A-EN 8-5[...]

8.1.3 Typical Wiring Diagrams F i g u r e 8 . 5 E M B 2 w i t h C o n t r o l R e l a y , P a r t 1 Appendix 8-6 BAS-SVX49A-EN[...]

F i g u r e 8 . 6 E M B 2 w i t h C o n t r o l R e l a y , P a r t 2 Appendix BAS-SVX49A-EN 8-7[...]

Figure 8.7 EMB2, Part 1 Appendix 8-8 BAS-SVX49A-EN[...]

Figure 8.8 EMB2, Part 2 Appendix BAS-SVX49A-EN 8-9[...]

Figure 8.9 ECB, Part 1 Appendix 8-10 BAS-SVX49A-EN[...]

Figure 8.10 ECB, Part 2 Appendix BAS-SVX49A-EN 8-11[...]

Figure 8.11 ECB with Contro l Relays, Part 1 Appendix 8-12 BAS-SVX49A-EN[...]

Figure 8.12 ECB with Contro l Relays, Part 2 Appendix BAS-SVX49A-EN 8-13[...]

Figure 8.13 Non-bypass Appendix 8-14 BAS-SVX49A-EN[...]

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Rev . 2011-08-12 177R0253 MG14D122 *MG14D122* A ugust 2011 B AS-SVX49A-EN Operator s Guide TR200 V er tical Bypass/Non Bypass P anel SAFETY W ARNING Only qualified per sonnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazar dous and requires [...]