Electronic Bypass Controller

Installation and Commissioning Guide Electronic Bypass Controller HVAC Drive H300, Unidrive M200 and Unidrive M400 Part Number: PSD-H300BP-ICG Issue: 5.0

Contents Section 1 - Introduction... 5 Section 2 - Installation Instructions... 6 2.1 Receiving...6 2.2 Nameplate Information...6 VFD Labels...7 Typical Standard VFD Rating Label...7 Typical VFD Approvals Label...7 2.3 Part Number Identification...8 2.4 Mounting & Clearances...9 2.5 Wiring and Precautions...10 2.5.1 General...10 2.5.2 Input Wiring...10 2.5.3 Output Wiring...11 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 Keypad...17 3.1.3 Electronic Bypass Keypad Layout...17 3.1.4 System Status LEDs...18 3.1.5 HAND / OFF / AUTO Buttons...18 3.1.6 TEST / VFD / BYPASS Buttons...19 3.1.7 LED Alarm Display...19 3.2 Starting Operation...19 3.3 Ending Operation...21 2 Electronic Bypass Controller Installation and Commissioning Guide

Section 4 Overview of the electronic bypass... 22 4.1 Control Board...22 4.2 Electronic Bypass Keypad Function Summary...22 Electronic Bypass Control Functions...23 4.3 Using the Electronic Bypass Configuration Switches...24 4.4 Using the Additional Customer Inputs...25 4.5 Motor Overload...26 4.6 Failure and Power Off Conditions...26 4.7 Control Modes of the Electronic Bypass...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 7 - Additional Information... 34 7.1 Specifications Electronic Bypass...34 7.2 Maintenance & Inspection...35 7.3 Start-up Checklist Electronic Bypass...36 7.4 Startup Checklist VFD...37 7.5 Startup for Cooling Tower - Fan and/or Pump Applications...38 Electronic Bypass Controller Installation and Commissioning Guide 3

Safety and Precautions WARNING 1. Read this manual in its entirety before installing or operating the electronic bypass package. This manual applies to electronic bypass packages with the Nidec Control Techniques HVAC Drive H300, Unidrive M200 or Unidrive M400 variable frequency drives, and control board part number 1067144-01 and is not intended to be used with any other products. 2. Do not connect or disconnect wiring, or perform signal checks while the power supply is turned ON. 3. The internal capacitor of the installed drive may be charged even after the power supply has been turned OFF. To prevent electrical shock, disconnect all power before servicing the electronic bypass. Wait at least 10 minutes after the power supply has been disconnected and all LEDs have been extinguished. 4. Do not perform a voltage withstand test on the electronic bypass or the installed drive. This electronic equipment uses semiconductors and is vulnerable to high voltage. Severe damage to the equipment may occur. 5. Do not remove the digital operator from the inverter unless the power supply has been turned OFF. Never touch the printed 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 NOT handle any components without following proper ESD precautions. Failure to observe these and other precautions highlighted in this manual will expose the user to high voltages, resulting in equipment damage, serious injury or death. The information contained within this document is proprietary to Nidec Control Techniques and may not be copied, reproduced or transmitted to other parties without the expressed written consent of Nidec Control Techniques. No patent liability is assumed with respect to the use of information contained herein. Moreover, because Nidec Control Techniques is constantly improving its high quality products, the information contained in the manual is subject to change without notice. Every precaution has been taken in the preparation of the manual. Nevertheless, the manufacturer assumes no responsibility for errors or omissions. Neither is liability assumed for damages resulting from the use of the information contained in this publication. 4 Electronic Bypass Controller Installation and Commissioning Guide

Section 1 - Introduction Thank you for purchasing your Nidec Control Techniques electronic bypass package. This manual provides information concerning the installation, wiring and general startup procedures for both the HVAC Drive H300, Unidrive M200 and Unidrive M400 lines of electronic bypass packages. The electronic bypass is a complete 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 instruction manual s guidelines for proper installation and programming of your electronic bypass package. HVAC Drive H300 Unidrive M200 Unidrive M400 Electronic bypass keypad Lower enclosure Disconnect handle Electronic Bypass Controller Installation and Commissioning Guide 5

Section 2 - Installation Instructions 2.1 Receiving After unpacking the electronic bypass package: 33 Verify that the part numbers on the package match the numbers on your purchase order, packing slip or tagging information. 33 Check the unit for physical damage which may have occurred during shipping. If any part of the package is missing or damaged, notify the carrier and your Nidec Control Techniques representative immediately. 33 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 contains information related to the VFD only. The nameplate information should be recorded and kept in a safe location. This information is required for any service or repair. Electronic Bypass Package Label 6 Electronic Bypass Controller Installation and Commissioning Guide

R VFD Labels Typical Standard VFD Rating Label Model Frame size Current rating Refer to User Guide H300-084 01840 A Voltage Drive format Input voltage Output voltage Normal Duty power rating Input frequency Customer and date code No.of phases & Typical input current for Normal Duty rating Key to approvals CE approval C Tick approval Europe Australia Approvals Normal Duty rating output current UL / cul approval RoHS compliant USA & Canada Europe Serial number Typical VFD Approvals Label Large label * Input voltage Model Input frequency H300-084-01840-A 125hp STDV02 I/P 380-480V 50-60Hz 3ph 164A O/P 0-480V 3ph 184A Designed in UK Made inu.k. Serial No: 3000005001 Normal Duty power rating Customer and date code No. of Input phase & Input current No. of Output phase & Normal Duty Rating Output current Serial number Output voltage Approvals * 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. Electronic Bypass Controller Installation and Commissioning Guide 7

2.3 Part Number Identification Packaged HVAC/R Drives from 1 to 600 HP [Order Code digit number] BASE ORDER CODE POWER & DOOR OPERATOR OPTIONS CONTROL OPTIONS P X XXXX X X X X - X 0 X X X X X 0 - X X X X 0 X X X X X 1 2 3-6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 [1] Package Type [12] Bypass Option [21] - [23] Option Module [27] Basin Heater** P = Pre-Engineered 0 = No Bypass 0 = None 0 = None S = Seismic 1 = Electronic 3-Contactor Bypass A = SM-APPS-LITE-V2 1 = 1 kw Seismic - Consult factory 2 = Classic (Manual) Bypass C = SM-BIPOLAR 2 = 2 kw 6 = Soft Starter Electronic 3-Contactor Bypass D = SM-CANOPEN 3 = 3 kw [2] Voltage Rating E = SM-DEVICENET 4 = 4 kw 8 = 208 Vac [14] Door-Mounted Keypad/HMI H = SM-ETHERCAT 5 = 5 kw 2 = 230 Vac 0 = None I = SM-ETHERNET 6 = 6 kw 4 = 460 Vac C = LCD Keypad K = SM-I/O-120V 7 = 7 kw 5 = 575 Vac E = LED Keypad L = SM-I/O-24V 8 = 8 kw Unidrive M200 and Commander HSK includes LED M = SM-I/O-32 9 = 9 kw [3] - [6] Horsepower Rating keypad as standard. HVAC Drive H300 and Affinity N = SM-I/O-LITE A = 10 kw 0001 = 1 HP 0060 = 60 HP BA includes LCD keypad as standard. Choose these P = SM-I/O-PLUS B = 11 kw options if keypad is required to be door mounted. 01P5 = 1.5 HP 0075 = 75 HP Q = SM-I/O-TIMER C = 12 kw 0002 = 2 HP 0100 = 100 HP [15] Input Filtering R = SM-INTERBUS D = 13 kw 0003 = 3 HP 0125 = 125 HP 0 = None S = SM-LON E = 14 kw 0005 = 5 HP 0150 = 150 HP 1 = Input Reactor 3% T = SM-PROFIBUS-DP F = 15 kw 0007 = 7 HP 0200 = 200 HP 2 = Input Reactor 5% V = SM-REGISTER 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 2 = SI-ETHERNET* 0040 = 40 HP 0500 = 500 HP multiple filtering options may change the size and/ 3 = SI-DEVICENET* [28] Spray Pump*** 0050 = 50 HP 0600 = 600 HP or style of the enclosure. 4 = SI-CANOPEN* 0 = None Matrix filter - consult factory. [7] Duty Rating 5 = SI-PROFINET-V2* 1 = 1 hp N = Normal Duty [16] Output Filtering 6 = SI-ETHERCAT* 2 = 2 hp 0 = None M200 & HSK have 1 option module 3 = 3 hp [8] Enclosure Style 1 = Output Reactor 3% slot only 5 = 5 hp 1 = NEMA 1 2 = dv/dt Filter Affinity has 2 option module slots 7 = 7 hp 2 = NEMA 12 3 = Sine Filter HVAC Drive H300 has 3 option slots A = 10 hp 3 = NEMA 3R 4 = Output Reactor 1.5% B = 15 hp B = NEMA 1 (Electronic Bypass Only) F = NEMA 1 (Disconnect with Fusing) [17] Multiple Motors [24] Phase Loss Monitor 2 = Two Manual Motor Protectors (MMP) 0 = None [29] De-icer / Sun Shield*** [9] Input Power Connection 3 = Three Manual Motor Protectors 1 = Yes 0 = None 1 = Circuit Breaker (25 kaic) 4 = Four Manual Motor Protectors 1 = De-icer 2 = Disconnect Switch with Fusing 5 = Five Manual Motor Protectors [26] Temperature Controller*** 2 = Sun Shield 3 = Circuit Breaker (65 kaic) 6 = Six Manual Motor Protectors 0 = None 3 = De-icer & Sun Shield 4 = Circuit Breaker (100 kaic) Cumulative amp ratings of motors must not 1 = Thermocouple Input fuses for drives are included as exceed the drive rating. Each motor must have its 2 = RTD [30] Siemens FLN standard for all input power options own overload protection. Multiple Manual Motor 0 = None Protectors are of equal size. [10] Product *SI used on Unidrive M200 & H300 1 = Yes A = Affinity Active Front End [18] Space Heater** ***Selection of options 26-29 B = Affinity Drive 0 = None require a cooling tower NEMA 3R H = Commander HSK Drive 2 = 200 W enclosure. 2 = Unidrive M200 4 = 400 W 3 = HVAC Drive H300 Larger heaters can be chosen for extremely cold X = HVAC Drive H300 AFE ambient temperatures. NOTE: **Available with NEMA 3R enclosure only 1) For options not included in the Order Code configurator, please consult factory for a custom quote. 8 Electronic Bypass Controller Installation and Commissioning Guide

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! 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! 2.4 Mounting & Clearances Install the electronic bypass package on a vertical surface and allow the following minimum clearances for normal heat dissipation. 12 in 6 in 12 in 6 in Air Flow TOP SIDE-TO-SIDE 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 Electronic Bypass Controller Installation and Commissioning Guide 9

2.5 Wiring and Precautions 2.5.1 General 1. DO NOT connect or disconnect wiring or perform signal checks while the power supply is turned ON. 2. Connect the power supply wiring to the electronic bypass input terminals L1, L2 and L3 on the main circuit disconnect device. 3. Connect the motor wiring to the bypass output terminals T1, T2 and T3 at the Class 10 Motor O/L or the output reactor if installed. 4. Never touch the output circuit directly or place the output line in contact with the package enclosure. 5. DO NOT connect power factor correction capacitors on the output circuit. 6. Power supply wiring and motor wiring must be in separate conduits with separate ground 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 covered under warranty. 2.5.2 Input Wiring The electronic bypass package may be supplied with several different input device options. These input options include protective devices as well as non protective devices. It is the responsibility of the installing parties to ensure that requirements for branch circuit protection of the appropriate size and location are observed. All incoming power is connected to terminals L1, L2, and L3. The following input options are available. Fused disconnect Circuit breaker Input line reactor Input RFI filter 10 Electronic Bypass Controller Installation and Commissioning Guide

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! Connect the main power supply, motor and control wiring using the following recommended conduit locations. The input phase sequence does not affect the output phase sequence of the VFD. It will affect bypass sequence and motor rotation direction. 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, T2, and T3) Dual motor O/L (Terminals (Motor 1 T1, T2, and T3) (Motor 2 T4, T5, and T6)) Output reactor Note: All contactors and relays supplied in the electronic bypass package are suppressed 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. Electronic Bypass Controller Installation and Commissioning Guide 11

2.5.4 Control Circuit Wiring 2.5.4.1 Analog Output A 0-10 Vdc analog output signal is available by connecting to Unidrive M200/M400 control terminals 7 (+) and 1 (-) or H300 control terminals 7 (+) and 9 (-). The default is output frequency. 2.5.4.2 Digital Input The electronic bypass combines digital inputs from the H300 inverter and the electronic bypass control board to allow maximum flexibility. As per the following table, the electronic bypass control board provides eight (8) digital inputs. Terminal No. TB2-3 TB2-4 TB2-5 TB2-6 TB3-1 TB3-2 TB3-3 TB3-4 TB2-8 &TB4-1,2,3 Description Safety (NC) Reset Automatic Run Fire (NC) Remote Bypass Remote VFD Damper Feedback Fireman s Override 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 125 Vac, 0.5 A on the electronic bypass control board. Terminal No. TB1-1 & TB1-2 TB1-3 & TB1-4 TB1-5 & TB1-6 TB1-7 & TB1-8 Description Power on Fault Damper actuator Automatic mode selected 12 Electronic Bypass Controller Installation and Commissioning Guide

2.5.5.4 Internal Control Wire Connections There are factory connections between the electronic bypass control board and the H300 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 H300 Unidrive 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 machines, motors or other high current electrical equipment. Run all ground wires in a separate conduit. When using several electronic bypass packages side by side, ground as shown below. (a) Acceptable (b) Acceptable (c) Not Acceptable Electronic Bypass Controller Installation and Commissioning Guide 13

2.6 Inspection Once all wiring is complete, verify that: 1. All wiring is installed. 2. Excess screws, metal filings and wire clippings are removed from inside the unit(s). 3. Screws and fasteners are securely tightened. 4. Exposed wiring has no contact with other wiring or terminals. 2.7 Checking Motor Rotation Before attempting a trial operation of the electronic bypass package, ensure that the enclosure door is securely closed. Also, ensure 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, ensure that the MAIN POWER LED is illuminated. If any alarms are illuminated, refer to Section 6 for explanation. There is no standard for the rotational direction 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 Check #1: Rotation on VFD power WARNING Place the VFD package in Hand (local) Mode control by pressing the VFD and HAND push buttons on the electronic bypass keypad. The VFD, HAND, INPUT and OUTPUT CONTACTOR LEDs will be illuminated. The VFD must be started and stopped by the START/STOP buttons on the VFD keypad. Use the up arrow on the VFD keypad to increase the speed reference of the VFD or the down arrow on the VFD keypad to decrease the speed reference of the VFD. Note the direction of rotation as the motor shaft begins to rotate as compared to the required rotation direction. To stop the VFD, press the OFF/RESET push button. 14 Electronic Bypass Controller Installation and Commissioning Guide

2.7.2 Check #2: Rotation on Bypass power NOTE: This operation will start the motor across the line. Place the electronic bypass in the Bypass Mode by pressing the BYPASS pushbutton on the electronic bypass keypad. The BYPASS LED will light. Press the HAND button on the electronic 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 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 the rotational direction 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. Electronic Bypass Controller Installation and Commissioning Guide 15

Section 3 - Operation Precautions: 1. Motor rotation MUST be checked in both VFD and Bypass Modes. Failure to confirm rotation may cause severe damage to the electronic bypass, motor or its driven equipment. 2. Only turn ON the input power supply after closing the front door. 3. DO NOT touch the VFD 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 to observe these precautions may result in equipment damage, serious personal injury or death. 3.1 Keypad Operation WARNING 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. In Auto Mode, the user-supplied 4 20 ma speed reference is connected to speed reference input (M200 terminals 4-6, M400 terminals 5-6, H300 terminals 6 9). The electronic bypass keypad controls the start/stop of the VFD and bypass as well as reacting to user-supplied safeties, Fire Alarm input, Damper control, Fireman s Override, auto transfer to bypass on VFD fault and other features and functions detailed in this guide. 16 Electronic Bypass Controller Installation and Commissioning Guide

The photo below shows the respective keypad locations. VFD Keypad Electronic Bypass Keypad 3.1.1 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 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 sections of the electronic bypass keypad: 1. System status LEDs 2. HAND / OFF / AUTO buttons 3. TEST / VFD /BYPASS buttons 4. Alarm LED display Electronic Bypass Controller Installation and Commissioning Guide 17

Incoming Power 1 Select Operation Mode 3. 2. 2 Select Run Mode 1. Power On Input Contactor TEST VFD HAND AUTO RUN VFD Bypass Contactor BYPASS OFF RESET Output Contactor Press OFF/RESET once to cancel RUN mode Press OFF/RESET twice to cancel OPERATION mode Alarm Display M Motor (1) Overload External Safety Fire Alarm VFD Fault (1) Rest mechanical overload inside enclosure 4. 3.1.4 System Status LEDs The 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 Buttons The Select Start Mode section offers simple control of the type of operation using three (3) buttons: 1. Hand Mode (Local) Control via the bypass and VFD keypads 2. Auto Mode (Remote) Control via terminal connections 3. Off/Reset Mode Stops either Hand or Auto operation 18 Electronic Bypass Controller Installation and Commissioning Guide

3.1.6 TEST / VFD / BYPASS Buttons There are three (3) buttons used to select the three modes of operation available: 1. Test Mode Energizes the VFD input contactor only 2. VFD Mode Energizes the VFD input and output contactors 3. Bypass Mode Allows bypass operation 3.1.7 LED Alarm Display There 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, 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. Electronic Bypass Controller Installation and Commissioning Guide 19

Step 2 Select the start mode by pressing either the HAND or AUTO buttons. Selecting HAND allows an immediate start in VFD or Bypass Mode, whichever was previously selected. The RUN LED will illuminate at this time. Selecting AUTO will illuminate the AUTO LED. Run will not occur until the customer-supplied run contact closes between terminals TB2-5 and TB2-8 (AUTORUN and 24V common). The RUN LED will illuminate when the contact closes. 1. 2. Incoming Power 1 Select Operation Mode 2 Select Run Mode Power On TEST HAND RUN Input Contactor VFD AUTO VFD Output Contactor Bypass Contactor Press OFF/RESET once to cancel RUN mode Press OFF/RESET twice to cancel OPERATION mode Alarm Display BYPASS OFF RESET M Motor (1) Overload External Safety Fire Alarm VFD Fault (1) Rest mechanical overload inside enclosure 20 Electronic Bypass Controller Installation and Commissioning Guide

3.3 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. Incoming Power 1 Select Operation Mode 2 Select Run Mode Power On TEST HAND RUN Input Contactor VFD AUTO VFD Bypass Contactor BYPASS OFF RESET Output Contactor Press OFF/RESET once to cancel RUN mode Press OFF/RESET twice to cancel OPERATION mode Alarm Display M Motor (1) Overload External Safety Fire Alarm VFD Fault (1) Rest mechanical overload inside enclosure Electronic Bypass Controller Installation and Commissioning Guide 21

Section 4 Overview of the electronic bypass All start/stop, safety, and fire alarm inputs are routed to the electronic bypass control board via customer terminal connections. The VFD analog output is directly connected to the VFD control terminals. The electronic bypass control card is factory set to accept a sinking type (dry contact closure) type input. The analog input is factory set to accept a 4 20 ma speed reference signal. All control wiring must be run in a separate conduit from ANY high voltage or power wiring. The wiring should also be properly grounded and shielded when necessary to ensure proper operation. 4.1 Control Board The following sections describe the electronic 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 labeled TEST, VFD, BYPASS, HAND, AUTO, and OFF/RESET. Each button has an associated LED that indicates the state of that button s function. In addition, the keypad contains four alarm LEDs which indicate Motor Overload, External Safety, Fire Alarm and VFD Fault. The left-hand side of the keypad represents the bypass schematically, using 5 LEDS to indicate Power ON, Input Contactor (closed), Bypass Contactor (closed), Output Contactor (closed) and VFD enabled. Finally, a RUN LED located between the HAND and AUTO buttons gives an indication that the motor is running. 22 Electronic Bypass Controller Installation and Commissioning Guide

Electronic Bypass Control Functions Type Location Description Signal / Level Rating 5 120 Vac single phase (neutral) Input Power 120 Vac Single Phase 4 120 Vac single phase (hot) J10 1 Input Contactor Contactor Outputs 2 Bypass Contactor 3 Output Contactor 1 Motor Overload Input 24 Vdc upon overload 2 Drive Fault Input 24 Vdc upon fault 3 24 Vdc Common to VFD Drive common VFD Connections J11 4 Frequency Local/Remote 5 N/A 6 Run Command 7 VFD Reset 1 Power On Closes when power is applied 2 Power On 3 Fault Closes upon a fault condition 4 Fault Relay Outputs TB1 5 Damper Activates Damper Solenoid 6 Damper 7 Auto Closes when placed in Auto 8 Auto 1 Safety Tie 1 2 Safety Tie 2 3 Safety NC Contact 4 Customer Reset NO Contact Digital Inputs TB2 5 Auto Run NO Contact 6 Fire NC Contact 7 Fused 24 Vdc 8 24 Vdc Common Digital Input Common 1 Remote Bypass Remote Bypass Command 2 Remote VFD Remote VFD Command 3 Damper Feedback Feedback from end switch 4 Fireman s Override Digital Inputs TB3 5 N/A 6 N/A 7 N/A 8 Positive logic ON 24 Vdc Common Digital Input Common 24 Vdc Common Digital Input Common 24 Vdc Common Digital Input Common Power Supplies TB4 N/A Contactor Supply 115 Vac Tie 1 115 115 Vac to Contactors Vac Tie 2 115 Vac Tie (Hot) 115 Vac to Contactors 6 External Speed Reference H300 4-20 ma 9 Speed Reference Common 4 External Speed Reference Analog Input M200 4-20 ma 6 Speed Reference Common 6 External Speed Reference M400 4-20 ma 5 Speed Reference Common Electronic Bypass Controller Installation and Commissioning Guide 23

4.3 Using the Electronic Bypass Configuration Switches The bypass configuration switches are a group of four switches that are used to tailor the following: O N 1 2 3 4 Automatic Bypass Fire Alarm Damper Control Fireman s Override Note: ON disables function Switch 1: Enables or disables the automatic bypass function. With switch 1 in the ON position and the electronic bypass package operating in VFD Mode, a VFD fault will cause both the operation and run modes to be canceled (stopping the motor) and the VFD FAULT LED to illuminate in the Alarm Display. With switch 1 in the OFF position, a VFD fault will cause the bypass contactor to close, keeping the motor running on line power. As with the switch 1 ON configuration, the drive fault will be displayed in the Alarm Display. See section 3.8.2. Switch 2: Controls the bypass response to a fire alarm condition. The OFF (active) position equals Purge ; the ON position equals an All Stop position. The default ON position of switch 2 causes 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 fire alarm input is used. With switch 2 in the active OFF position, the bypass will attempt to run the system to destruction in the event of fire. Receiving a fire alarm signal in this mode will force the unit to bypass, causing the motor to operate off the AC line. The motor cannot be stopped locally or by external contacts in this mode. The keypad will appear to be locked out. Only cycling power to the bypass will return it to normal operation. Switch 3: Used in damper applications where it is required to make sure a damper has opened in order to run the motor. The default ON position of Damper Control (switch 3) disables damper mode. With the Damper Mode set in the enabled OFF position, when the motor is told to start (either on the VFD or by the bypass from the AC line) a 120 second timer is started. The bypass controller must see the customer 24 Electronic Bypass Controller Installation and Commissioning Guide

damper feedback contact closed (TB3-3) within that time to prevent the bypass controller from faulting and preventing motor operation. The bypass keypad will annunciate the faulted condition by flashing one or more of the button status LEDs that happened to be on at the time of the fault. The bypass controller can be reset by cycling the customer reset input, which will reset the 120 second timer and retry motor operation. Should the damper open initially, but sometime during operation the damper feedback is lost, the electronic bypass package will trip, stopping the motor. Switch 4: With the VFD and AUTO pushbuttons pressed on the bypass keypad, Fire Alarm (switch 2) and Fireman s Override (switch 4) OFF, upon opening the fire alarm input (TB2-6) the unit goes into Bypass Mode and the bypass keypad will indicate a Fire Alarm. A VFD fault will occur and the input contactor will drop out. Upon closing the fireman s override input (TB3-4), the unit will go to Bypass and Hand Mode. Re-closing the fire alarm input and then opening the fireman s override input (TB3-4) will put the package back into VFD + 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 Timer has timed out without feedback being received. In Fireman s Override Mode, if the fireman s override is enabled along with the Damper Control, at the end of the 120 seconds if there is no feedback from the Damper End switch, the unit goes into bypass and operates as described above. 4.4 Using the Additional Customer Inputs In addition to the inputs described in the preceding sections, there are three other customer inputs for use in specific applications. Safety input (TB2-3): is normally closed. Opening it causes the motor to stop under all conditions and will lock out all requests to start the motor. A LED in the Alarm Display annunciates the status of the safety input. If there are no safeties, a jumper must be installed between TB-s-3 and TB-2-8 to allow operation. To reset the electronic bypass package from a safety trip, the safety interlock must be re-closed and the customer reset input (TB2-4) or the bypass keypad OFF/RESET button must be cycled. Electronic Bypass Controller Installation and Commissioning Guide 25

Remote bypass input (TB3-1): can be used to override the keypad selections and force the electronic bypass into Bypass Mode from an external contact. Once this signal is removed, the electronic bypass will not return to its previous mode of operation without keypad interaction. Remote VFD input (TB3-2): works just like the remote bypass input by forcing the electronic bypass into VFD Mode. The electronic bypass will not return to its previous mode when the signal is removed. 4.5 Motor Overload Motor Overload is generated by the overload relay built into the electronic bypass. Should this relay operate, the motor will stop independent of its mode of operation. The motor cannot be restarted while the MOTOR OVERLOAD indicator is illuminated. Once the relay is reset, operation can be restored by reselecting a run mode from the keypad. 4.6 Failure and Power Off Conditions Should the electronic bypass control card fail such that it cannot process inputs, the control card has an alternative mechanism for controlling the bypass contactor. Jumpers 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. An interlock prevents the closing of the 3 contactors at once. In the event the bypass control board should lose power, its EEPROM memory retains the last operating configuration, which is restored on the next power-up. 4.7 Control Modes of the Electronic Bypass When power is initially applied, the green main POWER ON LED is illuminated and will remain on as long as power is connected. The OFF/RESET will be the only other LED illuminated. The input contactor remains OFF. The VFD will have no power and its display will remain blank. A VFD or bypass mode must first be selected, followed by a command in Start Auto or Hand Mode. 4.7.1 TEST mode In Test Mode the functionality of the VFD, external speed reference devices, and system setup characteristics can be read, set and modified. In Test Mode the input contactor is energized. Note that the Test Mode and Bypass Mode can be operated simultaneously if desired. To place the VFD package in Test Mode, press the TEST button. The TEST and INPUT CONTACTOR LEDs will be illuminated. 26 Electronic Bypass Controller Installation and Commissioning Guide

To exit the Test Mode, press the OFF/RESET button on the electronic bypass keypad. The VFD input contactor will open and the TEST and INPUT CONTACTOR LEDs will go out. 4.7.2 VFD mode In VFD Mode both the input and output contactors are energized. A Start command must exist before the VFD can operate. To place the VFD package in VFD Mode, press the VFD pushbutton. The VFD, INPUT and OUTPUT CONTACTOR LEDs will be illuminated. To exit the VFD Mode, press the OFF/RESET button on the electronic bypass keypad. The VFD, input and output contactor will open and their respective keypad LEDs will go out. 4.7.3 Bypass Mode In Bypass Mode the bypass contactor will be energized. A Start command must exist before the bypass contactor will close. To place the VFD package in Bypass Mode, press the BYPASS pushbutton. The BYPASS LED will be illuminated. Note that the Bypass Mode and 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 the VFD button. Then press the HAND button. The VFD, HAND, INPUT and OUTPUT CONTACTOR and RUN LEDs will be illuminated. Pressing the HAND button also creates an enable command for the VFD. The VFD must be started and stopped by the START/STOP buttons on the VFD keypad. Motor speed is controlled by the up and down arrow buttons on the VFD keypad. To place in Bypass Hand Mode, press the BYPASS button. Then press the HAND button. The BYPASS, HAND, BYPASS CONTACTOR and RUN LEDs will be illuminated. To exit the Hand Mode, press the OFF/RESET button once on the electronic bypass keypad. The HAND and RUN LEDs will turn off. Press the OFF/RESET button again and it will turn off either the VFD or BYPASS LEDs and open the respective contactors. Electronic Bypass Controller Installation and Commissioning Guide 27

4.7.5 Auto Mode In the VFD Auto (automatic) mode, a building automation system or other external device is required to supply start/stop and speed reference information to the electronic bypass package. During Auto Mode operation, the electronic bypass keypad remains enabled for stopping, operation mode and bypass selection functions. Auto Mode can control both VFD and bypass operation modes. To place in Auto Mode, press the VFD button. Then press the AUTO button. The VFD, AUTO and INPUT and OUTPUT CONTACTOR LEDs will be illuminated. The RUN LED will not illuminate until the user-supplied (TB2-5) run contact closes. Motor speed is controlled by the user-supplied 4 20 ma reference signal. See section 4.3 and 4.4 if a 0 10 Vdc reference is to be used. To place in Bypass Auto Mode, press the BYPASS button. Then press the AUTO button. The BYPASS and AUTO LEDs will be illuminated. The bypass contactor and RUN LEDs will not illuminate until the user supplied (TB2-5) run contact closes. To exit the Auto Mode, press the OFF/RESET button 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 - Emergency, manual bypass 4.8.1 MANUAL Bypass In the Manual Bypass Mode, the motor begins bypass operation immediately upon selecting Hand Mode or upon the user-supplied contact closure in Auto Mode. The motor will stay in bypass until the user chooses to leave either Hand or Auto Mode. Bypass is also available while in the Test Mode of operation. To place in Manual Bypass Mode, press the BYPASS button. When the BYPASS LED illuminates, press either the HAND or AUTO button. When the HAND button is pressed the bypass contactor will energize and the motor will immediately start across the line. When the AUTO button is pressed, the bypass contactor will not energize until the user-supplied (TB2-5) run contact is closed. The bypass contactor will then energize and the motor will immediately start across the line. To exit the Bypass Mode, Press the OFF/RESET button on the electronic bypass keypad. 28 Electronic Bypass Controller Installation and Commissioning Guide

4.8.2 Automatic Bypass on VFD Fault In the Automatic Bypass on VFD Fault Mode of operation, when the electronic bypass control board senses a VFD fault it will automatically switch the motor to Bypass operation. This function is enabled by DIP switch 1, position 1, placed in the OFF position. Automatic Bypass will operate in both the VFD Auto and the VFD Hand Modes of operation. The functionality in each mode is exactly the same. CAUTION: Use caution when selecting this mode as the motor will accelerate to full speed anytime the VFD experiences any type of fault condition. 4.8.3 Emergency Bypass In the unlikely event of a failure of the electronic bypass control board, an emergency bypass jumper may be repositioned to enable the electronic bypass to be operated as a full voltage fixed speed starter. The emergency bypass jumper is located on the component side of the door-mounted control board. To change 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 immediately energized closing the contactor and starting the motor at full across-the-line voltage. The motor thermal overload protection is disconnected in this mode. To exit Emergency Bypass, turn the door interlocked disconnect to the OFF position. Power to the bypass contactor coil will be removed and the contactor will open disconnecting the motor. Remove the control board from the door and move jumper J6 from the emergency position to the open position. Close the enclosure door and place the door interlock in the ON position. Control will be returned to the control board for VFD or bypass operation. When in Emergency bypass mode the motor thermal overload relay is disconnected and will not protect the motor from an overload condition. Damage to the motor may occur. Electronic Bypass Controller Installation and Commissioning Guide 29

Section 5 - Programming 5.1 Required Programming The following parameters must be set to the values shown in order to ensure proper operation of the electronic bypass package. The Menu 0 Equivalent parameters apply to the H300 only. These settings are pre-programmed from the factory. DO NOT change any of these values unless directed to by Nidec technical support. Note these parameters should be programmed in the sequence shown. Parameter Menu 0 Equivalent Description For H300 Setting Fan Pump 01.014 Reference 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 Units 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/destination 10.033 10.033 menu.param 08.023 Digital I/O 3 source/destination 06.030 06.030 menu.param 08.024 Digital I 4 destination 01.054 01.054 menu.param 08.025 Digital I 5 destination 01.041 01.041 menu.param 09.004 Logic function 1 source 1 08.003 08.003 menu.param 09.006 Logic function 1 source 2 08.006 08.006 menu.param 09.010 Logic function 1 destination 01.043 01.043 menu.param 30 Electronic Bypass Controller Installation and Commissioning Guide

5.2 Recommended Programming Following is a list of parameters that should be programmed at the time of start-up. These values are recommendations only, actual settings should be determined by the application requirements, conditions, and the policies of the equipment owners. Refer to the respective drive User Guide for a full parameter list and explanation. Parameter Menu 0 Equivalent Description Setting Fan Pump 01.006 00.011 Max. Speed Hz 60 60 Hz 01.007 00.010 Min Speed Hz 15 6 Hz Units 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 optimize select OFF OFF - 06.009 00.023 Catch a spinning motor 1 1-07.019 - Analog output 1 source 05.001 05.001 menu.param 08.011 Digital I/O 01 1 1 Invert 08.021 - Digital I/0 01 Source Destination 10.001 10.001 Drive OK 11.044 00.031 Security status (1) (1) - Electronic Bypass Controller Installation and Commissioning Guide 31

Section 6 - Alarm & Faults There are two different locations a fault or alarm will be displayed: 1. The electronic bypass keypad 2. The VFD keypad 6.1 Electronic Bypass Keypad Alarms and Faults Incoming Power 1 Select Operation Mode 2 Select Run Mode Power On TEST HAND RUN Input Contactor VFD AUTO VFD Bypass Contactor BYPASS OFF RESET Output Contactor Press OFF/RESET once to cancel RUN mode Press OFF/RESET twice to cancel OPERATION mode Alarm Display M Motor (1) Overload External Safety Fire Alarm VFD Fault (1) Rest mechanical overload inside enclosure There are four (4) Alarm LEDs on the electronic bypass keypad indicating the faults that may occur. They are as follows: 1. Motor Overload: Indicates that the manual motor overload relay has tripped. Check that overload relay is properly set for motors 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. 32 Electronic Bypass Controller Installation and Commissioning Guide

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 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 including possible causes and remedies. Electronic Bypass Controller Installation and Commissioning Guide 33

Section 7 - Additional Information 7.1 Specifications Electronic Bypass The electronic bypass package features a user friendly application-specific keypad to simplify operation and provide status indication. Approvals: VFD Section UL508C Bypass Section UL508A Design: 3 contactor bypass NEMA 1 enclosure Electronic bypass keypad / annunciator 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 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 control 34 Electronic Bypass Controller Installation and Commissioning Guide

Operating conditions: Altitude: to 3,300 ft, higher with derating Ambient operating temp: +32 to +104 F (0 to +40 C) Storage temp: -40 to +140 F (-40 to +60 C) 95% relative humidity, non-condensing Input voltage: +10%, -10%; 208, 230 and 460 Vac Protected from exposure to direct sunlight Options: Input fused disconnect Input circuit breaker Input or output reactors Multiple motor overloads Input RFI filter Ethernet 7.2 Maintenance & Inspection This section describes the basic periodic maintenance and inspection procedures for the electronic bypass. CAUTION! To prevent electrical shock and damage, disconnect all power before servicing the electronic bypass package. Then wait at 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 Corrective Action External terminals, connectors, Loose screws or Secure / tighten. mounting screws, etc. connectors. Heat sink Build-up of dust and dirt. Blow with dry compressed air (4 to 6kg-cm 2 pressure). Printed Circuit Board (PCB) Accumulation of Blow with dry compressed conductive dust or oil. air (4 to 6kg-cm 2 pressure). If dust cannot be removed, replace the board. Cooling fan For abnormal noise and vibration. Replace the cooling fan. Power components Accumulation of dust and dirt. Blow with dry compressed air (4 to 6kg-cm 2 pressure). Electronic Bypass Controller Installation and Commissioning Guide 35

7.3 Start-up Checklist Electronic Bypass WARNING Motor rotation MUST be checked in both VFD and Bypass modes. Failure to confirm rotation may cause severe damage to the electronic bypass, motor or its driven equipment. Date (dd/mm/yyyy): Emerson Order #: Customer: Attn: Project Name: Site Contact: Drive Model Number: Package Model Number: Customer PO#: Phone/Fax/eMail Site Address: Contact Phone: Drive Serial Number: UL Number: Motor rotation MUST be checked in both VFD and Bypass modes. Failure to confirm rotation may cause severe damage to the electronic bypass, motor or its driven equipment. Pre-Power Checks Confirm proper operating voltage: 208 V 230 V 460 V Drive mounted (per instruction manual): YES NO Check all connections for loose wiring or terminations caused during 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 M200 terminals 4-6, M400 terminals 5-6; H300 terminals 6-9 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 and TB2-8: YES NO Factory jumper connected between TB4-5 & TB4-8: YES NO Power-Up Checks (Close enclosure door and disconnect / circuit beaker) Input wiring to drive (in separate conduit): YES NO Output wiring to drive (in separate conduit): CW CCW Ground wire from AC mains ground to drive: CW CCW Ground wire to motor from drive: YES NO Power ready to be energized to drive: YES NO 36 Electronic Bypass Controller Installation and Commissioning Guide

7.4 Startup Checklist VFD Date (dd/mm/yyyy): Emerson Order #: YES NO Power On LED illuminated YES NO Motor rotation in VFD Mode is correct YES NO Motor rotation in Bypass Mode is correct YES NO Motor rotation same in VFD and Bypass (Motor rotation must be correct or damage can occur!) YES NO Automatic controls functional YES NO Unit ready for startup with all connections made and control interface, power and load available? YES NO Enclosure inspected for shipping damage, physical integrity; door, latch and lock operation? YES NO Line and motor power connections tight and made to proper terminals with satisfactory clearances? YES NO Control wiring present and made to proper 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 settings, and purchased options setup completed? YES NO Line voltage and current Motor nameplate Line Voltage & Current Motor Nameplate V L12 : V L23 : V L31 : Hp: FLA: PF: I L1 : I L2 : I L3 : RPM: LR Code: Eff: Parameters changed from factory default and new value: Par Value Par Value Par Value YES NO After all parameters are set, save them by entering 1000 at parameter X.00 and hit Off/Reset YES NO Save parameters to SmartCard by entering Prog at parameter 0.030 and hit Off/Reset Comms Address: Comments: Start-up Checklist completed by: Date (dd/mm/yyyy): Electronic Bypass Controller Installation and Commissioning Guide 37

7.5 Startup for Cooling Tower - Fan and/or Pump Applications Task Parameter # Menu 0 Fan Pump Action Parameter Notes Parameter # Settings Settings Minimum Speed 1.007 0.01 15Hz 30-45Hz Press M For Marley Towers with Gearreducer, you can set this at 0Hz. Otherwise, fan may run at 15 Hz if no sleep/wake mode, or run signal interruption occurs. Pump Min Speed will be dependent on Pump Manufacturer. Check with equipment manufacturer when in doubt Accel Rate 2.011 0.012 100-300 16.7 Press M Fan Accel is dependent on HP and load. Cooling Tower recommended to be 120 Decel Rate 2.021 0.013 100-500 16.7 Press M Fan Decel is dependent on HP and load. Too low of a Decel Rate can result in a DC Bus Overvoltage trip on large fans. Cooling Tower recommended to be 120 Volt Mode Select 5.014 0.014 Fixed Fixed Press M Use Sre if OV faults persist after adjusting Decel rate Low Frequency 5.015 0.016 0.5 0.5 Press M Voltage Boost Dynamic V/F Flux 5.012 0.015 On On Press M optimize Insert Motor RPM 5.008 0.019 Motor RPM Motor RPM Press M Read Motor Name plate (ie. 1755?) - Put in Sync Speed Insert Motor FLA 5.007 0.02 Motor FLA Motor FLA Press M Read Motor Name Plate Amps Maximum Switching Frequency 5.006 0.021 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 11.042 0.033 Prog Prog Smart Card Set Date 6.016 0.034 mm/dd/yy mm/dd/yy Press M Set Time 6.017 0.035 HH.MM HH.MM Press M This is in Military Time Set Date & Time 6.019 0.037 Set Set Press M Allows inputting of Date & Time Turn off Set Date & Time set ability 0.037 Local Menu Local Menu Press M This makes 0.034 & 0.035 read only Set Auto Reset 10.034 0.048 5 5 Number of attempts after trip Set Auto Reset delay 10.035 0.049 10 10 Time delay between attempts to 10 seconds Controller Gain - Kp 4.013 50 50 Controller Gain - Ki 4.014 5 5 Thermal Protection Mode 4.016 On Off (Default) Speed Fold-back on Current Limit Full Power Breaking 10.03 0 0 To disable It.Br fault Time Full Power Breaking 10.031 0 0 Period Save Advanced 10 1000 1000 Menu Parameters Saves Parameters to Secure Location on SmartCard 10 3100 3100 Can extract Parameters by setting 6100 in Pr XX.00 Maintenance: Read last 10 faults 10.020-10.029 0.050-0.059 Most recent trip is P0.050 Date & Time Stamp for last 10 faults 10.041-10.060 0.60-0.79 Most recent date/time stamp is P0.060 & P0.061 Menu 0 Parameters for use with HVAC Drive H300 only. 38 Electronic Bypass Controller Installation and Commissioning Guide

Electronic Bypass Controller Installation and Commissioning Guide 39

www.nidecautomation.com 2017 Nidec Industrial Automation USA, LLC. The information contained in this manual is for guidance only and does not form part of any contract. The accuracy cannot be guaranteed as Nidec Industrial Automation USA, LLC have an ongoing process of development and reserve the right to change the specification of their products without notice. Nidec Industrial Automation USA, LLC. Registered Office: 7078 Shady Oak Road Eden Prairie, MN 55344-3505 USA.