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Fpc5010s - Smart Bypass Instruction Manual

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www.saftronics.com FPC5010S HVAC-VFD Harmonic Control INSTRUCTION MANUAL REV 0102 P/N 027-2113 2002 Saftronics Safety and Precautions www.saftronics.com ! WARNING 1. Read this manual in its entirety before installing or operating the FPC5010S. This manual applies to systems with the Saftronics GP10 inverter and control board part numbers 100-0148-02 / 03G with software version 1.02 installed 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 inverter may be charged even after the power supply has been turned OFF. To prevent electrical shock, disconnect all power before servicing the FPC5010S. Please wait 5 minutes after the power supply has been disconnected and all LED’s have been extinguished. 4. Do not perform a voltage withstand test on the FPC5010S or the installed VFD. This electronic equip ment uses semi conductors 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 FPC5010S is suitable for use on a circuit capable of delivering not more that 65,000 RMS symmetrical amperes, 480 Volts maximum (460 Volt Class units), 240 volts maximum (230 Volt class units). 7. Several printed circuit boards are installed in the FPC5010S. Damage may occur due to ESD Electro static Discharge. 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 the proprietary property of Saftronics, Inc. and may not be copied, reproduced or transmitted to other parties without the expressed written consent of Saftronics inc. No patient liability is assumed with respect to the use of information contained herein. Moreover, because Saftronics 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, Saftronics assumes no responsibility for errors or omissions. Neither is liability assumed for damages resulting from the use of the information contained in this publication. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 1 Table of Contents www.saftronics.com Table of Contents Safety and Precautions Chapter 1 - Introduction ................................................................................................ 5 Chapter 2 - Start-up ....................................................................................................... 6 2.1 Start-up Checklist .................................................................................................. 6 2.2 Quickstart .............................................................................................................. 8 2.2.1 Starting Operation ...................................................................................... 9 2.2.2 Ending Operation ....................................................................................... 9 2.3 Understanding the Control Board ......................................................................... 10 Chapter 3 - Installation Instructions ........................................................................... 13 3.1 Receiving ............................................................................................................ 13 3.2 Nameplate Information......................................................................................... 13 3.3 Part Number Identification ................................................................................... 14 3.4 Mounting & Clearances ....................................................................................... 15 3.5 Inspection ............................................................................................................ 16 3.6 Wiring ................................................................................................................. 16 3.6.1 Input Wiring ............................................................................................... 16 3.6.2 Output Wiring ............................................................................................ 17 3.6.3 Control Circuit Wiring................................................................................ 18 3.7 Checking Motor Rotation ..................................................................................... 24 3.7.1 Check #1: Rotation on VFD power ........................................................... 24 3.7.2 Check #2: Rotation on Bypass power ....................................................... 24 Chapter 4 - Overview of the FPC5010S ..................................................................... 25 4.1 Control Board ...................................................................................................... 25 4.2 Control Board Function Summary ........................................................................ 26 4.3 Application Modes of the FPC5010S .................................................................. 29 4.3.1 FAN Mode ................................................................................................ 31 4.3.2 PUMP Mode ............................................................................................. 34 4.3.3 COOLING TOWER Mode ......................................................................... 36 4.4 Control Modes of the FPC5010S ........................................................................ 38 4.4.1 AUTO Mode ............................................................................................. 38 4.4.2 TEST Mode .............................................................................................. 38 4.4.3 HAND Mode ............................................................................................. 39 4.5 Bypass Modes of the FPC5010S ........................................................................ 39 4.5.1 MANUAL Bypass ...................................................................................... 39 4.5.2 SMART Bypass ........................................................................................ 40 4.5.3 EMERGENCY Bypass .............................................................................. 40 4.6 Communication Protocols ................................................................................... 41 4.6.1 Metasys .................................................................................................... 44 4.6.2 Modbus .................................................................................................... 45 Chapter 5 - Programming ........................................................................................... 46 5.1 VFD / GP10 Required Programming ................................................................... 46 © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 3 Table of Contents www.saftronics.com 5.2 FPC5010S Parameter ........................................................................................ 46 5.2.1 Basic Parameters .................................................................................... 47 5.2.2 System Parameters .................................................................................. 50 5.2.3 Real time clock / History............................................................................ 53 5.3 PID ................................................................................................................. 53 Chapter 6 - Operation .................................................................................................. 56 6.1 Using the keypad ................................................................................................. 57 6.1.1 VFD Keypad ............................................................................................ 58 6.1.1.1 Appearance of Keypad Panel .................................................................. 58 6.1.1.2 Operation from the Keypad Panel ............................................................ 59 6.1.1.3 Entering Data on the Keypad Panel ......................................................... 61 6.2 HVAC Keypad ..................................................................................................... 73 6.2.1 Keypad Layout ......................................................................................... 73 6.2.2 System status LED’s ................................................................................ 74 6.2.3 VFD Hand / OFF / Auto, and Test buttons .................................................. 74 6.2.4 Bypass control buttons .............................................................................. 74 6.2.5 HVAC specific faults LED display ............................................................. 74 6.3 Starting Operation ............................................................................................... 75 6.4 Ending Operation ................................................................................................ 75 Chapter 7 - Saflink ....................................................................................................... 76 7.1 Installation ........................................................................................................... 76 7.2 Connecting .......................................................................................................... 77 7.3 Starting ................................................................................................................ 77 7.4 Using Saflink ....................................................................................................... 80 7.5 Learning more about Saflink ................................................................................ 82 Chapter 8 - Alarm & Faults .......................................................................................... 84 8.1 HVAC Keypad Alarms and Faults ........................................................................ 84 8.2 VFD Alarms and Faults ....................................................................................... 86 Chapter 9 - Appendix ................................................................................................... 88 9.1 Specifications...................................................................................................... 88 9.1.1 FPC5010S ............................................................................................... 88 9.1.2 GP10 Specifications ................................................................................. 90 9.2 Electrical Drawings ............................................................................................. 97 9.2.1 FPC5010S Logic Diagram ....................................................................... 97 9.2.2 FPC5010S Customer Connections .......................................................... 98 9.3 Layout and Dimensions ....................................................................................... 99 9.3.1 Nema 1 Enclosures .................................................................................. 99 9.3.2 Nema 12 / 3R Enclosures ....................................................................... 105 9.4 Maintenance & Inspection .................................................................................. 111 9.4.1 Daily Inspections..................................................................................... 111 9.4.2 Periodic Inspections ............................................................................... 111 9.5 Main Circuit Measurements ............................................................................... 114 9.6 Insulation Test .................................................................................................... 115 9.7 Replacement Parts ............................................................................................ 115 9.8 Warranty Service ............................................................................................... 116 4 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 1 - Introduction www.saftronics.com Chapter 1 - Introduction Thank you for purchasing the Saftronics FPC5010S Smart bypass HVAC controller. The FPC5010S is a complete integrated HVAC control system, that employs the latest technology in Variable Frequency Drives and incorporates a dedicated micro-processor based controller for HVAC applications. The FPC5010S controller uses a dedicated HVAC keypad that clearly shows system operating conditions and HVAC specific alarm status. The FPC5010S is designed for ease of installation and start-up. All control wiring and serial communication for energy management systems is landed on a common control board located in the bypass enclosure. The control card has 3 preset macro programs that pre-configure the FPC5010S to fit your application. An extensive list of I/O options insures all you system requirements are addressed without the need for extra equipment. The following list provides a brief overview of the I/ O specifications. · · · · · 8 Digital Inputs ( 120VAC, 24VDC or Contact input) 5 Form “C” Relay Outputs rated @ 250V, 10A 2 Analog Inputs ( 0 – 10 VDC or 4-20 mA) 2 Analog Outputs ( 0 – 10 VDC or 4-20 mA) Multiple serial ports Please follow the instruction manuals guidelines for proper installation and programming of the FPC5010S controller. GP10 VFD Bypass Enclosure HVAC Keypad © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 5 Chapter 2 - Start-Up www.saftronics.com Chapter 2 - Start-up 2.1 Start-up Checklist ! WARNING Motor rotation MUST be checked in both VFD and Bypass modes. Failure to confirm rotation may cause severe damage to the FPC5010S, motor or its driven equipment. 1. 2. 3. 4. Application Mode Direction of Rotation Digital input Digital output 5a. Analog input / AIN0 Fan DIP1/OFF, DIP2/OFF Pump DIP1/ON, DIP2/OFF Cooling Tower DIP1/ON, DIP2/ON VFD: CCW CW Bypass: CCW CW Dry Contact JP24-JP31 = OFF, JP8 & JP32 = ON 24Vdc JP24-JP31 = OFF, JP8 & JP32 = OFF 120Vac JP24-JP31 = ON, JP8 & JP32 = OFF R3 Run R4 Not programmed 0-10Vdc JP12, OFF= 0 – 10 Vdc 4-20 mA JP12, ON = 4-20 mA SAFLINK Programmed to match signal 6 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 2 - Start-Up www.saftronics.com 5b. Analog input / AIN1 0-10Vdc JP13, OFF = 0 – 10 Vdc 4-20 mA JP13, ON = 4-20 mA SAFLINK Programmed to match signal 6a. Analog output / AO0 0-10Vdc JP17, PIN 2&3 = 0 – 10 Vdc 4-20 mA JP17, PIN 1&2 = 4-20 mA SAFLINK Programmed to match signal 6b. Analog output / AO1 0-10Vdc JP23, PIN 2&3 = 0 – 10 Vdc 4-20 mA JP23, PIN 1&2 = 4-20 mA SAFLINK Programmed to match signal 9. Fan Mode / Fire Alarm Zero Speed DIP4 = OFF Purge DIP4 = ON NOTES: © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 7 Chapter 2 - Start-Up www.saftronics.com 2.2 Quickstart There are two keypads located on every FPC5010S integrated VFD system. VFD Keypad FPC5010S keypad VFD Keypad The keypad on the VFD is primarily used for monitoring purposes as limited programming is available for the VFD from this location Reference: See section 6.1.1 for more information. FPC5010S Keypad Complete control and application specific diagnostics of the FPC5010S is available via the FPC5010S keypad. Reference: 8 See section 6.1.2 for more information. FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 2 - Start-Up www.saftronics.com 2.2.1 Starting Operation There are two (2) basic steps required to begin operation. 1. Select a control mode by pressing as shown below. 2. Select a mode of bypass operation (optional) 2.2.2 Ending Operation There are two (2) options available for ending operation. 1. Press ‘VFD OFF’- Cancels both control mode and method of bypass. 2. Press ‘Bypass OFF’ – Cancels bypass selection only allowing the user to remain in the selected control mode. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 9 Chapter 2 - Start-Up www.saftronics.com FPC5010S Control Board The main control board is located in the bottom of the bypass enclosure. A door interlocked disconnect is installed on every unit. Reference: See section 4.1 for more information 2.3 Understanding the control board The following is a description of the FPC5010S control board configurable characteristics. DIP switch and jumper settings are required to properly configure the FPC5010S. All jumpers and switches are located on the control board which is in the lower cabinet. 1. Control Mode selection (SW1) 2. Digital Inputs (J13) 3. Digital / Relay Outputs (J14) 4. Analog Inputs (J12) 5. Analog Outputs (J12) 6. Saflink connection (J10) 7. Metasys /Modbus connection (J12) 2. 3. 7. 5. 4. 6. 1. 10 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 2 - Start-Up www.saftronics.com Step 1: Select an Application mode Fan Dip 1 = OFF, Dip 2 = OFF Pump Dip 1 = ON, Dip 2 = OFF Cooling Tower Dip 1 = ON, Dip 2 = ON The default Application mode is the Fan Mode. When power is initially applied to the unit, the “ Freez-Stat” fault light will be illuminated and operation will be prohibited. The control board is expecting a contact closure on terminal P4 and P5 (Damper and Freez-Stat) respectively. Action: Connect damper and freez-stat or Install jumpers (2) on terminals P4 and P5 to 33VAC or Change Application mode to Pump or Cooling Tower. Start Operation: Reference: You are now able to run the FPC5010S by pressing; 1. ‘HAND’ on FPC5010S keypad. 2. Up / Down Arrow key to set speed reference. See section 4.3 for more information. Step 2: Check direction of rotation Motor rotation must be checked in both VFD and Bypass modes. Reference: See section 3.7 for more information. Step 3: Configure Digital Inputs The digital inputs can be configured to respond to Dry contacts (sink), 24 Volts DC or 120 Volt AC (source). Dry Contacts JP24-JP31 = OFF, JP8 & JP32 = ON 24 Vdc JP24-JP31 = OFF, JP8 & JP32 = OFF 120 Vac JP24-JP31 = ON, JP8 & JP32 = OFF Reference: See section 3.6.3 for more information. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 11 Chapter 2 - Start-Up www.saftronics.com Step 4: Configure Digital / Relay Outputs There are a total of five (5) relay outputs on the FPC5010S, two (2) of which are 100% Saflink programmable with no jumper setting changes required. Reference: See section 3.6.3 for more information. Step 5: Configure Analog Input settings There are two configurable analog inputs on the FPC5010S. AIN0 and AIN1. Connect external speed reference or PID setpoint to AIN0. AIN1 is the PID feedback connection. AIN0 / JP 12 ON = 4-20 mA OFF= 0 – 10 Vdc AIN1 / JP 13 ON = 4-20 mA OFF= 0 – 10 Vdc NOTE: If analog inputs / jumper positions are changed as described above. Saflink must also be used to program the control board so that the values are scaled properly. Reference: See section 3.6.3 for more information. Step 6: Analog Output settings There are two configurable analog outputs on the FPC5010S. AO0 and AO1. AO0 / JP23 PIN 1&2 = 4-20 mA PIN 2&3 = 0 – 10 Vdc AO1 / JP17 PIN 1&2 = 4-20 mA PIN 2&3 = 0 – 10 Vdc Reference: See section 3.6.3 for more information. Step 7: Connect Saflink Connection Changes to the input and output settings are accomplished via the Saflink software supplied with the FPC5010S. Saflink is a windows based user interface which is shipped on a CD with a serial cable unique to the FCP5010S. Locate and install on a laptop. Reference: See section 7.2 for more information. Step 8: Metasys / Modbus Interface Metasys connections are made on terminal J12 as show below. Jumpers are connected on terminals TSE+ to TRE+ and TSE- to TRE-. Reference: 12 See section 4.6 for more information. FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 3 - Installation Instructions www.saftronics.com Chapter 3 - Installation Instructions 3.1 Receiving After unpacking the FPC5010S: · Verify that the part numbers on the package match the numbers on your purchase order, packing slip or tagging information. · 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 Saftronics representative immediately. · Verify that all internal hardware (i.e. components, wires, screws, etc.) is properly seated and fastened securely. 3.2 Nameplate Information The FPC5010S units have two nameplates for unit identification. The main label is located on the inside cover of the enclosure door. This nameplate supplies information on the entire unit. The second nameplate is located on the side of the inverter unit. This nameplate contains information related to the inverter only. The nameplate information should be recorded and kept with the unit. This information is required for any service or repair work. Black Label Information © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 13 Chapter 3 - Installation Instructions www.saftronics.com Drive Label information SER. No. : 0 1 1 0 - 0 0 0 1 2 M 0 0 01 GP10 Model No. Serial No. Production lot serial number Input Output VT Volts Amps Freq(Hz) Phase(s) NEMA Enclosure Type: Instruction Book CT Production week: Fiscal week (01 to 53) HP Volts Freq. Range (Hz) Amps Overload Production year: Last two digits of year (00 = 2000) Made in Mexico 3.3 Part Number Identification S N X X X X - X X X - X X X X X X X Product S = FPC Series Style N = FPC5010S Voltage Rating 8 = 208V 2 = 230V 4 = 460V Horsepower Rating P50 = 0.50 001 = 1 002 = 2 003 = 3 005 = 5 7P5 = 7.5 010 = 10 015 = 15 020 = 20 025 = 25 030 = 30 040 = 40 050 = 50 060 = 60 075 = 75 100 = 100 125 = 125 150 = 150 (208 / 230V Max) 200 = 200 250 = 250 300 = 300 350 = 350 400 = 400 450 = 450 500 = 500 600 = 600 700 = 700 800 = 800 14 (1) Input or output reactors are supplied loose (Field installed) in NEMA 1 enclosures. 208/230V (50-60HP), 460V (100-150HP) NEMA 1 packages only. (2) Output reactors are supplied loose (Field installed) in NEMA 1 enclosures. NEMA 1 packages only. (3) Communications options are mutually exclusive. (4) Reduced Voltage Bypass 208/230V 50HP and higher, 460V 100 HP and higher. For smaller ratings consult factory. FPC5010S HVAC Instruction Manual Options A = NEMA12 B = NEMA3R D = Duplex (Alternator) J = Johnson (Metasys N2) (3) L = LON Works Pending (3) M = MODBUS (Standard) (3) P = Speed Potentiometer 1 = Automatic Bypass 3 = 3-15 psi Pneumatic Input Overloads S = Single (Class 20) D = Dual (Class 20) Filtering 0 = No Filtering 1 = Input Line Reactor (3%) (1) 2 = Input RFI Filter 3 = Input Line Reactor (3%) (1) and Input RFI Filter 4 = Input Line Reactor (5%) (1) 5 = Input Line Reactor (5%) (1) and Input RFI Filter 6 = Output Reactor (3%) (1) 7 = Input Reactor (3%) and Output Reactor (3%) (2) 8 = Input Reactor (5%) and Output Reactor (3%) (2) 9 = Input Reactor (3%) and Input RFI Filter & Output Reactor (3%) (2) A = Input Reactor 5% and Input RFI Filter & Output Reactor (3%) (2) B = Input RFI Filter and Output Reactor (3%) (1) Input Power Disconnect 0 = None 1 = Circuit Breaker 2 = Non-Fused Disconnect 3 = Fused Disconnect 4 = Input Fuses 5 = Circuit Breaker & Input Fuses © 2002 Saftronics, Inc. Chapter 3 - Installation Instructions www.saftronics.com 3.4 Mounting & Clearances Install the FPC5010S unit on a vertical surface and allow the following minimum clearances to allow normal heat dissipation. Notes: · · · · · · Ambient operating temperature; 14°F to 122°F ( -10°C to 50°C) Install the unit in a location free from oil mist and dust. Install the unit in a location free from radioactive materials, combustible materials, harmful gasses or liquids. Do not install the unit in a location susceptible to excessive oscillations. Do not install the inverter in direct sunlight During installation, protect the unit from foreign particles such as metal shavings produced by drilling. 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 terminals L1, L2 and L3 on the terminal block located at the bottom of the bypass enclosure. DO NOT connect power supply wiring to output terminals T1, T2 and T3. 3. Connect the motor wiring to the terminal block located at the bottom of the bypass enclosure. DO NOT connect motor wiring to the VFD output terminals T1, T2 and T3. 4. Never touch the output circuit directly or place the output line in contact with the package enclosure. 5. Do not connect a phase advancing capacitor to the output circuit. 6. Power supply wiring and motor wiring must be in separate conduits with separate ground conductors. (Conduits shall not be used 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. Please observe National and Local codes when wiring electrical devices. Failure to observe these precautions may result in equipment damage or improper operation. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 15 Chapter 3 - Installation Instructions www.saftronics.com 3.5 Inspection After wiring completely, verify that: All wiring is correctly installed. Excess screws and wire clippings are removed from inside of the unit. Screws are securely tightened. Exposed wire has no contact with other wiring or terminals. 3.6 Wiring 3.6.1 Input Wiring The FPC5010S unit 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 branch circuit protection of the appropriate size and location is observed. The following input options are available. · · · · · · No input device Input fusing Non- Fused Disconnect Fused Disconnect Circuit Breaker Circuit Breaker w/ Fusing Connect the main power supply per the following diagrams. The phase sequence to the unit is irrelevant to output phase sequence of the inverter. The phase sequence of the bypass must be the same as the output of the inverter. Input Power Connection Drawings 16 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 3 - Installation Instructions www.saftronics.com 3.6.2 Output Wiring The FPC5010S unit is always supplied with a Class 20 Motor O/L on the output of the unit. However, the unit may be supplied with several different output options. The following output options are available. · Dual Motor Overload · Output Reactor · Dual Motor Overload with Output Reactor Connect the Motor leads to the unit per the following diagrams. Output Wiring Drawings Surge Suppressor All contactors and relays supplied in the FPC5010S package are suppressed. If adding additional inductive loads (i.e. magnetic contactors, magnetic relays, magnetic valves, solenoids, magnetic brakes, etc.) in or near the FPC5010S package use a surge suppressor across the coils to limit potentially damaging voltage transients on the supply lines. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 17 Chapter 3 - Installation Instructions www.saftronics.com 3.6.3 Control Circuit Wiring NOTE: Field connections are to be made only to the FPC5010S control board located in the bypass enclosure control board ONLY, and at the locations shown below. Connections to the GP10 are not normally required. Consult factory prior to making connections to the GP10. The control circuit of the FPC5010S is configurable by a combination of Pin / Jumper settings and software parameter settings. See Chapter 6 for details on using SAFLINK to complete the software setup. Refer to the table on page 3-2 for terminal block locations and page 3-5 for Jumper locations and orientations. Analog Input Terminal Block Connection Jumper Function Voltage 0-10VDC Milliamps** 4-20mA AIN0 GND JP-12 Speed Ref/PID Setpoint O X AIN1 GND JP-13 PID FDBK O X +15V E-pot GND N/A Ref. Supply Speed Ref Ground N/A N/A J-12 J-5 ** Default Setting O = Open, / Jumper not installed X = Shorted / jumper installed Terminal J-12 AINO Analog Input 0 This input is used to control the speed of the motor from an external source. The factory default for the analog inputs are 4-20 mA, however this may be changed to 0-10 VAC. This input is also used as the set point if the PID loop is active. AIN1 Analog Input 1 This input is used as the PID feedback input . The factory default for the analog inputs are 4-20 mA, however this may be changed to 0-10 VDC. GND This is the “common” connection for the analog inputs AIN0 and AIN1. Terminal J5 +15VDC E-Pot GND 18 These terminals are used to connect the door mounted speed pot if this option is supplied. FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 3 - Installation Instructions www.saftronics.com Analog Input Jumper locations AIN0 / JP 12 ON = 4-20 mA OFF= 0 – 10 Vdc AIN1 / JP 13 ON = 4-20 mA OFF= 0 – 10 Vdc NOTE: If analog inputs / jumper positions are changed as described above. Saflink must also be used to program the control board so that the values are scaled properly. JP23/AO0, JP17/ AO1 3 2 1 JP13/AIN1, JP12/AIN0 3 2 1 Analog Output Jumper Locations AO0 / JP23 PIN 1&2 = 4-20 mA PIN 2&3 = 0 – 10 Vdc AO1 / JP17 PIN 1&2 = 4-20 mA PIN 2&3 = 0 – 10 Vdc Connection Function Terminal Block Jumper AO0 GND JP-23 AO1 GND JP-17 J-12 Voltage 0-10VDC Milliamps* 4-20mA Pins 2-3 Pins 1-2 2-3 1-2 Output Frequency Output Current Output Voltage Frequency Reference Output Frequency Output Current Output Voltage Frequency Reference * Default setting Pin designations are indicated on the control board connection diagram. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 19 Chapter 3 - Installation Instructions www.saftronics.com Terminal J12 AO0 Analog Output 0 This is the output signal proportional to Output Frequency, Output Current, Output Voltage or Frequency Reference. The factory default for the analog inputs are 4-20mA, however this may be changed to 0 –10VDC. AO1 Analog Output 1 This is the output signal proportional to Output Frequency, Output Current, Output Voltage or Frequency Reference. The factory default for the analog inputs are 4-20mA, however this may be changed to 0 –10VDC. Digital Input Terminal Block J-13 Connection Function Description P1 Auto Run External Run Command P2 Reser ved Reser ved P3 Motor O/L External Motor Overload P4 ** ** P5 ** ** P6 ** ** P7 Local/Remote Changes Reference from Local to Remote, Auto Mode Only P8 Fault Reset Resets FPC5010S and VFD faults Com Sinking Common Common for 24 VDC and 120 VAC control voltages 33VAC Voltage Input Common Common for Dr y contact connections The digital inputs can be configured to respond to Dry contacts (sinking), 24 Volts DC or 120 Volt AC. Dry Contacts JP24-JP31 = OFF, JP8 & JP32 = ON 24 Vdc JP24-JP31 = OFF, JP8 & JP32 = OFF 120 Vac JP24-JP31 = ON, JP8 & JP32 = OFF Digital Inputs Referenced to J-13 33Vac for “Dry” contact use. Digital inputs referenced to J-13 COM for 24V or 120V external voltage use. ** 20 Terminal functions vary with the Application mode selected. See section 3.3 for a complete description of terminal functions. FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 3 - Installation Instructions www.saftronics.com JP32 JP24-JP31 JP8 Digital / Relay Outputs There are five (5 ) 250 Vac, 10.0 amp. Form C relay outputs. Three ( 3 ) and fixed and two ( 2 ) and programmable as shown below. Programming is via Saflink with no board jumper settings required. Terminal Block Connection Function Rating FNC FNO Fault FCM ANC ANO Automatic ACM HNC HNO Hand Form C 10 Amps J-14 HCM R4NC R4NO R4CM R3NC R3NO R3CM © 2002 Saftronics, Inc. Programmable Run Speed Agree Bypass Active Damper Actuator Programmable Run Speed Agree Bypass Active Damper Actuator FPC5010S HVAC Instruction Manual 21 Chapter 3 - Installation Instructions www.saftronics.com Terminal J-14 The J-14 terminals are 5 Form “C” relay output, rated 250V/10A. Three of the Relay Outputs have dedicated functions, while two are programmable multi-function type relay outputs. 1. FCM This relay output is a fault output. It is activated by ANY fault, externally, from the control board or VFD. If the auto retry feature is activated, the relay will not change state until the final retry attempt has failed and VFD operation has been terminated. Normally closed connection. Normally open connection. FNC FNO 2. ACM ANC ANO This relay output is an indication the unit is in Automatic Mode Normally closed connection. Normally open connection. 3. HCM HNC HNO This relay output is an indication the unit is in Hand Mode Normally closed connection. Normally open connection. 4. R3CM R3NC R3NO This relay output is a multi-function type output. Default = RUN Normally closed connection. Normally open connection. 5. R4CM R4NC R4NO This relay output is a multi-function type output. Default = Not Activated Normally closed connection. Normally open connection. Internal Control Wire Connections Wire Color Control Board Terminal Parameter Setting Description X1 yellow OC6 E1=9 X2 white OC5 E2=16 X3 brown OC7 E3=8 FWD orange OC2 FWD Command REV blue OC3 REV Command CM green GND 11 Jumper to CM GND FMA red AIN2 F31=2 DX+ black SE+ RE+ (Jumpered) VFD - Control Board Communication DX- white SERE(Jumpered VFD - Control Board Communication GP10 Terminal Terminal Block J4 Signal Common Terminal Block J12 22 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 3 - Installation Instructions www.saftronics.com Distance between FPC5010S and Motor If the total wiring distance between the FPC5010S and the motor is excessively long and the VFD carrier frequency (IGBT switch frequency) is high, harmonic leakage current from the wiring may adversely affect the VFD and peripheral devices. If the wiring distance is longer than those listed in the table below, reduce the inverter carrier frequency (Use function code F26 “Motor sound”). 5.0 Hp and Smaller Motor Insulation Level 1000 Volts 1300 Volts 1600 Volts 230 VAC 1312 ft / 400 M* 1312 ft / 400 M* 1312 ft / 400 M* 460 VAC 66 ft / 20 M 328 ft / 100 M 1312 ft / 400 M Motor Insulation Level 1000 Volts 1300 Volts 1600 Volts 230 VAC 328 ft / 400 M* 328 ft / 400 M* 328 ft / 400 M* 460 VAC 66 ft / 20 M 135 ft / 100 M 135 ft / 400 M 7.5 and Larger *Cable lengths determined by secondary effects and not voltage spiking (dv / dt). Grounding Grounding Resistance: 230V Class: 100W or less, 460V class 10W or less. Never ground the FPC5010S in common with welding machines, motors, or other high current electrical equipment. Run all ground wires in a separate conduit. When using several FPC5010S units side by side, ground the units as shown below. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 23 Chapter 3 - Installation Instructions www.saftronics.com 3.7 Checking Motor Rotation Before attempting a trial operation of the FPC5010S unit, insure that the enclosure door is securely closed. Also, insure all personnel are clear of the connected load as this operation will energize and rotate the motor. After applying 3 phase power to the FPC5010S insure that the MAIN POWER, VFD OFF, and BYPASS OFF LED’s are illuminated. If any alarms are illuminated refer to section 8.1 to clear the fault. WARNING: Motor rotation MUST be checked in both VFD and Bypass modes. Failure to confirm rotation may cause severe damage to the FPC5010S, motor or its driven equipment. 3.7.1 Check #1: Rotation on VFD power If the FPC5010S is equipped with an external speed POT, rotate the POT fully counterclockwise (zero ref.) prior to beginning rotation check. In HAND mode, the external POT and FPC5010S “HAND” speed arrows will both effect the operation of the drive. Disable “Smart Bypass” by pressing the grey smart button on the HVAC keypad. When disabled, the Smart LED will not be illuminated. Place the VFD package in HAND (local) control by pressing the HAND push button of the FPC5010S keypad. The HAND, bypass OFF, input and output contactor LED’s will be illuminated. Use the “HAND” SPEED up arrow to increase the speed reference of the VFD or the “HAND” SPEED down arrow to decrease the speed reference of the VFD. Note the direction of rotation as the motor shaft begins to rotate. To stop the VFD, press the red VFD OFF push button. Verify that the direction of the motor is correct, if not remove power to the unit and reverse any two motor leads at the motor or at the motor overload device. DO NOT change the condition of the connections at T1, T2 and T3 on the drive. Perform this process again to verify the proper motor direction. 3.7.2 Check #2: Rotation on Bypass power NOTE: This operation will start the motor across-the-line. Press the BYPASS ON button on the FPC5010S keypad. This will start the motor across-the-line. Check motor rotation. To stop the motor, press the VFD OFF or BYPASS OFF push buttons. Verify that the direction of the motor is correct, if not remove power to the unit and reverse any two leads on the bypass contactor. The bypass contactor is located in the bypass enclosure. It is the middle contactor, interlocked to the output contactor. Perform this process again to verify the proper motor direction. 24 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com Chapter 4 – Overview of the FPC5010S The FPC5010S control card is located in the lower left hand side of the enclosure. This control card incorporates all control I/O terminals for system operation. The control card may be configured for one of three distinct application modes for easy operation. Verify which mode best fits your application needs before any control wire termination is started. The three modes are Fan, Pump and Cooling Tower. The I/O configurations may be found in Chapter 3. The FPC5010S control card is factory set to accept a sinking type ( dry contact closure) type input . However, the digital inputs may be configured for 24 Vdc or 120VAC input( see page 18) for simpler interface to existing equipment or when greater noise immunity is desired. The analog input and outputs are factory set for 4 –20mA. The analog input and outputs may also be reconfigured for 0-10VDC. All control wiring must be run in separate conduit from ANY high voltage or power wiring. The wiring should also be properly grounded and shielded to insure proper operation. 4.1 Control Board The following is a description of the FPC5010S control board configurable characteristics. DIP switch and jumper settings are required to properly configure the FPC5010S. All jumpers and switches are located on the control board, which is in the bypass enclosure. 1. 2. 3. 4. 5. 6. 7. 8. Control Mode selection (SW1) Digital Inputs (J13) Digital Outputs (J14) Analog Inputs (J12) Analog / Relay Outputs (J12) Saflink connection (J10) Modbus / Metasys connection (J12) External POT connection (J5) 2. 3. 7. 5. 4. 6. 8. NOTE: Field connections are to be made to this control board ONLY, and at the locations shown below. 1. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 25 Chapter 4 - Overview www.saftronics.com 4.2 Control Board Function Summary Type Location Terminal Description Signal Level/Rating Input Power J2 L1 L2 GND Main Input Voltage 208/230 Main Input Voltage 208/230 Ground 208V / 230V 208/240V Setting Voltage Section J3 Motor Overload Relay J4 J12 Analog Inputs J5 Serial Communiations O/L GND AIN0 AIN1 GND +15V EPOT GND Control Voltage Selection Jumper For all Main Voltage Jumper Outside Terms as shown External Speed Ref. or PID Set Point Ref. PID Feedback Signal Signal Common Door-mounted Speed Pot Input Only effective in Loca/Hand Mode Signal Common HVAC Keypad Connection J9 J10 J11 RS-485 Connection Saflink Connection no connection Digital Inputs J13 Analog Outputs J12 SE+ SE+ SE+ SE+ P1 P2 P3 P4 P5 P6 P7 P8 Com 33VAC AO0 AO1 GND 240 480 240 Internal Class 20 Motor Overload Contact Input (NC) J8 J12 26 208 230 0-10VDC or 4-20mA 0-10VDC or 4-20mA ***see section 3.6.3 High Side Wiper GND Connection to GP10 Inver ter External Run Command Reser ved SW1 Switch Setting Dependant SW1 Switch Setting Dependant SW1 Switch Setting Dependant SW1 Switch Setting Dependant Local/Remote Mode Reference Only Fault Reset Common when using 24VDC or 120 VDC Input Common when using Contact Input Programmable analog output Programmable analog output Signal Common FPC5010S HVAC Instruction Manual The Digital Inputs are factor y set for contact inputs, sinking type. The Digital Inputs may be set for 120VAC or 24VDC input levels by modifying pins JP8, JP32 & JP24 JP31 ***see section 3.6.3 0-10VDC or 4-20mA 0-10VDC or 4-20mA ***see section 3.6.3 © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com Type Relay Outputs Control Board Fuse © 2002 Saftronics, Inc. Location Terminal Description J14 FNO FNC FCM ANO ANC ACM HNO HNC HCM R4NO R4NC R4CM NC R3NO R3NC R3CM Fault Normally Open Contact Fault Normally Closed Contact Fault Contact Common Automatic Mode Normally Open Contact Automatc Mode Normally Closed Contact Automatic Mode Contact Common Hand Mode Normally Open Contact Hand Mode Normally Closed Contact Hand Mode Contact Common Programmable Normally Open Contact Programmable Normally Closed Contact Programmable Contact Common No Connection Programmable Normally Open Contact Programmable Normally Closed Contact Programmable Contact Common F1 Control Board Fuse P/N 010-2004 FPC5010S HVAC Instruction Manual Signal Level/Rating 30 VAC / 15A 120VAC / 15A 277VAC / 10A Programmable Relays RUN Speed Agree Bypass Active Damper Actuator 500mA@500VAC 27 Chapter 4 - Overview www.saftronics.com Control board 100-0148-02G (208 Vac) and 100-0148-03G (230 / 460 Vac) Fuse Rating LED Identification LED D2 D3 D4 D5 D6 D8 D10 Function Blinking Keypad Communication OK VFD Communication OK Modbus / Metasys Communication OK Control Board Communication OK Input Contactor Malfunction Output Contactor Malfunction Bypass Contactor Malfunction Illuminated Dark No Communication No Communication No Communication No Communication Energized Energized Energized No Communication No Communication No Communication No Communication De-Energized De-Energized De-Energized D2-D5 indicates communications between the VFD and the control board. If LED’s stop blinking, this indicates a major communications error. Cycle power to control board if LED’s resume blinking communications are restored. 28 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com D10 D8 D6 D5 D4 D3 D2 SW1 4.3 Application Modes of the FPC 5010S There are three (3) pre programmed application specific control modes that are available in the FPC5010S. Control modes are selectable via the dip switch SW1 By changing DIP1 and 2, each mode can be independently selected. In each mode the functionality of the digital inputs P4, P5 and P6 can be configured to perform unique application specific functions. The FPC5010S keypad specifically displays the condition of the events controlled by these inputs. The three applications are: - Fan mode - Pump mode - Cooling Tower mode The control modes of the FPC5010S are selectable via switch SW1. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 29 Chapter 4 - Overview www.saftronics.com Dip Switch SW1 Dip switch SW1 is a five (5) position dip switch. DIP1 and DIP2 determine the functionality of digital input P4, P5, & P6 located on Control Terminal J-13. DIP3 allows Smart Bypass function to be disabled. DIP4 allows user to select Fire Alarm function during fan mode operation. DIP5 allows the control board to reset to factory default parameters. The default position for all switches is the off position. Dip Switch SW1 # Fan Pump Cooling Tower DIP1 OFF ON ON DIP2 OFF OFF ON Smart Bypass Smoke Alarm Test N/A N/A N/A DIP3 DIP4 ON=Disabled N/A N/A OFF=Purge N/A N/A DIP5 N/A ON=Factor y Reset* *Power must be recycled for factor y reset to take effect. 30 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com 4.3.1 FAN mode DIP Switch settings Terminals P4 – P6 default settings: P4 – Damper Closed P5 – Freeze-Stat P6 – Fire Alarm (Smoke) Damper Control Damper closed is expecting a closed (default) contact from a damper end switch indicating that the damper is open and the fan may safely operate. As long as there is not a connection (damper closed) between P4 and 33 VAC* both VFD and Bypass are prevented from operating. Damper actuation (Terminal P4, Normally Closed) In conjunction with the damper closed input circuit in the fan mode, whenever a run command is issued in HAND or AUTO, VFD or BYPASS, relay R3 or R4 changes state. This relay can be used to control a damper actuator solenoid. Relay / Digital outputs R3 or R4 must be programmed to enable damper control. Access SAFLINK as shown below to enable damper control. To enable the desired operation of relay R3 or R4 in the FPC5010S, the selection must be sent to the FPC5010S. This change can be sent by selecting either of the following two option buttons. Send single parameter, which is located to the left of the parameter number & description as shown above. Or © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 31 Chapter 4 - Overview www.saftronics.com Transmit entire page, which is located at the bottom of the page. Upon receiving a start signal, the FPC5010S will delay starting by the amount of time programmed into parameter B6-01 “Damper Actuator Delay” to allow the damper to fully open. Once the damper is opened and the damper end switch is closed, the FPC5010S will allow the motor to operate. Issuing a stop command will reverse the procedure. IMPORTANT: The Damper actuation function is a customer safety interlock. If the damper actuator feature is not desired, a jumper wire must be placed between P4 and 33 VAC* to allow the FPC5010S to be operated. Without this jumper installed, the FPC5010S keypad will have the “Damper closed” and “VFD fault” LED’s illuminated and the unit will not start. Freeze-Stat (Terminal P5, Normally Closed) Freeze-Stat input allows an external sensor to inhibit operation if unsafe operating conditions are present (i.e. freezing conditions, extreme humidity etc). Under normal operating conditions, a normally open contact from the sensor is wired to terminal P5 and 33 VAC*. IMPORTANT: The Freeze-Stat function is a customer safety interlock. If the Freeze-Stat feature is not desired, a jumper wire must be placed between P5 and 33 VAC* to allow the FPC5010S to be operated. Without this jumper installed, the FPC5010S keypad will have the “Damper closed” and “VFD fault” LED’s illuminated and the unit will not start. Fire Alarm (Terminal P6, Normally Open) Fire Alarm (Smoke) input can be configured for two different modes of operation. - Zero speed mode - Purge mode Fire alarm control is determined by the setting of DIP switch SW1 DIP4. When a change is made to a DIP setting, power must be cycled to the FPC5010S in order for the change to take effect. After reapplying power, LED D5 will begin to blink to confirm that the change has been accepted. If LED D5 does not begin to blink an error has occurred and the power should be cycled again and the condition of LED D5 rechecked. Zero speed mode (default) The default condition is the zero speed mode with DIP4 of SW1 set in the off position. In the zero speed mode, a contact closure between P6 and 33 VAC* causes the FPC5010S to stop and remain at zero speed until the condition is reset. This feature is available in both VFD or BYPASS modes of operation. Normal operation will resume after the fire contact opens and a fault reset is issued. Purge Mode In the purge mode, DIP switch SW1, DIP4 must be in the ON position. A contact closure between P6 and 33 VAC* will cause the motor and fan to operate in bypass mode at full speed. During this mode of operation the motor overload trip circuit is disabled. When in the Pump or Cooling Tower modes of operation, of SW1, DIP4 has no functionality and its condition is ignored. 32 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com Fan Mode Drawing J12 _ AIN0 J12 External Speed Ref. or PID Set Point Frequency Output _ AO0 4-20mA + _ GND Common Common GND AIN1 PID Feedback Signal Current Output AO1 4-20mA + GND Common Common GND 4-20mA + _ 4-20mA + Analog Inputs: 0 - 10 Vdc 500Ohms / 0 -10VDC 10k Ohms J13 J14 P1 External Auto Run FNO Fault N.O. P2 Reserved FNC Fault N.C. P3 Motor Over temp. FCM Fault Common P4 Damper Closed ANO Automatic Mode N.O. P5 Freeze Stat ANC Automatic Mode N.C. P6 Fire Alarm ACM Automatic Mode Common P7 Local/Remote HNO Hand Mode N.O. P8 Fault Reset HNC Hand Mode N.C. 33VAC Contact Input Common HCM Hand Mode Common COM Voltage Input Common R4NO Programmable Relay 4 Run Speed Agree Bypass Active Damper Actuator R4NC R4CM NC R3NO FAN R3NC R3CM © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual Programmable Relay 3 Run Speed Agree Bypass Active Damper Actuator 33 Chapter 4 - Overview www.saftronics.com 4.3.2 PUMP mode DIP Switch settings Terminals P4 – P6 default settings: P4 – Low Level Alarm P5 – Vibration Alarm P6 - Motor Pre-heat (Anti-condensation) Low Level Alarm (Terminal P4, Normally Open) Low Level Alarm input will inhibit operation if the level of the well or other holding tank is too low to allow the pump to maintain a suction. The default condition requires a normally open contact between P4 and 33 VAC*. Vibration Alarm (Terminal P5, Normally Open) Vibration Alarm input inhibits operation if excessive vibration from the vibration sensor is detected. The default condition requires a normally open contact between P5 and 33 VAC*. Motor Pre-heat (Terminal P6, Normally Open) Motor Pre-heat when activated allows a small amount of voltage to be pulsed to the motor windings, to prevent moisture build up in the motor. The default condition requires a normally open contact between P6 and 33 VAC*. CAUTION: When motor Pre-heat is selected motor creeping / rotation may occur. Disable this function prior to servicing or coming in contact with any rotating components of the application. Failure to do so may cause serious injury or death. 34 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com Pump Mode Drawing J12 _ AIN0 J12 External Speed Ref. or PID Set Point Frequency Output _ AO0 4-20mA 4-20mA + _ GND Common Common GND AIN1 PID Feedback Signal Current Output AO1 4-20mA + GND Common Common GND + _ 4-20mA + Analog Inputs: 0 - 10 Vdc 500Ohms / 0 -10VDC 10k Ohms J13 J14 P1 External Auto Run FNO Fault N.O. P2 Reserved FNC Fault N.C. P3 Motor Over temp. FCM Fault Common P4 Low Level Alarm ANO Automatic Mode N.O. P5 Vibration Alarm ANC Automatic Mode N.C. P6 Motor Pre-Heat ACM Automatic Mode Common P7 Local/Remote HNO Hand Mode N.O. P8 Fault Reset HNC Hand Mode N.C. 33VAC Contact Input Common HCM Hand Mode Common COM Voltage Input Common R4NO Programmable Relay 4 Run Speed Agree Bypass Active Damper Actuator R4NC R4CM NC R3NO Pump R3NC R3CM © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual Programmable Relay 3 Run Speed Agree Bypass Active Damper Actuator 35 Chapter 4 - Overview www.saftronics.com 4.3.3 COOLING TOWER mode DIP Switch settings Terminals P4 – P6 default settings: P4 – Reverse Enable P5 – Vibration Alarm P6 - Motor Pre-heat Command (Anti-condensation) Reverse Enable (Terminal P4, Normally Open) Reverse Enable when enabled, allows the cooling tower fan to operate in reverse rotation. This is useful for de-icing the fan blades. The default condition requires a normally open contact between P4 and 33 VAC*. Vibration Alarm (Terminal P5, Normally Open) Vibration Alarm input inhibits operation if excessive vibration from a vibration sensor is detected. The default condition requires a normally open contact between P5 and 33 VAC*. Motor Pre-heat (Terminal P6, Normally Open) Motor Pre-heat when activated allows a small amount of voltage to be pulsed to the motor windings, to prevent moisture build up in the motor. The default condition requires a normally open contact between P6 and 33 VAC*. CAUTION: When motor Pre-heat is selected motor creeping / rotation may occur. Disable this function prior to servicing or coming in contact with any rotating components of the application. Failure to do so may cause serious injury or death. 36 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com Cooling Tower Mode Drawing J12 _ AIN0 J12 External Speed Ref. or PID Set Point Frequency Output _ AO0 4-20mA 4-20 mA + _ GND Common Common GND AIN1 PID Feedback Signal Current Output AO1 4-20 mA + GND Common Common GND + _ 4-20mA + Analog Inputs: 0 - 10 Vdc 500Ohms / 0 -10VDC 10k Ohms J13 J14 P1 External Auto Run FNO Fault N.O. P2 Reserved FNC Fault N.C. P3 Motor Over temp. FCM Fault Common P4 Reverse ANO Automatic Mode N.O. P5 Vibration Alarm ANC Automatic Mode N.C. P6 Motor Pre-Heat ACM Automatic Mode Common P7 Local/Remote HNO Hand Mode N.O. P8 Fault Reset HNC Hand Mode N.C. 33VAC Contact Input Common HCM Hand Mode Common COM Voltage Input Common R4NO Programmable Relay 4 Run Speed Agree Bypass Active Damper Actuator R4NC R4CM NC R3NO Cooling Tower R3NC R3CM © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual Programmable Relay 3 Run Speed Agree Bypass Active Damper Actuator 37 Chapter 4 - Overview www.saftronics.com 4.4 Control Modes of the FPC5010S There are three preprogrammed control modes of the FPC010S. When power is initially applied, The green MAIN POWER SWITCH LED becomes illuminated and will remain on as long as power is connected and the FPC5010S is awaiting a user selection of the desired control mode. The VFD OFF and BYPASS OFF will be the only LED’s illuminated. The input contactor remains in the off position. The VFD will have no power and its display will remain blank. When any one of the three control modes is selected the input contactor closes and remains closed until power is removed from the FPC5010S. 4.4.1 AUTO mode In the AUTO / automatic mode, a building automation system or other external device is required to supply start / stop and speed reference information to the FPC5010S. During AUTO mode operation, the FPC5010S keypad remains enabled for stopping, control mode changing and bypass selection functions. To place the VFD package in AUTO (remote) mode, press the grey AUTO push button. In AUTO mode, the VFD AUTO and BYPASS OFF, LED’s will be illuminated on the FPC5010S keypad. A contact closure on P1 to 33 V\\ACac* will close both the input and output contactor and illuminate their respective LED’s. If the FPC5010S is equipped with a door mounted speed POT, this can be used in place of the signal from the building automation system in the event that local control of the FPC5010S is required. With a contact closure to terminal P7 on terminal block J-13, the FPC5010S will respond to the external door mounted POT AND the up / down arrow keys on the FPC5010S keypad. The up / down arrow keys on the FPC5010S keypad will incrementally increase or decrease the latest stored value of frequency reference. Changes to the door mounted POT will override any stored values of reference frequency and resume control the VFD’s operation. To exit the AUTO mode, press the VFD OFF button on the FPC5010S keypad. The VFD OFF, BYPASS off and input contactor LED’s will be illuminated. The input contactor may be programmed to remain on/closed by changing parameter 16 “Input Contactor Lock” to “Enabled”. See section 5.2.2 for more details. 4.4.2 TEST mode In TEST mode the functionality of the VFD, external speed reference devices, SAFLINK communication tool and system set-up characteristics can be read, set and modified. In the TEST mode, bypass starting and VFD operation are disabled. To place the VFD package in TEST mode, press the grey VFD TEST button. The VFD TEST, BYPASS OFF and input contactor lights will be illuminated. To exit the TEST mode, press the VFD OFF button on the FPC5010S keypad. The VFD OFF and BYPASS OFF LED’s will remain illuminated. The input contactor may be programmed to remain on/closed by changing parameter 16 “Input Contactor Lock” to “Enabled”. See section 5.2.2 for more details. 38 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com 4.4.3 HAND mode In the HAND mode, starting, stopping and speed references are all controlled entirely from the door mounted devices. To place the VFD in the HAND mode, press the green VFD HAND button. The VFD, VFD HAND, input and output contactors, and BYPASS OFF LED’s will be illuminated. Pressing the HAND button acts as a run command for the VFD and the power is delivered to the motor based on the condition of the external speed POT or the current condition of the up / down arrow keys on the FPC5010S keypad. Upon initial power on when no external speed POT is connected, VFD will require the “HAND” Speed up / down arrow keys to be pressed to begin operation. To exit the HAND mode, press the VFD OFF button on the FPC5010S keypad. The VFD OFF and BYPASS OFF and input contactor LED’s will remain illuminated. The input contactor may be programmed to remain on/closed by changing parameter 16 “Input Contactor Lock” to “Enabled”. See section 5.2.2 for more details. 4.5 Bypass Modes of the FPC5010S There are three modes of operation for bypassing the VFD and operating on full line power. BYPASS ON Manual bypass operation BYPASS SMART Dynamic bypass / Harmonic reduction Emergency bypass Emergency, manual bypass 4.5.1 MANUAL bypass With no control mode selected, pressing BYPASS ON begins bypass operation immediately. The motor will stay in bypass until user selects BYPASS OFF. BYPASS ON is available in any control mode. In HAND or AUTO modes pressing bypass will decelerate the load before starting the motor across-the-line. To place the VFD package in BYPASS ON / manual bypass mode, press the BYPASS ON button. The bypass contactor will close and the motor will immediately be started across-the-line. In BYPASS ON / manual bypass mode the BYPASS ON and bypass contactor LED’s will be illuminated on the FPC5010S keypad. To exit the BYPASS ON mode, Press either the VFD OFF or the BYPASS OFF button on the FPC5010S keypad. Pressing the VFD OFF button discontinues operation of both the BYPASS ON and the selected control mode. The VFD OFF, BYPASS OFF and input contactor LED’s will remain illuminated and the motor will coast to a stop. Pressing the BYPASS OFF button discontinues the operation of the BYPASS ON mode while remaining in the selected control mode. The VFD ON, BYPASS OFF and input contactor LED’s will remain illuminated and the motor will coast to a stop. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 39 Chapter 4 - Overview www.saftronics.com 4.5.2 SMART bypass In the BYPASS SMART mode of operation, the full functionality of harmonic reduction and energy savings of the FPC5010S can be realized. Based on preprogrammed, modifiable values of reference frequency or reference frequency & load, the FPC5010S will automatically enter a bypass mode of operation when set values at met. The FPC5010S transfers the motor from VFD control to bypass operation in a controlled manner assuring smooth transfer into bypass operation and back into VFD control. BYPASS SMART can be selected in both the VFD AUTO and the VFD HAND modes of operation. The functionality in each mode is exactly the same. To place the VFD package in BYPASS SMART / automatic bypass mode, press the BYPASS SMART button on the FPC5010S keypad at any time. A control mode must be selected either before or after pressing the BYPASS SMART key. The FPC5010S will begin to monitor the operation of the VFD, motor and the condition of the load. In the BYPASS SMART mode, VFD ON, the input and output contactor, BYPASS OFF and BYPASS SMART LED’s will be illuminated as well as the LED corresponding to the selected VFD mode of operation. When maximum load conditions are met and the FPC5010S transfers the motor to bypass operation. The output contactor LED will turn off and the bypass contactor LED will become illuminated. At this time the Green “Smart bypass active:” LED will also become illuminated to indicate that the motor is now operating in bypass / harmonic reduction mode. Conversely, when the load falls below the maximum limit, the FPC5010S will transfer the motor back to the energy savings / VFD control mode and the LED’s will be illuminated as described above. To exit the SMART BYPASS mode, press the BYPASS SMART button on the FPC5010S keypad at any time. The FPC5010S will transfer control back the VFD and operation will continue without interruption. LED’s will be illuminated as described above for the selected VFD mode of operation. 4.5.3 EMERGENCY bypass In the unlikely event of a failure of the FPC5010S control board, a mechanical, emergency bypass switch has been installed to enable the FPC5010S to be operated as a full voltage fixed speed starter. The emergency bypass switch is located inside the enclosure in the top left corner. To activate this switch, use the door interlocked disconnects to open the enclosure door and turn the switch clockwise to the ON position. When the enclosure door is closed and the door interlock in the ON position, the coils to the bypass contactor will be immediately energized causing the contactor to close starting the motor at full across-the-line voltage. To exit emergency bypass, turn the door interlocked disconnect to the OFF position. Power to the contactor coils will be removed and the bypass contactor will open disconnecting the operation of the motor. Turn the emergency bypass switch counter clockwise to the OFF position prior to starting any repairs necessary to return the FPC5010S to its full harmonic reduction and energy savings functionality. When operating in Fan Mode / Zero Speed Fire alarm, a contact closure on terminal P6 will disable Bypass operation and the Fire Alarm LED will be illuminated. When the Fire Alarm Fault is reset, the unit will resume bypass operation immediately. 40 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com 4.6 Communication Protocols The FPC5010S can communicate with either MODBUS or METASYS communication protocols. Each requires a communication card to be installed on the control board. This card is an optional accessory and will not be installed as standard. Confirm that the card is installed prior to attempting to use either type of communication. If the card is not installed, contact your local Saftronics distributor to add this option. The cards may field installed if required. There are no customer connections to this card. See below for Terminal locations. Control Board P/N 100-0148-02G / 03G J10 Communications Jumper P/N 018-9013 Metasys / Modbus control board P/N 100-0153-01 © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 41 Chapter 4 - Overview www.saftronics.com NOTE: The Communications jumper P/N 018-9013 uses the same connection as the Saflink cable P/N: 046-9008. Therefore, Saflink and Metasys / Modbus cannot be used concurrently. If Metasys / Modbus control board P/N: 100-1053-01 is installed, removal of the J10 termination of the communication jumper is required prior to connecting Saflink. Metasys / Modbus Connection Terminating resistor JP10 Communication LED Control Board 100-0148-02G / 03G 42 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com RS485 Communication (2 wire) is accomplished by installation of jumpers and connections as shown below. For RS422 communication (4 wire), remove jumpers. User Connection J12 TSE+ TSE- TRE+ TRE(-) (+) FPC5010S Serial Control To enable the FPC5010S serial control option, program the “Serial Control” parameter in the FPC5010S control card to enable. This will permit start, stop, and reference to be set via serial link by your Metasys control system. When enable if loss of communication between FPC5010S and Metasys control system is lost the FPC5010S will time out and shut down the motor after 4 minutes. If this occurs once communications are restored, a serial start command needs to be given to restart the drive. FPC5010S Node address setting Metasys addressing can be changed by the FPC5010S Saflink (P/N – 046-7020) or FPC5010S optional keypad (P/ N 012-9007). The parameter on Saflink or the keypad will display “Serial Option Address”, change to the desired address. (Range 1 – 255) NOTE: Make sure no two addresses on the same network are the same. Line termination The Line Termination resistor is JP10 on the FPC5010S Control Board these two pins need to be shorted together to enable termination resistor. See the diagram above for the location of this jumper Communication LED’s This LED (D4) indicated a valid communication message between the Saftronics FPC5010S Control Card and the Metasys N2 communication bus. Baud rate The baud rate is preset to 9600bps with a response time of 10ms. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 43 Chapter 4 - Overview www.saftronics.com 4.6.1 Metasys N2 METASYS System protocol is a general interface for accessing data (Designed by Johnson Controls) that resides in devices, such as the Saftronics FPC5010S Control boards, that are connected to the N2 network. Every N2 devices has its own specified address. NPT NPA Units Point Description AI 1 Code (see Table A) Last fault code AI 2 Hz/0.1 (600 = 60 Hz) Output frequency AI 3 Amps/10 Output current BI 1 1=RUN, 0=STOP RUN Status BI 2 1=REV, 0=FWD Direction (Cooling Tower Mode only) N/A BI 3 1=RDY Ready Status N/A AO 1 Hz/0.1 (600=60 Hz) Target frequency BO 1 1=START, 0=STOP START / STOP BO 2 1=REV, 0=FWD Direction Control (Cooling Tower Mode only) N/A BO 3 1=RESET FAULT N/A Fault reset Range / Value N/A 0- 4000 (0-400 Hz) Drive size dependent N/A 0-4000 (0-400 Hz) N/A FPC5010S Metasys Point Map LAST FAULT CODE REGISTER FOR TABLE AI-1 44 Bit Description Code 0 Motor Overload 1 1 Damper Closed 2 2 Freeze-Star t 4 3 Low Level 8 4 Vibration 13 5 Smoke Alarm 32 6 Purge Alarm 64 7 VFD Fault 128 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 4 - Overview www.saftronics.com 4.6.2 Modbus Modbus Address for FPC5010S Read-out and Write-in possible Function codes supported 03H and 10H only single register read write supported. Start/Stop Address (5000H) Bit 0 Run Command Bit 0 and 1 Reverse run (cooling tower mode only for reverse run) Frequency Reference Address (5001H) This is scaled on .01 hertz Only Read-out possible Output frequency Output current Output voltage Output kilowatts (3F05H) (3F06H) (3F07H) (0038H) Fault Registers Terminal Status 3F03H Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 Bit 9 Bit 10 Bit 11 Bit 12 Bit 13 Bit 14 Bit 15 Input contactor Output contactor Bypass contactor Fault relay Auto relay Hand mode R3 relay R4 relay P1 active P2 active P3 active P4 active P5 active P6 active P7 active P8 active see table A below for bit set information Fault 1 Register (3F10H) Fault 2 Register (3F11H) Fault 3 Register (3F12H) Fault 4 Register (3F13H) Fault 5 Register (3F14H) Fault 6 Register (3F15H) Fault 7 Register (3F16H) Fault 8 Register (3F17H) Fault 9 Register (3F18H) Fault 10 Register (3F19H) LAST FAULT CODE REGISTER FOR TABLE AI-1 Bit Description Code 0 Motor Overload 1 1 Damper Closed 2 2 Freeze-Star t 4 3 Low Level 8 4 Vibration 13 5 Smoke Alarm 32 6 Purge Alarm 64 7 VFD Fault 128 © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 45 Chapter 5 - Programming www.saftronics.com Chapter 5 - Programming 5.1 VFD / GP10 Required Programming The following parameters must be set to the following values in order to ensure proper operation of the FPC5010S bypass packages. DO NOT CHANGE ANY OF THESE VALUES. No. Function Name (LCD Operator Display) Description E-01 X1 Terminal Function (X1 FUNC) External Alarm 9 E-02 X2 Terminal Function (X2 FUNC) Switching from line to drive 16 E-03 X3 Terminal Function (X3 FUNC) Alarm Reset 8 F-02 Operation Method (OPR METHOD) S/ST sequence via terminals 1 F-31 FMA Function (FMA FUNC) Monitor terminal FMA displays output current 2 H-30 Serial Link LINK FUNC Enabled communication of speed reference via RS485 1 H-32 Modbus-RTU (MODE ON ER) Continue operation in the event of a communication non-response 3 Setti-ng 5.2 FPC5010S Parameters The performance of the FPC5010S may be modified or additional optional features enabled via SAFLINK. There are two subgroups of modifiable parameters accessible through SAFLINK. 1. General Parameters 1st Parameters nd 2. 46 VFD Parameters 2 Parameters Control Board Parameters System Parameters Advanced Control Board Parameters FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 5 - Programming www.saftronics.com 5.2.1 Basic Parameters 1st Parameters (A) The following parameters are available via SAFLINK by selecting “Parameters Basic” from the FCP5010S Basic menu. For a complete description of parameter description and operational characteristics see below. No. Parameter A1 Parameters Range Default Value Description Acceleration / Deceleration Time A1-01 Acceleration time 0.01 - 3600 S 6.0 < 30 Hp 20 > 30 HP Sets parameter F07 in GP10 A1-02 Deceleration time 0.01 - 3600 S 6.0 < 30 Hp 20 > 30 HP Sets parameter F08 in GP10 A2 Parameters V/Hz Pattern A2-01 Maximum Output Frequency 50 - 120 Hz 60 Hz Sets parameter F02 in GP10 A2-02 Motor Base Frequency 50 - 120 HZ 60 Hz Sets parameter F04 in GP10 A2-03 Rated Voltage 208 - 480 V -- Sets parameter F025 in GP10 A2-04 Maximum Output Voltage 230V / 80-240 V 460V / 320-480V 230V 460V Sets parameter F06 in GP10 A3 Parameters Motor Setup A3-01 Motor Capacity -- -- Sets parameter P02 in GP10 A3-02 Rated Current -- -- Sets parameter P03 in GP10 © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 47 Chapter 5 - Programming www.saftronics.com 2nd Parameters (B) The following parameters are available via SAFLINK by selecting “Parameters Second Group” from the FCP5010S Advanced menu. For a complete description of parameter description and operational characteristics see below. No. Parameter B1 Parameters B1-01 to B1-08 Relay 3 Function B2-02 Relay 4 Function B3-01 B3-02 B3-03 B3-04 B3-05 B3-06 48 Description 25 - NO 26 - NC Appl. Mode Dependent Sets condition of digital inputs P1 to P8 on control board Digital Outputs B2-01 B3 Parameters Default Value Digital Inputs Terminal P1-P8 B2 Parameters Range 27 - Not used 28 - During run 29 - Speed agree 30 - Bypass active 31 - Damper Actuator 27 - Not used 28 - During run 29 - Speed agree 30 - Bypass active 31 - Damper Actuator 28 - During run Sets condition of digital input R3 on control board 27 - Not Used Sets condition of digital input R4 on control board 0 - 100% 100% Sets gain for analog input AIN0 -100% - 100% 0% Sets Bias of analog input AIN0 0 - 10 Vdc 4 - 20 mA 1-10 Vdc Scales software for desired analog input signal type. **must match configuration for jumpers JP12 0 - 100% 100% Sets gain for analog input AIN1 -100% - 100% 0% Sets Bias of analog input AIN1 0 - 10 Vdc 4 - 20 mA 1 - 10 Vdc 0 - 100% 100% -100% - 100% 0% Analog Inputs Analog Input 0 (AIN0) Gain Analog Input 0 (AIN0) Bias Analog Input 0 (AIN0) Mode Analog Input 1 (AIN1) Gain (PID Setpoint) Analog Input 1 (AIN1) Bias Analog Input 1 (AIN1) Mode (PID Feedback) B3-07 EPOT Gain B3-08 Analog Input EPOT Bias Scales software for desired analog input signal type. **must match configuration for jumpers JP13 Sets gain for analog input external POT. (Terminal J5) FPC5010S HVAC Instruction Manual Sets Bias of analog input EPOT © 2002 Saftronics, Inc. Chapter 5 - Programming www.saftronics.com 2nd Parameters (B) (Continued) No. Parameter Range B4 Parameters Analog Outputs Analog Output 0 B4-01 0 - 100% (AO0) Gain Analog Output 0 B4-02 -100% - 100% (AO0) Bias Analog Output 0 (AO0) Mode B4-03 0 - 10 Vdc 4 - 20 mA Analog Output 1 (AO1) Gain 0 - 100% (PID Setpoint) B5 Parameters PID Setup 22 - Enabled B5-01 PID Selection 23 - Disabled 24 - Inver ted B4-04 Default Value Description 100% Sets gain for analog output AO0 0% Sets Bias of analog output AO0 0 -10 Vdc 100% Sets gain for analog output AO1 Disabled Enables control board control of PID B5-02 PID Propor tional Gain 0.0 - 10.0 (p.u.) 0.0 = disabled 1.0 (p.u.) B5-03 PID Integral Time 0.0 - 10.0 S 0.0 = disabled 1.0 S B5-04 PID Derivative Time 0.0 - 10.0 S 0.0 = disabled 0.0 S 0.0 - 100% 0.0 = disabled 0.0 - 100% B5-06 PID High turn off level 100% = disabled 0.0 - 100% B5-07 PID Sleep level 100% = disabled 0.0 - 100 S B5-08 PID Sleep delay time 0.0 = disabled B6 Parameters Application Setup B5-05 B6-01 PID Low turn on level Damper actuator delay time 1 - 200 sec 0.0% 100% 100% 0.0 S 3 sec Scales software for the inver ter's resonse to a propor tional difference between PID setpoint and PID feedback values Set software for the inver ter's summation time of integral error between PID setpoint and PID feedback values Sets software for the inver ter's a rated of change wetween PID setpoint and PID feedback values Sets level of PID Feedback when VFD resumes operation Sets level of PID Feedback when VFD discontinues operation Sets level of VFD output when VFD resumes operation Sets the time between sleep level condition met and VFD resuming operation. Sets time allowed for a damper closure. The control board checks the conidition of terminal P4 after this time to determine fault status B7 Parameters B7-01 B7-02 Serial Options 22 - Enabled Serial Control 23 - Disabled Scales software for desired analog output signal type. **must match configuration for jumpers JP12 Serial Option Address 1-31 1 Enables / Disables external serial communication Sets a unique address for each FPC5010S in a network B8 Parameters B8-01 B8-02 © 2002 Saftronics, Inc. Auto Transfer 39 - Disabled Automatic Transfer 40 - Enabled 22 - Enabled Auto Retr y Attempts 0 - 10 39 - Disabled 0 Enables/Disables transfer to bypass on inver ter fault Resets inver ter fault and restar ts operation the number of times set into B8-02 FPC5010S HVAC Instruction Manual 49 Chapter 5 - Programming www.saftronics.com 5.2.2 System Parameters The performance of the FPC5010S may be modified or additional optional features enabled via SAFLINK. The following parameters are available by selecting “System Parameters” from the FCP5010S Advanced menu. NOTE: When a change to a parameter is made in the following screen, the change must be sent to the FCC5010S by selecting the “Transmit single parameter” option button located directly to the left of each parameter number. 50 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 5 - Programming www.saftronics.com FPC5010S Modifiable Parameters No. Parameter Range Default Value 01 VFD Model 01 - GP10 01-GP10 02 VFD Device Address 1 - 31 1 The Modbus communication address for the drive 03 VFD Power-up delay time 1 - 10 S 2 Delay time between run command and VFD star ting VFD operation 04 05 06 07 08 09 10 VFD Power-down delay VFD baseblock time Bypass on delay Bypass off delay Speed agree time Speed disagree time Smar t bypass delay time 100 - 5000 ms 100 - 5000 ms 100 - 5000 ms 100 - 5000 ms 1-60 S 1-60 S 100-5000 ms Description Describes the installed VFD 200 ms Delay time between the end of the deceleration cycle and the opening of he output contactor VFD operation 500 ms Delay between closig of the output contactor and the removal of baseblock (resume VFD operation). SMART bypass Manual bypass 500 ms Delay between output contactor opening and bypass contactor closing. Manual bypass 500 ms Delay between bypass off signal received and bypass contactor opening SMART bypass Manual bypass 5 Time required for frequency (and load) to exceed threshold as set in parameter 13 before changeover from VFD operation to SMART bypass operation SMART bypass 5 Time required for frequency (and load) to exceed threshold as set in parameter 13 before resuming VFD operation SMART bypass 500 ms Delay between the opening of the output contactor and the closing of the bypass contactor SMART bypass 11 Preheat frequency 1.0-25.0 Hz 1 Hz The three phase frequency supplied to motor during preheat cycle. WARNING: Raising this value may cause motor rotation to occur. PUMP mode COOLING TOWER mode 12 VFD minimum frequency 1.0-25.0 Hz 1 Hz Minimum output frequency of the FPC5010S VFD operation © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 51 Chapter 5 - Programming www.saftronics.com No. Parameter 13 SMART bypass minimum frequency 40.0 - 60.0 Hz 58 Hz Frequency at which changeover and return from VFD to SMART bypass operation occurs SMART bypass 14 SMART bypass maximum frequency 50.0 - 70.0 Hz 62 Hz Maximum output frequency of VFD when in SMART bypass mode SMART bypass 15 16 17 18 19 52 Power ride thru Input contactor lock SMART bypass mode SMART bypass load level Fire Alarm Frequency Range 22 - Disabled 23 - Enabled 22 - Disabled 23 - Enabled 34 - Frequency 35 - Frequency and load 20 - 250% 60 - 120 Hz Default Value Description 22 - Disabled In AUTO mode, automatic restar ting of the FPC5010S after power loss is executed at the conditions present at the time power was removed AUTO mode 23 - Disabled Maintains closure of input contactor after initial operation mode selection is made. Contactor remains closed until power is disconnected or "disabled" is selected 34 - Frequency Enables the measurement of frequency or frequency and load, to define VFD to SMART bypass changeover threshold. SMART bypass 100% Load level threshold used in conjunction with parameters 013 & 014 (frequency) to determine changeover and return from VFD to SMART bypass. SMART bypass 60 Hz FAN / PURGE mode only. The frequency that the VFD outputs during Fire Alarm condition FAN mode 22 - Disabled 23 - Enabled 22 - Disabled Enables automatic frequency adjustments to prohibit stall due to over current VFD operation 20 Stall Prevention 21 Stall Prevention Level 20 - 105% Amps. 100% Current level in percent Amps. Used in stall prevention control. VFD operation 22 Generator Star t Delay 0 - 60 S 0 (disabled) Delay for FPC5010S to begin operation on stand-by generator use. ALL modes FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 5 - Programming www.saftronics.com 5.2.3 Real time clock / History The FPC5010S has a real time clock built into the control board. By selecting the FPC5010S advanced parameters then selection “Real time Clock Setup” the following screen will be displayed. The following values may set: Day Month Year Time History sampling Once this date is accurately entered, select the “Set RTC” button to store this information in the FPC5010S control board. 5.3 PID The FPC5010S integrated VFD system includes enhanced PID (Proportional, Integral, and Derivative) functionality. The FPC5010S controls all characteristics of PID operation. DO NOT enable the PID function via the VFD keypad. PID connections PID set point The PID set point signal should be connected to terminal block J-12 between AIN0 and GND. The PID set point may be either a 0-10Vdc or 4-20mA. (see analog inputs see section 3.6.3). © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 53 Chapter 5 - Programming www.saftronics.com If the FPC5010S is equipped with a door mounted speed POT, it can be used in place of the signal from the building automation system in the event that local control of the PID set point is required. With a contact closure to terminal P7 on terminal block J-13, the FPC5010S will respond to the external door mounted POT AND the up / down arrow keys on the FPC5010S keypad. The up / down arrow keys on the FPC5010S keypad will incrementally increase or decrease the latest stored value the PID set point. Changes to the door mounted POT will override any stored values of the PID set point and control the VFD’s operation. CAUTION: Install only 10 KOhm, 2 Watt potentiometers or power supply damage may occur. PID feedback The PID feedback signal must be connected to terminal block J-12 between AIN1 and GND. That signal may be either a 0-10Vdc or a 4-20mA signal. (see analog inputs see section 3.6.3). Programming PID with SAFLINK PID parameters are available in the Parameters Second group by selecting one of the following identical paths. Select the “FPC5010S Advanced” page and enter the Parameters second group as shown below. Or select the 2nd parameters group from the toolbar at the top of the screen. The following screen will appear with all PID parameters available for programming. 54 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 5 - Programming www.saftronics.com It is not possible to change PID settings while the FPC5010S is in operation To enable the modified PID settings , the selection must be sent to the FPC5010S. This change can be sent by selecting either of the following two option buttons. Send single parameter, which is located to the left of the parameter number & description as shown above. Or; Transmit entire page, which is located at the bottom of the page. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 55 Chapter 6 - Operation www.saftronics.com Chapter 6 - Operation ! WARNING Precautions: 1. Motor rotation MUST be checked in both VFD and Bypass modes. Failure to confirm rotation may cause severe damage to the FPC5010S, motor or its driven equipment. 2. Only turn ON the input power supply after closing the front door. Do not open the front door while the package is powered up. 3. Do not touch the heatsink, due to very high temperatures. 4. Since it is easy to change operation from low to high speed, verify the safe working range of the motor and machine before operation. 5. Do not check digital and anlog input signals during operation. 6. VFD parameters have been factory set for operation in the FPC5010S package. Do not change these settings, as the total package will not operate properly. Failure to observe these precautions may result in equipment damage, serious personal injury or death. 56 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com 6.1 Using the keypad There are two keypads located on every FPC5010S integrated VFD system. VFD Keypad FPC5010S / HVAC keypad VFD Keypad FPC5010S / HVAC Keypad Complete operational control of the FPC5010S is from the HVAC Keypad. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 57 Chapter 6 - Operation www.saftronics.com 6.1.1 VFD Keypad The keypad on the VFD is primarily used for monitoring purposes as limited programming is required to operate the FPC5010S. Descriptions for the available monitoring functions from the VFD keypad are described below. The keypad panel has various functions for specifying operations such as frequency setting, run/stop command, confirming and changing function data, confirming status, and copying function code settings. Review the use of each function before attempting to operate the drive from the keypad panel. The keypad panel can also be removed or inserted during inverter operation. However, if the keypad panel is removed during keypad panel operation (e.g., run/stop, frequency setting), the drive stops and outputs an alarm. 6.1.1.1 Appearance of Keypad Panel LED monitor 4-digit display. Used to display data such as setting frequency, output frequency and alarm code. Auxiliary Information Related to LED Monitor Indicates selected units or multiple of the data shown on the LED monitor and is displayed on the top line of the LCD monitor. The ■ symbol indicates selected units or multiple number. The symbol indicates that there is an upper screen not currently displayed. LCD Monitor: Used to display various items of information such as operation status and function data. An operating guide message, is scrolled and displayed at the bottom of the LCD monitor.This LCD monitor has a backlight feature which turns on when the control power is applied or any keypad key is pressed, and stays on approximately 5 minutes after the last key stroke. Status Indicators on LCD Monitor: Displays current operating status: FWD: Forward operation REV: Reverse operation STOP: Stop Control keys Displays the selected operating mode: (valid during keypad panel operation): REM: terminal block Used for drive run and stop LOC: keypad panel COMM: communication terminal FWD Forward operation command JOG: jogging mode REV Reverse operation STOP Stop command Operation keys: The symbol indicates that there is a lower screen not currently displayed. RUN LED (valid during operation from keypad panel): Indicates that an operation command was input by pressing the FWD or REV key. Used for switching screens, data change,frequency setting, etc. Operation Keys Primary Function Used to switch the current screen to the menu screen or switch to the initial screen in operation / trip mode. PRG FUNC DATA Used to switch the LED monitor or to determine the entered frequency, function code, or data Used to change data, move the cursor up or down, or scroll the screen Used to move the cursor horizontally at data change. When this key is pressed with the up or down key, the cursor moves to the next function block. SHIFT RESET 58 Used to cancel current input data and switch the displayed screen. If an alarm occurs, this key is used to reset the trip status (valid only when the initial alarm mode screen is displayed) STOP + Used to switch normal operation mode to jogging operation mode or vice versa. The selected mode is displayed on the LCD monitor. STOP + RESET Switches operation mode (from keypad panel operation mode to terminal block operation mode or reverse). When these keys are operated, function F01 data is also switched from 0 to 3 or from 1-4 to 0. The selected mode is displayed on the LCD indicator. FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com 6.1.1.2 Operation From the Keypad Panel (LCD Screen, Level Structure) Normal Operation The keypad panel operating system (screen transition, level structure) is structured as follows: 60.00 Operation Mode PRG FUNC DATA 60.00 60.00 FUNC DATA 60.00 Supplementary Screen Program Menu RESET Screen for each Function RESET FUNC RESET DATA PRG Alarm Modes If an alarm is activated, operation is changed from normal keypad panel operation to an alarm mode operation. The alarm mode screen appears and alarm information is displayed. The program menu, function screens, and supplementary screens remain unchanged as during normal operation, though the switching method from program menu to alarm mode is limited to PRG. 60.00 Operation Mode Keypad panel operating system during normal operation Alarm is activated Alarm mode processing (including RESET ) Alarm Alarm mode PRG Alarm Program Menu FUNC DATA RESET Alarm FUNC D ATA DAT Screen for each Function Alarm Supplementary Screen FUNC RESET D ATA PRG © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 59 Chapter 6 - Operation www.saftronics.com Overview of Contents Display for each Level 60 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com 6.1.1.3 Entering Data on the Keypad Panel Operation Mode The screen for normal inverter operation includes a screen for displaying drive operating status and a screen for graphically displaying the status in the form of a bar graph.The operator can switch between both screens by using the function (E45). 1) Operating Status (E45=0) 60.00 60.00 RUN STOP Direction of rotation = blank (no command) or FWD/REV Operating status = STOP (no command) or RUN FWD PRG PRG MENU F/D LED SHIFT PRG PRG MENU F/D LED SHIFT 2) Bar Graph (E45=1) 60.00 Hz Output frequency (maximum frequency at full-scale) Output current (200% of inverter rating at full-scale) Torque calculation (200% of motor rating at full-scale) A % Fout/Iout/TRQ Setting Digital Frequency On the operation mode screen, press or to display the set frequency on the LED. Data is increased or decreased in the smallest possible unit, depending on which key is pressed. The adjustments in data will occur rapidly if the operator holds down or . To select a digit use SHIFT and then data can be set directly. To save the frequency settings press FUNC . DATA Press RESETand PRG to to return to the operation mode. If keypad panel settings are not selected, the present frequency setting mode appears on the LCD. When selecting the PID function, the PID command can be set with a process value (refer to technical documentation for details). 1) Digital (keypad panel) settings (F01=0 or C30=0) RUN 56.89 60.00 60.00 FWD PRG PRG MENU F/D LED SHIFT SET Hz> LOCAL 50 - 400 F/D DATA SET SET Hz> LOCAL 50 - 400 F/D DATA SET STORING... 2) Non-digital setting 60.00 RUN PRG F/D © 2002 Saftronics, Inc. PRG MENU LED SHIFT 60.00 Screen explanation Present frequency setting mode Frequency setting range Operations guide When FUNC DATA pressed and writing Frequency setting value 12+V1 Screen explanation Present frequency setting mode F/D Operations guide DATA SET Frequency setting value FPC5010S HVAC Instruction Manual 61 Chapter 6 - Operation www.saftronics.com Switching to LED Digital Monitor During normal operation, press FUNC DATA to switch to LED monitor display. When monitored data is switched, the LED monitor contents are displayed. When power is turned on, the monitor contents set by the function (E43) are displayed on the LED. When running (E44 = 1) (E44 = 0.1) Output frequency 1 (before slip compensation) Output frquency 2 (after slip compensation) Setting frequency Output current Output voltage (specified value) When stopping E43 0 1 2 3 4 5 6 7 8 9 10 11 12 (E44 = 0) Setting frequency Setting frequency Setting frequency Output current Output voltage (specified value) Synchronous speed setting value Line speed setting value Load rotation speed setting value Torque calculation value Power consumption PID setting value PID remote setting value PID feedback value Unit Remarks Hz A V Synchronous speed r/min. Line speed m/min. Load rotation speed r/min. Torque calculation value % Power consumption kW PID setting value PID remote setting value Ñ Ñ PID feedback value Ñ For 4 digits or more, the lasr digits are cut, with x10, x100 marked on the indicator. ± indication Displayed only when PID is effective in PID operation selection. Program Menu Screen The Program Menu screen is shown below. Only four items can be displayed simultaneously. Move the cursor or to select an item, then press FUNC with DATA to display the next screen. 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK 5. MAINTENANCE 6. LOAD FCTR 7. ALM INF 8.ALM CAUSE 9. DATA COPY DISPLAY 4. I/O CHECK 5. MAINTENANCE 6. LOAD FCTR 7. ALM INF Setting Function Data On the Program Menu screen, select 1. Data Setting. The Function Select screen appears with function codes and names on it. Select the desired function. 60.00 RUN PRG F/D PRG MENU LED SHIFT PRG 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK FUNC DATA Function Code 62 60.00 60.00 60.00 F00 DATA PRTC F01 FREQ COM 1 F02 OPR METHOD F03 MAX Hz-1 Function Name FPC5010S HVAC Instruction Manual FUNC DATA F01 FREQ COM 1 0 0-11 Data Setting Range Data © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com The function code consists of alphanumeric characters with unique letters assigned to each function group. Function Code F00 - F42 E01 - E47 C01 - C33 P01 - P09 H03 - H39 A01 - A18 o01 - o29 Function Fundamental functions Terminal Extension Functions Frequency Control Functions Motor Parameters High Performance Functions Alternative Motor Parameters Optional Functions To scroll the Function Select screen rapidly, use F00 DATA PRTC F01 FREQ CMD 1 F02 OPR METHOD F03 MAX Hz-1 Can only be selected with an option connected + F00 DATA PRTC F01 FREQ CMD 1 F02 PPR METHOD F03 MAX Hz-1 Select the desired function and press Remarks or + + to move the screen as a unit sorted alphabetically. F42 TRQ VECTOR 1 E01 X1 FUNC E02 X2 FUNC E03 X3 FUNC A18 SLIP COMP 2 F00 DATA PRTC F01 DATA PRTC F02 OPR METHOD + FUNC DATA to switch to the Data Setting screen. On the Data Setting screen, the data values on the LCD can be increased or decreased in the smallest possible unit by pressing or . Holding down or causes the values to increase or decrease more rapidly. Otherwise, select the digit to be modified using and then set data directly. When data is modified, the value before modification will be displayed at the same time for reference purpose. To save the data, press FUNC DATA . Pressing cancels the changes made and returns control to the Function Select screen. The modified data will be effective in inverter operation after the data has been saved by saved, there is no change to the inverter operation. FUNC DATA . If the data is not When data setting is disabled in the case of “Data protected” or “Data setting invalid during inverter running,” make the necessary changes as indicated in Table below. Display LINK ACTIVE NO SIGNAL(WE) DATA PRTCTD INV RUNNING FWD/REV ON © 2002 Saftronics, Inc. Reason for No Modification Currently writing from RS-485 / RTU option to function is being made The edit enabling comman function is selected using a general-purpose input terminal. Data protection is selected for function F00. Release Method Send a cancel command to function writing from RS485 RTU. Stops a "write" operation from the link For functions E01 to E09, turn data terminal 19 (edit enabling command selection) ON Change function F00 to 0 Stop inverter operation An attempt was made to change a function that cannot be changed during inverter operation. An attempt was made to change a function that Turn FWD/REV command off cannot be changed with the FWD/REV command on. FPC5010S HVAC Instruction Manual 63 Chapter 6 - Operation www.saftronics.com Checking Function Data Select 2. DATA CHECK on the Program Menu screen.The Function Select screen then appears with function codes and names. 60.00 RUN FWD 60.00 PRG PRG > PRG MENU F/D > LED SHIFT 1. DATA SETTING > 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK Function code 60.00 60.00 F00 F01 F02 F03 FUNC DATA 0 *1 *1 60 Hz Data changed from initial value FUNC DATA F00 DATA PRTC 0 0-1 Data Select the desired function and press FUNC/DATA to check the function data. By pressing FUNC/DATA, the screen switches to the Data Setting screen, where data can be modified. Monitoring Operating Status Select 3. OPR MNTR on the Program Menu screen to display the current inverter operating status. Use between the four operation monitor screens. RUN FWD PRG > PRG MENU F/D > LED SHIFT PRG 1. DATA SETTING 2. DATA CHECK > 3. OPR MNTR 4.I/O CHECK 60.00 SYN=xxxxxx LOD=xxxxxx LIN=xxxxxx to switch 60.00 60.00 60.00 and FUNC DATA Fout=xxxx.xHz Iout=x.xxA Vout=xxxV TRQ=xxx% Output frequency Output current Output voltage Torque calculation method 60.00 Synchronous rotation speed (r/min) Load speed (r/min) Line speed (m/min) Fref=xxxx.x Hz xxx xx xx xx Setting frequency Operation status FWD/REV: Rotating direction IL: Current limiting VL: Voltage limiting LU: Under voltage TL:Torque limiting 60.00 SV=xxxxx PV=xxxxx TLD=xxx% TLB=xxx% 64 PID setting value PID feedback value Driving torque limiting setting Braking torque limiting setting FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com I/O Check Select 4. I/O on the Program Menu screen. Check to display analog and digital input/output signal status for the drive and options. Use and to switch between the seven screens of data. 60.00 RUN FWD PRG > PRG MENU F/D > LED SHIFT 60.00 Y1 Y2 Y3 Y4 PRG 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR > 4.I/O CHECK 12=±xx.xV 22=±xx.xV 32=±xx.xV V2=±xx.xV 60.00 AO=xxxxV CS=xxxmA DI=xxxxH DO=xxH 60.00 P1=±xxxx0p/s Z1=xxxp/s P2=±xxxxxOp/s Z2=xxxp/s 60.00 FUNC DATA REM FWD REV X1 Signal OFF. Signal ON Analog input signal Terminal 12 input Terminal 22 input voltage (AIO option) Terminal 32 input voltage (AIO option) DIO option I/O status Analog output voltage (AIO option) Analog output current (AIO option) Digital input terminal (HEX indication) Digital ouput terminal (HEX indication) X2 X3 X4 X5 Input terminal status (terminals) X6 X7 X8 X9 COM FWD REV X1 X2 X3 X4 X5 60.00 C1=xx.xmA C2=xx.xmA 60.00 FMA=xx.xH FMP=xx.xV FMP=xxxxp/s Signal OFF. Signal ON Input terminal status (via communication) 60.00 Output terminal status Y5 60.00 © 2002 Saftronics, Inc. 60.00 X6 X7 X8 X9 Signal OFF. Signal ON Analog input signal Terminal C1 input current Terminal C2 input current (AIO option) Output for meter FMA output voltage FMP output voltage FMP output frequency PG/SY option input status Master-side A/B phase 4x frequency Master-side Z phase 4x frequency Slave-side A/B phase 4x frequency Slave-side Z phase 4x frequency FPC5010S HVAC Instruction Manual 65 Chapter 6 - Operation www.saftronics.com Maintenance Information Select 5. on the Program Menu screen. Maintenance to display information necessary for maintenance and inspection. Use and to switch between the five screens of data. 60.00 RUN FWD PRG > PRG MENU F/D > LED SHIFT 60.00 60.00 PRG 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK FUNC DATA ATA TIME=xxxxxH EDC=xxxV TMPI=xxxx˚C TMPF=xxxx˚C TCAP=XXXXXH (61000H) TFAN=XXXXXH (25000H) 66 Maximum temperature of heatsink 60.00 Capacitor on PC Board accumulation time ( ): Judgement level Cooling fan operating ( ): Judgement level time 60.00 NRK=xxxxx NRR=xxxxx NRO=xxxxx (Maximum value in hour units) (Maximum value in hour units) > 5. MAINTENANCE 60.00 Cumulative powered on time DC link circuit voltage Maximum temperature of inside drive Imax=xx.xA CAP=xxx.x% Maximum current (rms) (Maximim value in hour units) Main capacitor capacity 60.00 No. of communication errors: keypad panel No. of communication errors: RS-485 No. of communication errors: option INV=Hxxxxx KEYPAD= Kxxxxx OPTION=Pxxxxx FPC5010S HVAC Instruction Manual ROM version (drive) (40Hp or more: Hxxxxx 30Hp or less Sxxxxx) ROM version: keypad panel ROM version: option © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com Load Rate Measurement Select 6. Load Rate Measurement (LOAD FCTR) on the Program Menu screen.The maximum current, average current, and average braking power during the set measuring time are measured and displayed. 60.00 RUNFWD PRG > PRG MENU F/D > LED SHIFT 60.00 PRG 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK 60.00 FUNC DATA T=3600s Imax=0.00A Iave=0.00A BPave=0.0% 5. MAINTENANCE > 6. LOAD FCTR 60.00 T=150s Imax=0.00A Iave=0.00A BPave=0.0% Change measuring using and and Start measuring Displays the remaining measuring tim, when reaches zero, ends the measurement. Measuring time FUNC DATA 60.00 T=600s Imax=0.00A Iave=0.00A BPave=0.0% Set measuring time (Measures maximum current, average current and average braking power in 600s intervals.) 60.00 T=3600s Imax=56.4A Iave=23.5A BPave=10.4% © 2002 Saftronics, Inc. Display returns to initial value Maximum current Average current Average braking power (Motor rated output/100% FPC5010S HVAC Instruction Manual 67 Chapter 6 - Operation www.saftronics.com Alarm Information Select 7. Alarm Information (ALM INF) on the Program Menu screen. A variety of operating data at the time the latest alarm occurred is displayed. Use UP and DOWN to switch between the nine screens of alarm information data. 60.00 RUN FWD PRG > PRG MENU F/D > LED SHIFT OC1 60.00 PRG 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK FUNC DATA Fout=xxxx.xHz Iout=x.xxA Vout=xxxV TRQ=xxx% 5. MAINTENANCE 6. LOAD FCTR > 7. ALM INF OC1 OC1 Fref=xxxx.xHz xxx xx xx xx TIME=xxxxxh EDC=xxxV TMPI=xxxx˚C TMPF=xxxx˚C Code of latest alarm (High speed blinking during alarm mode only) Output frequency at alarm Output current at alarm occurence Output voltage at alarm occurence Torque calculation value at alarm occurence Cumulative operating hours at alarm occurence DC link circuit voltage at alarm occurence Temperature inside drive at alarm occurence Heatsinktemperatureatalarmoccurence Setting frequency at alarm occurence Operating status at alarm occurence FWD/REV: Rotating IL: Current limiting VL: Voltage limiting LU: Under voltage TL: Torque limiting OC1 NRK=xxxxx NRR=xxxxx NRO=xxxxx OC1 REM FWD REV X1 X2 X3 X4 X5 X6 X7 X8 X9 Input terminal status at a alarm occurence (terminals) SIGNAL OFF, SIGNAL ON OC1 Output terminal status at a alarm occurence OC1 Y1 Y2 Y3 Y4 No. of communication errors at alarm occurence: Keypad panel No. of communication errors at alarm occurence: RS 485 No. of communication errors at alarm occurence: Options COM FWD REV X1 X2 X3 X4 X5 X6 X7 X8 X9 Input terminal status at a alarm occurence (communication) SIGNAL OFF, SIGNAL ON SIGNAL OFF, SIGNAL ON Y5 OC1 OC1 5=xxx 4=xxx 3=xxx 2=xxx Previous alarm Before previous alarm Two times before previous 0/1 -1 -2 -3 =xxx =xxx =xxx =xxx xxx xxx xxx xxx Multiple alarms (Simultaneously occuring alarms) Latest alarm No. of occurences Alarm history No. of occurences Updated at alarm occurence. If the cause of an alarm is the same as the previous one, only the number og occurences is incremented. Alarm code Up to four alarm codes can be dosplayed simultaneously. 68 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com Alarm History and Factors Select 8. Alarm Cause on the Program Menu screen, to display the alarm history. Press FUNC/DATA to display troubleshooting information for the alarm selected. 60.00 RUN FWD PRG > PRG MENU F/D > LED SHIFT 60.00 60.00 PRG 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK FUNC DATA 5. MAINTENANCE 6. LOAD FCTR 7. ALM INF > 8. ALM CAUSE 0.1=xxx xxx -1=xxx xxx -2=xxx xxx -3=xxx xxx xxxxxxxxxxxxx xxxxxxxxxxxxx xxxxxxxxxxxxx xxxxxxxxxxxxx © 2002 Saftronics, Inc. Alarm code of the selected alarm Alarm occurence factor of the selected alarm Alarm history 60.00 5=xxx 4=xxx 3=xxx 2=xxx OC1 Lastest alarm FUNC DATA 0.1=xxx xxx -1=xxx xxx -2=xxx xxx -3=xxx xxx FPC5010S HVAC Instruction Manual Multiple alarms (simultaneously occuring alarms) Move the cursor using and to select one of the alarm occured 69 Chapter 6 - Operation www.saftronics.com Data Copy Select 9. Data Copy to display the Data Copy on the Program Menu screen. Read screen. A copy operation is then performed in the following order: function data is read from the first inverter, the keypad panel is removed and attached to a second inverter, the data from the first inverter is written to and stored in the second inverter. The “verify” feature also makes it possible to compare and check differences in the data stored in the keypad panel and the data stored in the inverter. Read data Write data 60.00 Attach keypad panel, Turn power ON. RUN FWD PRG PRG > PRG MENU F/D > LED SHIFT 60.00 RUN FWD PRG PRG > PRG MENU F/D > LED SHIFT 60.00 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK PRG 60.00 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK 5. MAINTENANCE 6. LOAD FCTR 7. ALM INF 8. ALM CAUSE > 9. DATA COPY 5. MAINTENANCE 6. LOAD FCTR 7. ALM INF 8. ALM CAUSE > 9. DATA COPY FUNC DATA READ Data copy screen Mode (read mode) FUNC DATA 30 HP-2 FUNC DATA READ Drive type of data stored by keypad panel READ Reading 30 HP-2 WRITE 30 HP-2 READ COMPLETE Remove keypad pananel 70 Data of drive type read by keypad panel Read complete Mode (write mode) FUNC DATA 30 HP-2 WRITE Writing 30 HP-2 WRITE COMPLETE FPC5010S HVAC Instruction Manual Write complete © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com Data check (verify) Error processing 60.00 1. Change disabled during operation RUN If a write operation is attempted during a drive operation, or vice versa, the error message below will appear. After stopping the drive and pressing RESETretry the write operation. FWD PRG > PRG MENU F/D > LED SHIFT PRG 30HP-2 60.00 1. DATA SETTING 2. DATA CHECK 3. OPR MNTR 4. I/O CHECK WRITE INV RUNNING 2. Memory error 5. MAINTENANCE 6. LOAD FCTR 7. ALM INF 8. ALM CAUSE > 9. DATA COPY If a write operation is attempted while data has not been saved (i.e. no data) in the keypad panel data memory during the read mode or when the drive type of data read by keypad panel is different from the drive type to which data is to be written, the following error message will appear. FUNC DATA 30HP-2 READ Drive type of data stored in the keypad panel WRITE MEMORY ERROR 3.Verify error 30HP-2 During a data check (verify) operation, if data stored in the keypad panel differs from data stored in the drive, the following error message is displayed to indicate the function number. The data is suspended.To continue the data check and check for other mismatching data, press FUNC DATA . To stop the data check and switch to another WRITE operation, press 30 HP-2 VERIFY RESET. Mode (data check) 50HP-2 WRITE ERR-F25 FUNC DATA 30 HP-2 VERIFY Data check in progress 30 HP-2 VERIFY COMPLETE © 2002 Saftronics, Inc. Data check complete FPC5010S HVAC Instruction Manual 71 Chapter 6 - Operation www.saftronics.com Alarm Mode If an alarm occurs, the Alarm Screen indicating the alarm contents is displayed. Use and to display alarm history and multiple alarms (if more than two alarms occur simultaneously). Alarm detection on order 1.OC1 1=xxx xxx xxxxxxxxxxxxx PRG>PRG MENU RESET>RESET 72 Alarm code No. of consecutive occurences Alarm name Operation guide FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com 6.2 HVAC Keypad Operation of the FPC5010S integrated VFD system is controlled completely by the FPC5010S keypad located on the door of the lower enclosure. Programming is not available from this keypad as it is performed, if required, using the SAFLINK software included with the unit. 6.2.1 Keypad Layout There are four (4) main sections of the FPC5010S keypad; 1. System status LED’s 2. VFD HOA - Hand / OFF / Auto, and Test buttons 3. BYPASS control buttons 4. HVAC specific faults LED display © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 73 Chapter 6 - Operation www.saftronics.com 6.2.2 System status LED’s The system status LED’s represents a one line power diagram with a total of five (5) LED’s located on the keypad. 1. Main power switch 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 FPC5010S can easily seen. An illuminated LED indicates power ON, VFD running or contactor closed conditions. 6.2.3 VFD Hand / OFF / Auto, and Test buttons The HOA / TEST section offers simple control of the systems operation. There are three modes of operation of the FPC5010S; 1. AUTO Mode Control via terminal connections. 2. TEST Mode VFD testing and Manual bypass starting. 3. HAND Mode Control via door mounted devices. 6.2.4 Bypass control buttons There are three LED’s and two modes of operation for selectable from the keypad. 1. OFF 2. BYPASS ON Manual bypass operation 3. BYPASS SMART Automatic bypass / Harmonic reduction 6.2.5 HVAC specific faults LED display There are six (6) LED’s on the FPC5010S keypad indicating the various application specific faults that may occur. They are as follows 74 1. Motor Overload 2. Damper Closed 3. Fire Alarm 4. VFD Fault 5. Freeze-Stat 6. (Reserved) FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 6 - Operation www.saftronics.com 6.3 Starting Operation There are two (2) basic steps required to begin operation. 1. Select a control mode by pressing as shown below. 2. Select a mode of bypass operation (optional) 6.4 Ending Operation There are two (2) options available for ending operation. 1. Press ‘VFD OFF’- Cancels both control mode and method of bypass. 2. Press ‘Bypass OFF’ – Cancels bypass selection only allowing the user to remain in the selected control mode. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 75 Chapter 7 - SAFLINK www.saftronics.com Chapter 7 - SAFLINK Included with every FPC5010S integrated VFD system is the Saftronics SAFLINK online programming and monitoring tool. The following required equipment has been provided with your FPC5010S unit. SAFLINK Software CD 9-PIN, Serial Communication cable (P/N 046-9008) The SAFLINK software should be installed on a laptop computer with PENTIUM II or higher, running WIN98/NT or higher. 7.1 Installation Locate the SAFLINK CD included with your FPC5010S and insert it into the CD drive of your computer. If this CD is not available visit the Saftronics Inc. website at www.saftronics .com to download a free copy of the software. Installing from the CD The CD is designed to be self loading once the CD is installed into your computer. If the program does not self load you may manually load SAFLINK from Windows by selecting RUN from within the Start menu. When prompted for the path for the source file, select browse, choose the drive corresponding to the CD drive then select setup.exe. Saflink will install itself on your computer. Follow the instructions on the screen to complete the installation. Downloading from www.saftronics.com Once at the Saftronics homepage, select the “software” link and scroll down until FPC5010S SAFLINK appears on the screen as shown below. The software program is in Zip format. You will need the WinZip utility, available from WinZip Computing, Inc. Click on the download button to start downloading the file to your computer. Save the downloaded file to an empty temporary folder or move it to an empty temporary folder. After downloading, open the folder using Windows Explorer and double click on the file name. After the file has been unzipped, click on setup.exe. Once setup is complete all the files in the temporary folder may be deleted. 76 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 7 - SAFLINK www.saftronics.com 7.2 Connecting Install the 9-PIN (female) connector of the SAFLINK communication cable P/N 046-9008 in the (male) serial port of your laptop computer. The phone jack connects to the FPC5010S main circuit board located in the lower portion of the enclosure. Connect to the phone jack socket J10 as shown below. J10 7.3 Starting To run Saflink go to Start/Programs/Saflink and click on the program name. When you first enter SAFLINK the following screen will appear with the following four option buttons located on the right side of the screen. 1. Register Software 2. Open File 3. Go online 4. Close © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 77 Chapter 7 - SAFLINK www.saftronics.com It is possible to run SAFLINK both ONLINE (connected) and OFFLINE (unconnected) from your FPC5010S. Once familiar with SAFLINK, the above start-up menu may be bypassed by removing the check mark from the box in front of “Show welcome screen” Software Registration It is recommended but not required to register your SAFLINK software. Benefits: · Free software Support (E-mail) · Free software updates Several options for registration are available to the user by pressing the “Register software” button and following the onscreen instructions. Do you have Software Related Questions? Our team is here to help you! · Need help setting up the software? · Communication setup? Send an E-mail to: [email protected] Open File It is possible to store files containing programming parameters and operating characteristics of multiple applications using a single version of SAFLINK. Set-up can be accomplished both OFFLINE (disconnected) or ONLINE (connected) to the FPC5010S. Files will be stored in a user selected location as FPC5010S User Program Files (*.FCW). Pressing the OPEN FILE button will access these stored files for viewing, changing or downloading to your FPC5010S. For more information on Loading, Saving, Deleting, Modifying, Downloading or Comparing files select “File operations” form the contents section of the HELP menu located on the toolbar for SAFLINK. Going Online Going online means connecting to, and communicating with, the FPC5010S. Be sure the FPC5010S has been turned on, then press TEST to energize the inverter, prior to going online or a communication error will occur. Establishing communication with the drive via serial link can be done by pressing the ONLINE button located in the main screen. The program shows a serial communication setup screen as shown below The following items have to be setup correctly in order to establish communication with the drive. 78 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 7 - SAFLINK www.saftronics.com Communication Medium Select which communication medium is used to communicate with the drive. Connection Type Specifies the electrical connection to the drive. R232C: Single drive connection RS422: Multiple drive connection using a 4 wire interface RS485: Multiple drive connection using a 2 wire interface Direct Link RS232/422/485 Select communication port on the computer side to which the drive is connected. Specify baudrate, parity and communication address (RS422 or RS485 only) © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 79 Chapter 7 - SAFLINK www.saftronics.com Testing the communication setup Press the test button to test if the connections have been made properly and communication is enabled. When the green LED bar goes to 100% the communication is setup correctly. If SAFLINK indicates that an error has occurred, recheck connections and confirm that the FPC5010S is powered up but not running. Retest the connection by pressing the test button as described above. Press Accept to make changes to the serial setup permanent or cancel to discard settings. Accessing the communication setup Changing the serial communication setup throughout the program can be done by selecting the Serial Setup option out of the Drive Settings Menu or by clicking on the button that shows a computer workstation. Close Selecting close will exit the setup screen and allow the user to begin to use SAFLINK. A series of questions will be asked by SAFLINK to determine whether the user will be working ONLINE or OFFLINE. 7.4 Using SAFLINK To begin programming SAFLINK for your FPC5010S, a visual setup screen is available which enables the user programming access to the most commonly used parameters. A right of left click on any object will give complete information terminals, connections or programming parameters as shown here. 80 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 7 - SAFLINK www.saftronics.com Programming any of the parameters can be achieved by first pressing one of the buttons located at the bottom of the window. Writing Information to the FPC5010S. Once the desired operating characteristics are programmed into SAFLINK it is necessary to load / write this information into the FPC5010S. This is accomplished by first choosing the “FPC5010S basic” menu. Then by choosing the “Write Settings to the FPC5010S” option button located on the left side of the main screen The SAFLINK cable must be connected to the FPC5010S, the power turned on and the communication connection confirmed prior to attempting to write settings. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 81 Chapter 7 - SAFLINK www.saftronics.com 7.5 Learning more about SAFLINK SAFLINK contains Help features which fully describe its features and functions. Detailed information can be accessed via the Toolbars as shown below. Selecting Contents from this menu displays the following outline of available topics. 1. Communication Setup, going ONLINE Choosing the correct PC settings for communication with the drive 2. Choosing the correct drive type Setting up the correct Drive type, Flash version, and Control mode using automatic and manual selection 3. Changing Drive Parameters Receiving and Transmitting Drive parameters 4. File operations Loading, saving and deleting Drive parameter files 5. Viewing parameters settings Overview of Program Memory and Drive Parameters 6. Comparing parameter settings Comparing Program memory settings against Drive parameter settings 7. Printing parameter settings Printing parameter listings of program memory or actual drive settings 8. Monitor function Monitoring drive signals 9. Digital operator function Controlling the Drive by using the Digital operator simulator 10. Oscilloscope function Monitoring constants on the programs built in oscilloscope 82 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 7 - SAFLINK www.saftronics.com 11. Status / Fault diagnoses function Get an up to date fault diagnoses and status report 12. Visual programming function Visually program the drive 13. History/Data Log, RTC setup Read-out data history stored in the system. 14. Networking Using the program on a drive communication network. 15. Information Center Keeping track of all program actions. 16. Program Setup Custom program configuration. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 83 Chapter 8 - Alarm & Faults www.saftronics.com Chapter 8 - Alarm & Faults There are two different locations a fault or alarm will be displayed: 1. The HVAC Keypad 2. The VFD 8.1 HVAC Keypad Alarms and Faults There are six (6) HVAC LED’s on the FPC5010S keypad indicating the various application specific faults that may occur. They are as follows: 84 1. Motor Overload 2. Damper Closed 3. Fire Alarm 4. VFD Fault 5. Freeze-Stat 6. (Reserved) FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 8 - Alarm & Faults www.saftronics.com 1. Motor Overload Indicates that an external motor overload relay has tripped. Check that overload relay is properly set for motors full load ampere rating. Check for excessive motor current. If motor thermostats are installed and connected to terminal P3, 133 VAC check for motor overtemp. 2. Damper Closed Indicates that a damper is in the closed position. In fan mode. If damper is not used. Check terminal block J-13 for a jumper between P4 and 33VAC. If damper is used. Verify that damper is open and that end switch has changed state. 3. Fire Alarm Indicates that a Fire condition exists. If fire alarm is set for purge mode VFD package will operate the motor at full speed. If fire alarm is set for zero speed mode VFD package will disable the motor and prevent it from being operated. Check the status of terminal P6, 33 VAC. 4. Freeze-Stat Indicates that the protective device connected to the VFD package has tripped. Check device connected between J13-P5 and 33VAC. If Freeze Stat is not used. Check terminal block J-13 for a jumper between P5 and 33VAC. 5. VFD Fault Indicates that the VFD has had a fault. The fault code will specifically displayed on the VFD keypad. Section 7.2 that follows describes in detail the fault display, possible causes and remedies. 6. (Reserved) Indicates that the Control Board detects a fault from a change in the state of digital input terminals P4 and /or P5. Pump Terminal P4 - Low Level Alarm Terminal P5 - Vibration Alarm - Vibration Alarm Cooling Tower Terminal P5 © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 85 Chapter 8 - Alarm & Faults www.saftronics.com 8.2 VFD Alarms and Faults List of Protective Functions In the event of an abnormality in the inverter’s operation, the protective function will activate immediately to trip the inverter and display the alarm name on the LED monitor while the motor coasts to a stop. A list of the alarms with their explanations is included in the table below, and troubleshooting charts in Section 7. Note: Number in front of Alarm Code indicates multiple alarms. 86 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 8 - Alarm & Faults www.saftronics.com Alarm Reset To release the trip status, enter the reset command by pressing the RESET key on the keypad panel or sending the appropriate signal to the RST terminal after removing the cause of the trip. Since the reset command is an edge operation, input a command sequence such as OFF-ON-OFF as shown in Fig.6-2-1. When releasing the trip status, set the operation command to OFF. If the operation command is set to ON, inverter will start operation after resetting. 10ms or more Reset command Keypad panel display Alarm output OFF ON OFF Normal display Alarm display (Operable) OFF ON OFF Trip WARNING If the alarm reset is activated with the operation signal ON, the inverter will restart suddenly, which may be dangerous. To ensure safety, disable the operating signal when releasing the trip status, as accident may result. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 87 Chapter 9 - Appendix www.saftronics.com Chapter 9 - Appendix 9.1 Specifications 9.1.1 FPC5010S The FPC5010S features Smart Bypass (Patent pending). This innovation results in dramatic reductions in undesirable harmonic distortions. The FPC5010S also features a user friendly application specific keypad to simplify operation or indication of status. This package was designed from the ground up to be the worlds best HVAC package. Approvals: UL508c Design: 3 contactor bypass Two (2) analog inputs. Programmable for: Dynamic Harmonic reduction 0-10 Vdc, scalable NEMA 1, 12 or 3R enclosure 4-20 mA, scalable HVAC keypad / Annunciator Panel Auto transfer to bypass on fault (selectable) Fan, Pump and Cooling tower modes Programmable Automatic Retry / Fault reset SAFLINK PC Programming tool Smoke / Fire alarm. Programmable to: 32-bit Microprocessor Purge mode Narrow footprint Zero speed mode PID controller Smart Bypass enable/disable 120Vac, 24 Vdc or dry contact digital inputs VFD test mode Class 20 motor overload relays Damper closed disable input Real time clock for data logging Frequency reference loss protection Elapse time meter Speed search function Damper actuator Control (10 Amp relay contact ) PID sleep modes Fault log with time / Date stamp Digital manual speed control Data log with time / Date stamp Freeze-stat alarm input Five (5) 230 Vac relay outputs. Motor preheat command input Two (2) analog outputs. Programmable for: 0-10 Vdc, scalable 4-20 mA, scalable 88 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com Operating conditions Altitude: to 3,300 ft, higher with derating Ambient operating temp. +14o to +122o F (-10o to +50o C) Storage temp .-4o to +140o F (-20o to +60o C). 95% Relative Humidity, non-condensing. Input voltage +10%, -15%. 208, 230 and 460 Vac Protected to exposure to direct sunlight Options Input non fused disconnect Input fused disconnect Input circuit breaker Input fuses and circuit breaker Input fuses only Input or output reactors Manual speed potentiometer Dual motor overloads EMI/RFI filters Modbus Metasys © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 89 Chapter 9 - Appendix www.saftronics.com 9.1.2 GP10 Specifications Category Nominal Motor Item Description 230V, 3 Phase 1/4 Hp to 150 Hp (VT) 1/4 Hp to 150 Hp (CT) 460V, 3 Phase 1/2 Hp to 800 Hp (VT) 1/2 Hp to 600 Hp (CT) Braking Torque (Standard VT) 1/4 Hp to 30 Hp 20% 40 Hp and Higher 10% - 15% Braking Torque (Optional VT) 1/4 Hp to 30 Hp 110% 40 Hp and Higher 80% Enclosure, Standard 1/4 Hp to 30 Hp NEMA 1 Standard, NEMA 4 Optional to 15 Hp, NEMA 12 Optional all ratings 40 Hp and Up NEMA 1 Standard, IP00 optional all ratings Cooling Method Fan Cooled 1 Hp and above Standards UL/cUL No input fuses required CE EN61800-3 for EMC EN61800-2 for Low Voltage Input Item (VT) Description Up to 30 Hp, 230V200V - 230V (+10%, -15%), 50 or 60 Hz (+/- 5%) Up to 30 Hp, 460V380V - 480V (+10%, -15%), 50 or 60 Hz (+/- 5%) 40 Hp and Above, 200V - 220V (+10%, -15%), 50 Hz (+/- 5%) / 200V - 230V (+10%, -15%), 60 Hz (+/230V 5%) 40 Hp and Above, 380V - 440V (+10%, -15%), 50 Hz (+/- 5%) / 380V - 480V (+10%, -15%), 60 Hz (+/460V 5%) Unbalance Voltage Unbalance within 3% Power Dip For input voltage greater than Vmin, the drive will operate at rated output continuously. For input voltage less than Vmin, the drive will operate at 85% of rated output for 15 Msec. Vmin(230V Series) = 165V, Vmin(460V Series) = 310V Smooth recovery method is selectable Condition Item Description Altitude 1000 meters or less Derate at 1% for each 100 meters from 1000 to 3000 meters (Above 3000 meters, consult factory) Temperature Ambient -10 to 40 oC and above (units less than and equal to 30Hp must have ventilation covers removed for 50 oC) Storage -20 to 65oC Vibration IEC61200-2 Humidity 5 - 95% Relative Humidity (Non-condensing) Output Item Description 230V, 3 Phase 3 Phase, 200V, 50Hz or 3 Phase, 200V, 220V, 230V, 60 Hz 460V, 3 Phase 3 Phase, 380V, 400V, 415V, 440V, 50Hz or 3 Phase, 380V, 400V, 440V, 480V, 60 Hz Frequency 50 / 60 Hz Overload 110% of rated current for 1 min Max. Frequency 50 - 120 Hz Base Frequency 25 - 120 Hz Starting Freq. 0.1 - 60 Hz Carrier Frequency0.75 - 15 kHz up to 30 Hp 0.75 - 10 kHz 125 Hp and above, 40 to 100 Hp - .75 - 6kHz, 125 Hp and above Minimum carrier frequency changes dependent on maximum output frequency Accuracy (Stabilty) Analog +/- 0.2% of maximum frequency (speed) at 25 +/- 10oC Digital +/- 0.01% of maximum frequency (speed) between -10 and 50oC Setting Resolution Analog 1/3000 of maximum frequency (speed) Digital 0.01 Hz for frequency up to 99.9 Hz (0.1 Hz for frequency > 100 Hz) 90 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com Control Control Method Operation Frequency Setting Acceleration Setting Frequency Limiter Bias Frequency Frequency Gain Jump Frequency Catch Spinning Motor Auto-Restart Switching Operation Slip Compensation Torque Limiting PID Control Automatic Deceleration 2nd Motor Settings Fan Stop Operation Motor Autotune Energy Saving Keypad © 2002 Saftronics, Inc. Item Description Sinusoidal PWM V/Hz Dynamic Torque Vector Control (Sensorless Vector Control) Methods Keypad Terminal Board (Remote) Bus Communication Keypad (UP or DOWN) Potentiometer 1-5KW (1/2 W) Optional Analog 0 - 5 VDC 0 - +/Ð 10 VDC Bi-polar (Reversible operation by signal polarity) 0 - 10 VDC (10 - 0 VDC selectable) 4 - 20 MA (20 - 4 MA selectable) Digital Up/Down Control (Increases with UP, decreases with DOWN) Multi-step (4 different frequencies via SS1 and SS2) Multi-step (8 different frequencies via SS1, SS2, and SS4) Multi-step (16 different frequencies via SS1, SS2, SS4, and SS8) Programmed pattern operation - 8 stages Serial RS485 with Modbus RTU - Standard Networks Optional network cards Four Modes 0.01 - 3600 seconds (Independent Acc/Dec, four times, three modes - Linear, SCurve, Non-linear) Automatic When the motor acc.(dec.) torque reaches a preset value, the acc. (dec.) time is automatically extended for tripless operation. High and low values are presettable -120.0 to +120.0 Hz Adjustable from 0 - 200 % Jump frequency setting (3 points), jump hysteresis width (1 point) Smoothly pick up a rotating motor without stopping (speed search method) - No DB required FWD or REV Autorestart is available after a momentary power failure (speed search method) Continuous operation mode is selectable Control terminals are provided for smooth switching operation from line power to drive Related to load torque and magnified for negative slips frequencies Automatic overcurrent adjustments 2 torque limiting functions can be preset Process controller - standard Automatic extension of deceleration time when braking torque limit is reached for tripless operation without a DB resistor Settings for a second motor: base freq., rated voltage, rated current, no load current, impedances Automatically manage cooling fan operation to extend life - up to 30Hp operation is preset, above 30Hp signal is preset Offline Tuning Selectable with motor rotating and without motor rotating Online Tuning Dynamically compensates regulator for changes in motor temperature Reduces losses at light loads Item Description Backlit LCD Display Smart Keypad to copy parameters from one drive to another Extension cable adapter for RJ45 connector FPC5010S HVAC Instruction Manual 91 Chapter 9 - Appendix www.saftronics.com Indication Operation Mode Item LED LCD Program Mode Trip Mode 92 Other Feature Languages OC1 OC2 OC3 FUS OU1 OU2 OU3 LV OH1 OH2 OH3 dBH OL OLU EF LIM FUS Er1 Er2 Er3 Er4 Er5 Er6 Er7 Er8 History Description Output frequency Output current, Output Voltage Motor synchronous speed (RPM) Line speed (M/min) Load shaft speed (RPM) Output torque (%) Frequency setting PID (Set 1 value, Set 2 value, Feedback value) Power consumption Motor load factor Status Indicators, FWD,REV, STO{P, REM, LOC, COMM, JOG Heatsink temperature Drive internal temperature I/O Test - indicates signal existence or absence of digital I/O and signal value of analog I/O RMS current - 1 cycle %DB - 1 cycle DC Link power charge display Function Code and Function Name, Data or Data Code English, French, German, Italian, Japanese, Spanish Overcurrent during acceleration Overcurrent during deceleration Overcurrent running at constant speed Fuse blown Overvoltage during acceleration Overvoltage during deceleration Overvoltage running at constant speed Low voltage Overheating of heatsink External thermal relay tripped Overtemperature of inside air Overheating of DB circuit Motor overload Drive unit overload Ground Fault Input Phase Loss DV Fuse Open (40 Hp and above) Memory error KEYPAD communication error CPU error Option card error, detected by the control card Option card error, detected by the option card Operations procedure error. Output wiring error - impedance unbalance RS485 communications error Trip history - passed four events (Trip and Warning) FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com Protection Overload Overvoltage Incoming Surge Undervoltage Overheating Short Circuit Ground Fault Item Description Detection of electronic thermal overload relay Detection of DC link circuit overvoltage (230V series - 400V, 460V series - 800V) Drive protection from surge voltage input (Max. 1.2 x 50 usec 7KV peak) Detection of DC link circuit undervoltage (230V series - 200V, 460V series - 400V) Drive overheating protection by temperature detection Short circuit protection for drive output circuit Ground fault protection for drive output circuit - 3 phase circuit detection method Zero phase current detection method - 40 Hp and above Electronic thermal overload relay can be selected for general purpose motor or dedicated drive motor Calculation of thermal time constant can be preset 2nd motor electronic thermal overload relay Internal electronic thermal overload relay - up to 15 Hp Overheating detection thermal overload relay installed in braking resistor unit - 15 Hp and above (option) Overheating detection PTC thermistor can be connected to terminals C1-11 Drive protection for line side phase loss Drive protection for motor side phase loss during tuning Detection of output impedance unbalance during tuning Detection of loss of C1 current signal Auto reset times and reset interval can be preset Item L1/R, L2/S, L3/T U, V, W P1, P(+) Description Connect a three phase power source Connect to a three phase induction motor Connect the DC reactor for power factor correcting or harmonic current reduction Shipped in same carton with drive Connect the braking unit - optional for 20 Hp and above Connect the external braking resistor - 230V/460V series up to 10 Hp Ground terminal for drive chassis (housing) Connect the same AC power source used for Power Input as backup for control circuit power supply Description +10V DC power supply, maximum allowable output current 10ma 0-10V / 0-100%, 22K ohm input impedance 0-5V / 0-100% can be selected by signal gain setting Inverse mode operation by polarity Reversible operation can be selected by function code Frequency command, torque control, PG feedback, or PID control Common for analog signal 4-20ma / 0-100 % (input impedance 250 ohm) Inverse mode operation Frequency command, PID feedback 0 - +/- 10V / 0 - +/- 100% (input impedance 22Kohm) Motor Overload DB Resistor Overheating Motor Overheating Phase Loss Signal Loss Auto-reset Terminal Functions Main Circuit Power Input Drive Output DC Reactor Braking Unit Ext. Braking Resistor Unit Ground Aux. Control Power Analog Inputs Potentiometer Power Voltage Input P(+), N(-) P(+). DB G R0, T0 Item 13 12 Common Current Input 11 C1 Analog Input 1 V2 © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 93 Chapter 9 - Appendix www.saftronics.com Digital Inputs Forward Operation Reverse Operation Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 Digital Input 5 Digital Input 6 Digital Input 7 Digital Input 8 Digital Input 9 3 Wire Stop Coast Stop Trip Command Alarm Reset Multistep Frequency Item FWD REV X1 X2 X3 X4 X5 X6 X7 X8 X9 HLD BX THR RST SS1 / SS2 SS4 SS8 ACC/DEC Time Select RT1 RT2 JOG 2nd Frequency Select 2nd Motor Select DC Brake Command 2nd Torque Limiter Line/drive Switching JOG HZ2/HZ1 M2/M1 DCBRK TL2/TL1 SW50 / SW60 UP Command UP DOWN Command DOWN Write Enable WE-KP PID Control Cancel HZ/PID Inverse Mode Changeover IVS Interlock Signal (52-2) IL Link Enable (RS485) LE Universal Digital Input U-DI Timed Alarm Stop STP Command RS485 I/O Terminal DX+, DX-, SD 94 PLC Terminal PLC Common CM Description ON - Motor runs in the forward direction, OFF - Motor decelerates and stops ON - Motor runs in the reverse direction, OFF - Motor decelerates and stops Functions selected via function codes - Sink type terminal specification default with source type hardware selectable ON state - maximum input voltage 2V, maximum source current 5ma OFF state - maximum voltage 27V, maximum leakage current 0.5ma Selectable from the following ON - the drive latches the FWD or REV signal, OFF - the drive releases the latch ON - motor will coast to a stop, no alarm signal will be issued OFF - OH2 trip is issued and latched, motor will coast to a stop ON - Momentary on for > 0.1 sec will reset faults 4 different frequencies can be selected by ON/OFF pattern on terminals SS1 and SS2 8 different frequencies can be selected by ON/OFF pattern on terminals SS1, SS2, and SS4 16 different frequencies can be selected by ON/OFF pattern on terminals SS1, SS2, SS4, and SS8 Second ACC/DEC time can be selected by terminal RT1 4 different ACC/DEC times can be selected by ON/OFF pattern on terminals RT1 and RT2 ON - JOG frequency is activated ON - drive will stop and the 2nd frequency command becomes effective ON - drive will stop and Motor 1 values are changed to Motor 2 values ON - DC injection braking is active during deceleration ON - Torque Limiter 2 is active ON - Motor is changed from drive operation to line operation (Main circuit signal output via Y1-Y5) ON - drive output frequency increases (change rate determined by ACC time) ON - drive output frequency decreases (change rate determined by DEC time) ON - data can be changed by KEYPAD operation ON - PID control is canceled ON - Operation mode is toggled from Normal to Inverse or Inverse to Normal Connection for auxiliary contact 52-2 ON - Bus link or RS485 link is active ON - Enables input from RS485 or LAN options OFF- The drive decelerates and stops Connections for RS485 serial port communications Modbus RTU standard protocol Connection for PLC power supply that avoids drive current loops on Sink type inputs when PLC power supply is off. Common for digital inputs FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com Analog Outputs Analog Monitor Universal Analog Output Pulse Rate Monitor Transistor Outputs Power Supply Transistor Output 1 Transistor Output 2 Transistor Output 3 Transistor Output 4 Drive Running Frequency Equivalence Item FMA / 11 FMP / CM Item P24 Y1 Y2 Y3 Y4 RUN FAR Description Output DC voltage is proportional to selected function's value. Functions are selected by FC31 0-10 VDC Slip frequency (0 - max frequency) Output frequency (0 - max frequency) Output current (0 - 200 %) Output voltage (0 - 200 %) Output torque (0 - 200 %) Load factor (0 - 200 %) Input power (0 - 200 %) PID feedback value (0 - 100 %) PG feedback value (0 - max speed) Analog output pass through for communications Pulse rate is proportional to selected function's value. maximum output current: 2ma The average value of the pulse train is proportional to the selected function's value, output functions same as for FMA Description DC power supply - +24V, 100ma ON state maximum output voltage 2V, sink current 50ma OFF state maximum allowable voltage 27V, leakage current 0.1ma Select from the following programmable ON - output frequency is larger than starting frequency ON - difference between output frequency and setting frequency is smaller than FAR hysteresis width Frequency Level DetectionFDT ON - output frequency is larger than preset detection level Undervoltage Detection LV ON - drive undervoltage stops and operation command is ON Torque Polarity B/D ON - drive is in braking mode Torque Limiting TL2/TL1 ON - drive is in torque limiting mode Auto-restarting IPF ON - drive auto restarting mode active or restart waiting mode is active KEYPAD Operation ModeTP ON - drive is in KEYPAD operation mode Drive Stopping STOP ON - drive is in stopping mode or DC braking mode Overload Early Warning OL ON - electronic thermal calculated value is larger than preset protection level (Selectable) ON - output current is larger than preset detection level Line/drive Changeover SW88 Outputs signal 88 for line/drive changeover SW52-2 Outputs signal 52-2 for line/drive changeover SW52-1 Outputs signal 52-1 for line/drive changeover Motor 2 / Motor 1 SWM2 Outputs motor changeover control switch for switching between motor 1 and motor 2 Auxiliary Terminal AX ON - drive is running Times UP TU Outputs a 100ms ON pulse for time up for pattern operation Cycle Complete T0 Outputs a 100ms ON pulse for cycle complete for pattern operation Stage 1 Indicator STG1, STG2, STG4 Pattern operation stage indicator (binary encoded) Alarm 1 Indicator AL1, AL2, AL4, Trip alarm number (binary encoded) Fan Control FAN Outputs the drive fan control signal for 40 Hp and larger drives Auto-resetting 1-TRY ON - auto resetting mode or reset waiting mode active Universal Digital Output U-DO ON - Enables output from RS485 or LAN options Overheating Early Warning OH ON - heatsink temperature is larger than preset detection level Synchronization CompleteSY Synchronization signal for synchronize operation option Life Time Alarm LIFE ON - calculated lifetime is larger than preset alarm level Common CME Common terminal for transistor output signals © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 95 Chapter 9 - Appendix www.saftronics.com Relay Output Alarm Relay Output Item 30A, 30B, 30C Programmable Relay OutputY5A, Y5C Options Item LAN LAN LAN LAN LAN LAN Tachometer KEYPAD Extension Cable 96 Description Activates when a protective function is activated, programmable with the default state function code settable voltage rating Selectable the same as Y1-Y4 Description GENIUS Profibus DP N2 - Metasys Interbus-S Modbus Plus DeviceNet Adaptor for RJ45 cable, up to 100' FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. © 2002 Saftronics, Inc. BP OC 40 38 ROL BP X1 X3 X2 X4 FPC5010S HVAC Instruction Manual 43 BYPASS SAFETY 42 41 39 2 35 OFF 32 46 ON 22 30 1A,600V CLASS CC FU3&4 44 30 39 30 37 30 45 33 31 J6 GND J5 J2 BYPASSC 22 112 102 103 111 IC 101 = MOUNTED IN ENCLOSURE BYPASS C OUTPUT C 0.5A,500VAC INPUT C J3 F1 OUTPUTC BYPASS CONTACTOR 34 IC 36 O/L H2 H4 T1 150VA H1 H3 102 GND MECHANICAL INTERLOCK OUTPUT CONTACTOR ROL FU5 2A,250V 1.5A,600V CLASS CC 101 L2 INPUT CONTACTOR 2 L3 OR 103 L1 OVERLOAD INTERFACE RELAY ROL 1 L2 OR 102 L1 OR 101 99 98 A, mH DC LINK CHOKE ANALOG OUTPUT 0-10VDC PULSE OUTPUT GP10 INVERTER DX- DX+ RUN CONTACT FAULT CONTACT DUAL DIRECTION TRANSFER SWITCH OUTPUTS 11 FMA X2 X3 CM X1 FWD P(+) L3/T L2/S L1/R Y5A Y5C 30A 30B CMY Y Y4 Y3 Y2 Y1 11 CM FMP G W V U 2 36 51 3 2 1 55 SET @ A 2 M AC MOTOR HP VAC 3 PHASE AFLC ON NEMA-1 ENCLOSURES (FPC5010(S) ONLY), THE DIGITAL OPERATOR IS LOCATED ON THE INVERTER. ALL GROUNDED WIRES RUN TO COMMON BUS BAR. SEE F-02, F-03, F-04, OR F-05. CONTACTS RATED: 27VDC MAX 50mA MAX (1-2F) 30 O/L= - A 1 2 3 4 5 6 T3 52 T1 143 50 CT1-3= : T2 OC 142 141 BP Chapter 9 - Appendix www.saftronics.com 9.2 Electrical Drawings 9.2.1 FPC5010S Logic Diagram 97 Chapter 9 - Appendix www.saftronics.com 9.2.2 FPC5010S Customer Connections J3 F1 0.2A,500VAC INPUT C L2 240 480 240 OUTPUT C JP9 D6 D8 JP8 SW1 JP17 JP23 JP12 JP13 TO JP14 D2 D3 D4 D5 J1 H5 J10 JP10 JP18 J9 JP21 JP22 JP16 JP14 J8 J11 JP3 JP4 J7 JP20 JP2 JP1 JP19 TO VFD-2CN ON FPC-20 J6 RE- SE- SE+ JP25 JP26 JP27 JP28 JP29 JP30 JP31 P1 P2 P3 P4 P5 P6 P7 P8 COM 33VAC JP24 J12 TRE- COMMON D10 JP32 TSE- JP32 FNO FNC FCM ANO ANC ACM HNO HNC HCM R4NO R4NC R4CM N.C. R3NO R3NC R3CM PROGRAMMABLE AO0 PROGRAMMABLE JP30 OC0 RESET 1 1 1 1 R3CM J14 CUSTOMER RELAY OUTPUTS HAND CONTACTS J13 AUTO CONTACTS JP28 R4NO R4NC LOCAL/REMOTE J12 HNO HNC PROGRAMMABLE PROGRAMMING PORT SAFLINK FNC FCM ANO ANC PROGRAMMABLE PROGRAMMABLE CUSTOMER DIGITAL INPUTS EXTERNAL MOTOR OL SE+ P1 P2 P3 TEXT BYPASS C RE- RE+ TRE- AUTO RUN J2 OC0 COMMUNICATIONS INPUT ANALOG INPUT 1(PID FEEDBACK) ANALOG OUTPUT 1 RS-485 PORT CONTROL BOARD ANALOG COMMON CUSTOMER ANALOG INPUTS FAULT CONTACTS © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 98 ANALOG OUTPUT 0 1 1 1 EPOT Chapter 9 - Appendix www.saftronics.com 9.3 Layout and Dimensions 9.3.1 Nema 1 Enclosures FPC5010S 208V / 230V 460V 0.5-10HP 0.5-15HP 39.00 38.00 9.00 10.00 10.30 © 2002 Saftronics, Inc. 11.19 12.79 FPC5010S HVAC Instruction Manual 99 Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 460V 15-25HP 20-25HP 54.00 53.00 14.73 16.33 10.00 11.25 11.55 100 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 460V 30-40HP 30-75HP 71.00 72.00 16.75 18.00 18.30 © 2002 Saftronics, Inc. 12.19 13.88 FPC5010S HVAC Instruction Manual 101 Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 50-75HP 460V 100-150HP 76.13 77.50 18.75 30.80 102 FPC5010S HVAC Instruction Manual 17.30 18.99 © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 100-125HP 460V 200-250HP EXHAUST SOLID STATE MOTOR CONTROLS SOLID STATE MOTOR CONTROLS 90 INTAKE FANS 24 © 2002 Saftronics, Inc. 36 FPC5010S HVAC Instruction Manual 24 103 Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 460V 150HP 300-800HP EXHAUST 90 INTAKE 24 104 INTAKE 48 FPC5010S HVAC Instruction Manual 24 © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com 9.3.2 Nema 12 / 3R Enclosures FPC5010S 208V / 230V 460V 0.5-10HP 0.5-15HP 16.00 37.25 38.51 3.00 © 2002 Saftronics, Inc. 12.00 10.00 FPC5010S HVAC Instruction Manual 105 Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 460V 15-25HP 20-30HP 16.00 56.00 13.00 106 57.26 3.00 FPC5010S HVAC Instruction Manual 10.00 © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 460V 30-40HP 40-75HP 21.00 72.00 16.00 © 2002 Saftronics, Inc. 3.00 73.25 15.00 FPC5010S HVAC Instruction Manual 107 Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 460V 50-75HP 100-150HP EXHAUST PORT 48 INTAKE FAN 16 36 24 60 108 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 100-125HP 460V 200-250HP EXHAUST 90 INTAKE FANS 24 © 2002 Saftronics, Inc. 36 FPC5010S HVAC Instruction Manual 24 109 Chapter 9 - Appendix www.saftronics.com FPC5010S 208V / 230V 460V 150HP 300-800HP EXHAUST 90 INTAKE 24 110 INTAKE 48 FPC5010S HVAC Instruction Manual 24 © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com 9.4 Maintenance & Inspection This section describes the basic maintenance and inspection procedures for the FPC5010S. The FPC5010S will function longer if kept clean, cool and dry, and if all precautions highlighted in this manual are observed. Periodically inspect the FPC5010S package as described in the table below to prevent accidents and to ensure high performance with high reliability. 9.4.1 Daily Inspections During operation, a visual inspection for abnormal operation can take place externally without removing the covers. The inspection should cover the following areas: (1) The performance, according to standard specifications, is as expected. (2) The environment conforms to standard specifications. (3) The keypad panel display is normal. (4) There are no abnormal sounds, vibrations, or odors. (5) There are no indications of overheating or discoloration. 9.4.2 Periodic Inspections Periodic inspections should be made after stopping operations, cutting off the power source, and removing the surface cover. Note that after turning off the power, the smoothing capacitors in the DC section of the main circuit take time to discharge. To prevent electric shock, confirm with a multimeter that the voltage has dropped below the safety value (25 V DC or below) after the charge lamp (CRG) goes off. WARNING 1. Start the inspection at least five minutes after turning off the power supply for inverters rated 30 Hp or less. Wait at least ten minutes for inverters rated at 40Hp or more. Check that the charge lamp (CRG) went off and that the voltage is 25VDC or less between terminal P(+) and N(-). Electric shock may result. 2. Only authorized personnel should perform maintenance and component replacement operations. Remove metal jewelrr, such as watches and rings, and always use insulated tools. 3. Never modify the drive. Electric shock or injury may result. © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 111 Chapter 9 - Appendix www.saftronics.com Area to Check Items to Check How to inspect Evaluation Criteria Environment 1) Check the ambient temperature, humidity, vibration, atmosphere (dust, gas, oil mist, water drops). 2) Is the area surrounding the equipment free of foreign objects. 1) Conduct a visual inspection and use appropriate meters. 2) Visual inspection 1) Results comply with all standard specifications. 2) The area is clear. Voltage Are the voltages in the main circuit and the control circuit normal? Measure with a multi-meter. Results comply with all standard specifications. Keypad panel 1) Is the display hard to read? 2) Are the characters complete? 1) Visual inspection 2) Visual inspection 1), 2) The display can be easily read and characters are normal. Structure (frame or cover) 1) 2) 3) 4) Is there abnormal sound or vibration? Are nuts or bolts loose? Is there deformation or damage? Is there discoloration as a result of overheating? 5) Are there stains or dust? 1) Visual and aural inspection 2) Tighten 3), 4), 5) Visual inspection 1), 2), 3), 4), 5) No abnormalities Common 1) Are there loose or missing nuts or bolts? 2) Are there deformations, cracks, damage, or discoloration due to overheating or deterioration in the equipment and insulation? 3) Are there stains and dust? 1) Tighten. 2), 3) Visual inspection 1), 2), 3) No abnormalities Note: Discolorationof the bus bar does not indicate a problem. Conductors and wiring 1) Is there discoloration or distortion of a conductor due to overheating? 2) Are there cracks, crazing or discoloration of the cable sheath? 1), 2) Visual inspection 1), 2) No abnormalities Visual inspection No abnormalities Cooling System Control Circuit Main Circuit Terminal block Is there damage? Smoothing capacitor 1) Is there electrolyte leakage, discoloration, crazing, or swelling in the case? 2) Is the safety valve not protruding, or are valves protruding too far? 3) Measure the capacitance if necessary. 1), 2) Visual inspection 3) *Estimate life expectancy from maintenance information and from measurements using capacitance measuring equipment. 1), 2) No abnormalities 3) Capacitance is within 85% of initial value Resistor 1) Is there any unusual odor or damage to the insulation by overheating? 2) Is there an open circuit? 1) Visual and olfactory inspection 2) Conduct a visual inspection or use a multi-meter by removing the connection on one side. 1) No abnormalities 2) Less than about ±10% of the indicated resistance value Transformer and reactor Is there abnormal buzzing or an unpleasant smell? Aural, olfactory, and visual inspection No abnormalities Magnetic conductor and relay 1) Is there a rattling noise during operation? 2) Are the contacts rough? 1) Aural inspection. 2) Visual inpection. 1), 2) No abnormalities Control PC board and connector 1) Are there any loose screws or connectors? 2) Is there an unusual odor or discoloration? 3) Are there cracks, damage, deformation, or excessive rust? 4) Is there electrolyte leakage or damage to the capacitor? 1) 2) 3) 4) 1), 2), 3), 4) No abnormalities Cooling fan 1) Is there abnormal sound or vibration? 2) Are nuts or bolts loose? 3) Is there discoloration due to overheating? 1) Aural and visual inspection. Turn manually (confirm the poewr is off). 2) Tighten. 3) Visual inspection 4) *Estimate life expectancy by maintenance information 1) The fan must rotate smoothly. 2), 3) No abnormalities Ventilation Is there foreign matter on the heat sink or intake and exhaust ports? Visual inspection No abnormalities Aural inspection. Visual and olfactory inspection Visual inspection *Estimate life expectancy by visual inspection and maintenace information See additional notes on following page. 112 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com Note: If equipment is stained, wipe with a clean cloth. Use a vacuum to remove dust. *Estimate of life expectancy based on maintenance information. The maintenance information is stored in the drive keypad panel. It indicates the electrostatic capacitance of the main circuit capacitors and the life expectancy of the electrolytic capacitors on the control PC board and the cooling fans. Use this data as the basis to estimate the life expectancy of parts. 1) Determining the capacitance of the main circuit capacitors This drive is equipped with a function to automatically indicate the capacitance of the capacitors installed in the main circuit when powering up the drive after disconnecting the power according to the prescribed conditions. The initial capacitance values are set in the drive when shipped from the factory, and the decrease ratio (%) to those values can be displayed. Use this function as follows: (1) Remove any option boards from the inverter. Disconnect the DC bus connections to the main circuit [Terminals P(+) and N(-)] from the braking unit or other inverters, if connected. The power factor correcting reactor (DC reactor) does not need be disconnected. A power supply introduced to the auxiliary input [Terminals R0, T0] that provides control power should be isolated. (2) Disable all the digital inputs (FWD, REV, X1-X9) on the control terminals. Also disconnect RS485 serial communication, if used. Turn on the main power supply. Confirm that the cooling fan is rotating and that the inverter is not operating. (There is no problem if the “OH2 External thermal relay tripped” function is activated by the digital input terminal.) (3) Turn the main power off. (4) Turn on the main power again after verifying that the charge lamp is completely off. (5) Open the maintenance information on the keypad panel and confirm the capacitance values of the built-in capacitors. 2) Life expectancy of the PC control board The actual capacitance of a capacitor is not measured in this case. However, the integrated operating hours for the control power supply, multiplied by the life expectancy coefficient as defined by the temperature inside the inverter, will be displayed. Hence, the hours displayed may not agree with the actual operating hours, depending on the operational environment. Since the integrated hours are counted in unit hours, power input for less than one hour will be disregarded. 3) Life expectancy of cooling fan The integrated operating hours of the cooling fan are displayed. Since the integrated hours are counted in unit hours, power input for less than one hour will be disregarded. The displayed value should be considered a rough estimate because the actual life of a cooling fan is influenced significantly by the temperature. Table: Rough estimate of life expectancy using maintenance information Parts Capacitor in main circuit Recommended Level 85% or less of the initial value Electrolytic capacitor on control PC board 61,000 hours Cooling fan 40,000 hours (5 Hp or less), 25,000 hours (Over 7.5 Hp)* * Estimated life expectancy of a ventilation-fan at inverter ambient temperature of 40¡C © 2002 Saftronics, Inc. FPC5010S HVAC Instruction Manual 113 Chapter 9 - Appendix www.saftronics.com 9.5 Main Circuit Measurements The indicated values depend on the type of meter, because the harmonic component is included in the voltage and current of the main circuit power (input) and the output (motor) side of the inverter. If measuring with a meter for commercial power frequency use, use the meters shown in the table below. The power factor cannot be measured using power factor meters currently available on the market, which measure the phase difference between voltage and current. If power factors must be measured, measure the power, voltage, and current on the input side and output side, then calculate the power factor using the following formula: Power factor = Power [W] 3 x Voltage [V] x Current [A] x 100 [%] Table: Meters for Measuring Main Circuit Item Input (power supply) Side Voltage Meter name Meter type Ammeter AR,S,T Current Output (motor) Side Voltage DC Link Circuit Voltage P(+) - N(-) Current Voltmeter Powermeter Ammeter Voltmeter Powermeter VR,S,T WR,S,T AU,V,W VU,V,W WU,V,W Moving iron Rectifier or Digital Moving iron Rectifier Digital power type moving-iron power meter type type meter type DCVoltmeter V Moving coil type Symbol Note: If the output voltage is measured with a rectifier type meter, an error may occur. Use a digital AC power meter to ensure accuracy. 114 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc. Chapter 9 - Appendix www.saftronics.com 9.6 Insulation Test Avoid megger testing on an drive since an insulation test was completed at the factory. If a megger test must be completed, proceed as described below. Incorrect testing methods may result in product damage. If the specifications for the dielectric strength test are not followed, the drive may be damaged. If a dielectric strength test must be completed, contact your local distributor or nearest Fuji Electric sales office. (1) Megger test for the main circuit 1. 2. 3. 4. 5. Use a 500V DC megger and isolate the main power before starting measurement. If the test voltage is connected to the control circuit, remove all connection cables to the control circuit. Connect the main circuit terminals using common cables, as shown in Figure below. Perform the megger test only between the common cables connected to the main circuit and ground (Terminal ). A megger indicating 5M Ohm or more is normal. (This is the value measured with only the drive connected.) (2) Insulation test in the control circuit Megger and dielectric strength tests are not performed on the control circuit. Use a resistance multimeter with a high resistance range to check the control circuit. 1. Remove all external cables from the control circuit terminals. 2. Conduct a continuity test between grounds. A result of 1M Ohm or more is normal. (3) Exterior main circuit and sequence control circuit Remove all cables from drive terminals to ensure that test voltage is not applied to the drive. 9.7 Replacement Parts The life expectancy of a part depends on the type of part, the environment, and operating conditions. Parts should be replaced as shown in the table below. Table: Part replacement Part name Standard period for replacement Cooling fan 3 years Exchange for a new part Smoothing capacitor 5 years Exchange for a new part (determine after checking Electrlytic capacitor on the PC board 7 years Exchange for a new PC board (determine after checking) Fuse 10 years Exchange for a new part Ñ Determine after checking Other parts © 2002 Saftronics, Inc. Comments FPC5010S HVAC Instruction Manual 115 Chapter 9 - Appendix www.saftronics.com 9.8 Warranty Service The purpose of this section is to provide specific instructions to the user of the standard drive referenced in this book regarding warranty administration and how to obtain assistance on both in-warranty and out-ofwarranty equipment. If assistance is required to determine warranty status, identify defective parts, or obtain the name of your local distributor, contact: Saftronics, Inc. Technical Support 5580 Enterprise Parkway Ft. Myers, FL 33905 Phone: 941-693-7200 Fax: 941-693-2431 Web site: www.saftronics.com email: [email protected] Before calling the number at left to determine warranty status, the drive serial number will be required. This is located on the drive nameplate. If the drive is still under warranty, further information will be required per the “InWarranty Failure Checklist” shown on page 9-2 of this instruction manual. Please complete and return the Warranty Registration Card located inside back cover. OUT-OF WARRANTY PROCEDURES When the defective part has been identified, contact your local authorized Saftronics drives distributor to order replacement parts. 116 FPC5010S HVAC Instruction Manual © 2002 Saftronics, Inc.

Fpc5010s - Smart Bypass Instruction Manual

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