Johnson Controls VSD II Series Installation Manual
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Johnson Controls VSD II Series Installation Manual

Johnson Controls VSD II Series Installation Manual

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VSD Series II
Installation Manual
Effective October 2012
New Information

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Summary of Contents for Johnson Controls VSD II Series

  • Page 1 VSD Series II Installation Manual Effective October 2012 New Information...
  • Page 3 Important Notice–Please Read The product discussed in this literature is subject to terms and conditions outlined in Johnson Controls Inc. selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Johnson Controls Inc.
  • Page 4 ® Custom Engineered Drives and Obsolete Products 1. JOHNSON CONTROLS agrees to accept VSD Open products for return and without penalty or restocking charge. JOHNSON CONTROLS will issue a 100% credit—provided the product is in its original unopened package and is returned within 120 days of receipt of product by JOHNSON CONTROLS.
  • Page 5 –> HVAC Controls –> Variable Speed Drives Johnson Controls Product Sales Operation Call the Johnson Controls PSO Team if you need assistance with placing an order, stock availability or proof of shipment, expediting an existing order, emergency shipments, product price information and returns (including warranty returns).

  • Page 6: Table Of Contents

    VSD Series II Table of Contents SAFETY Before Commencing the Installation ....... . . Definitions and Symbols .
  • Page 7 VSD Series II List of Figures Drive System (PDS) ........... . AC Power Networks with Grounded Center Point (TN-/TT Networks) .
  • Page 8 VSD Series II List of Tables Identification on the Residual-Current Circuit-Breakers ......Assignment of Frequency Inverters to Example Motor Circuit ....Maintenance Measures and Intervals .

  • Page 9: Before Commencing The Installation

    VSD Series II Safety Warning! Dangerous Electrical Voltage! Before Commencing the Installation Disconnect the power supply of the device Measures should be taken to ensure the proper restart of ● ● programs interrupted after a voltage dip or failure. This Ensure that devices cannot be accidentally restarted ●...

  • Page 10: Definitions And Symbols

    VSD Series II Safety Definitions and Symbols Warnings and Cautions WARNING CAUTION This symbol indicates high voltage. It calls your When selecting the cable cross-section, take the voltage attention to items or operations that could be dangerous drop under load conditions into account. to you and other persons operating this equipment.
  • Page 11 VSD Series II WARNING CAUTION The frequency inverter outputs (U, V, W) must not be Debounced inputs may not be used in the safety circuit connected to the input voltage (destruction of the diagram. device, risk of fire). Ground contact currents in frequency inverters are greater than 3.5 mA (AC).
  • Page 12 VSD Series II VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 13: Engineering

    Engineering Engineering Introduction This chapter describes the most important features in the energy circuit of a drive system (PDS Power Drive System) that you should take into consideration in your project planning. Drive System (PDS) Item Number Description Network configuration, input voltage, input frequency, interaction with p.f.

  • Page 14: Electrical Power Network

    Engineering Electrical Power Network Input Connection and Configuration Input Voltage and Frequency The VSD Series II frequency inverters can be connected and The standardized input voltages (IEC 60038, VDE017-1) for operated with all control-point grounded AC power networks energy suppliers (EVU) guarantee the following conditions at (see IEC 60364 for more information).
  • Page 15 Engineering Voltage Balance Idle Power Compensation Devices Because of the uneven loading on the conductor, and with Compensation on the power supply side is not required for the direct connection of greater power ratings, deviations VSD Series II frequency inverters. From the AC power supply from the ideal voltage form and asymmetrical voltages can network, they take on very little reactive power of the be caused in three-phase AC power networks.

  • Page 16: Safety And Switching

    Engineering Safety and Switching Fuses and Cable Cross-Sections Residual-Current Device (RCD) The fuses and wire cross-sections allocated for power-side RCD (Residual Current Device): Residual current device, connections depend on the rated input current I LN of the residual current circuit breaker (FI circuit breaker). frequency inverter (without input reactor).

  • Page 17: Emc Measures

    Engineering The leakage current to ground is greater than 3.5 mA with a EMC Measures frequency inverter. Based on the requirements of EN 50178, Electrical components in a system (machine) have a an increased ground (PE) has to be connected. The cable reciprocal effect on each other.

  • Page 18: Motor And Application

    Engineering Motor and Application Motor Selection Parallel Connection of Several Motors to One Frequency Inverter General recommendations for motor selection: Use three-phase powered asynchronous motors with ● short-circuit rotors and surface cooling, also called asynchronous motors or standard motors for the frequency-controlled drive system (PDS).

  • Page 19: Example Of A Motor Ratings Plate

    Engineering Motor and Circuit Type The motor’s stator winding can be connected in a star or Because of the higher thermal loading, using only the next delta configuration, in accordance with the rated operational higher motor output according to the list (1.1 kW) is recommended.

  • Page 20: Bypass Motor Control (Example)

    Engineering Bypass Operation If you want to have the option of operating the motor with CAUTION the frequency inverter or directly from the input supply, the input branches must be interlocked mechanically. Debounced inputs may not be used in the safety circuit diagram.

  • Page 21: System Overview

    System Overview System Overview Component Identification VSD Series II Description of the VSD Series II BYPA SS HO A Back 2 sec. BYP ASS STOP RESE T HO A STAR T Back 2 sec. STO P RES ET STA RT Item Number Description...

  • Page 22: Block Diagram, Elements Of Vsd Series Ii Frequency Inverters

    System Overview Block Diagram, Elements of VSD Series II Frequency Inverters R– U/T1 V/T2 W/T3 Item Number Description Supply L1, L2/N, L3, PE, input supply voltage U LN = U e at 50/60 Hz: 200V class, three-phase input connection (3 AC 230V/240V) 400V class, three-phase input connection (3 AC 400V/480V) Internal interference suppression filter, category C2 to IEC/EN 61800-3 EMC-connection of internal interference suppression filter to PE...

  • Page 23: Selection Criteria

    System Overview Selection Criteria The frequency inverter [3] is selected according to the supply When connecting multiple motors in parallel to the output of voltage U LN of the input supply [1] and the rated current of a frequency inverter, the motor currents are added the assigned motor [2].

  • Page 24: Proper Use

    System Overview Proper Use Maintenance and Inspection The VSD Series II frequency inverters are not domestic VSD Series II frequency inverters are maintenance free. appliances. They are designed only for use as HVAC or However, external influences may affect the function and the pumping system components.

  • Page 25: Storage

    System Overview Storage Service and Warranty If the frequency inverter is stored before use, suitable In the unlikely event that you have a problem with your VSD ambient conditions must be ensured at the site of storage: Series II frequency inverter, please contact your local sales office.

  • Page 26: Vsd Series Ii Overview

    VSD Series II Overview VSD Series II Overview This chapter describes the purpose and contents of this Check to make sure that the package includes the Installation manual, the receiving inspection recommendations and the Manual (LIT-12011772), Quick Start Guide (LIT-12011771) VSD Series II Open Drive catalog numbering system.

  • Page 27: Rating Plate

    VSD Series II Overview Rating Plates Manuals Carton Label VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 28: Catalog Number Selection

    261 = 261 Amp (200 Hp, 132 kW) L = Lon Works, C4 Card (Open Only) 310 = 310 Amp (250 Hp, 160 kW) Note Solutions pending. Check with your Johnson Controls representative for availability. VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 29: Power Ratings And Product Selection

    VSD Series II Overview Power Ratings and Product Selection VSD Series II Drives—208–230 Volt NEMA Type 1/IP21 or NEMA Type 12/IP54 Assigned Drive Rated Current and hp De-Rated Motor Ratings x = Can Be: Drive Rating Open Drive 1 = N1 = IP21 Low Overload 230V Drive...

  • Page 30: Nema Type 1/Ip21 Or Nema Type 12/Ip54

    VSD Series II Overview VSD Series II Drives—380–480 Volt NEMA Type 1/IP21 or NEMA Type 12/IP54 Assigned Drive Input Rated Current and hp De-Rated Motor Ratings x = Can Be: Open Drive 1 = N1 = IP21 Low Overload 460V Drive NEC Motor Low Overload...

  • Page 31: Electrical Installation

    VSD Series II Overview Electrical Installation WARNING Carry out wiring work only after the frequency inverter has been correctly mounted and secured. WARNING Electric shock hazard—risk of injuries! Carry out wiring work only if the unit is de-energized. CAUTION Debounced inputs may not be used in the safety circuit diagram.

  • Page 32: Installation Requirements

    Installation Requirements Installation Requirements This chapter contains all of the information required to properly Measure the mounting space to ensure that it allows the install and prepare the VSD Series II VSD for operation. The minimum space surrounding the VSD Series drive. Drive contents are listed to serve as a list of tasks needed to dimensions are on Page 21.

  • Page 33: Nema Type 1/12 Open Drives (1-250 Hp)

    Installation Requirements NEMA Type 1/12 Open Drives (1–250 hp) Approximate Dimensions in Inches (mm) Mounting Drive Dimensions VSD Series II Frames FS4—FS7 Hole Center- Center Frame Line Weight in Size Voltage (VT) Amperes Lbs (kg) 230 Vac 0.75–4 0.55–3.0 3.7–12.5 7.77 12.89 12.32...

  • Page 34: Power Wiring Selection

    (UL recognized, IEC 60269-4) ● Refer to the following tables for cable sizing guidelines gS (IEC 60269-4) ● ● Consult with Johnson Controls for further information on North America 208–240V Page 43 fusing requirements. North America 380–480V Page 44 All other International 380–600V...

  • Page 35: Power Connection Tightening Torque

    Installation Requirements Power Connection Tightening Torque Tightening Tightening Torque Torque Fame Size Voltage hp (VT) Amperes (in-lbs) (Nm) 230 Vac 0.75-4 0.75–3.0 3.7–12.5 400 Vac — 1.1–5.5 3.4–12 460 Vac 1.5–7.5 — 3.4–12 230 Vac 5–10 4–7.5 18–31 400 Vac —...

  • Page 36: Input Power And Motor Cable Stripping Lengths

    Installation Requirements Input Power and Motor Cable Stripping Lengths Ground Ground Power Motor Input Power and Motor Cable Stripping and Wire Lengths Power Wiring Motor Wiring in Inches (mm) in Inches (mm) Frame Size Voltage hp (VT) Amperes 230 Vac 0.75–4 0.55–3.0 3.7–12.5...

  • Page 37: Cable Routing

    Installation Requirements Cable Routing If conduit is being used for wiring, use separate conduits for Refer to the table on Page 23 for maximum cable lengths by line voltage (mains), motor cables, and all interface/control frame size. wiring. If three or more motor cables are used, each conductor must Avoid running motor cables alongside or parallel to any have its own overcurrent protection.
  • Page 38 Installation Requirements Power Wiring Notice Do not discard the plastic bag containing the wiring hardware. Remove the cover by removing (4) screws, then lifting the cover away from the base. Wiring Hardware Contents European rubber grommet and ● flat rubber grommet (for IP54 integrity). Modification label ●...
  • Page 39 Installation Requirements Power Wiring/Grounding, continued Line Motor Wire power terminals (L1,L2,L3), motor terminal (U/T1, U/T2, U/T3), Removable Removable and grounding terminals per diagram EMC Filter Clip EMC Filter Clip R– U/T below. Power and motor leads must Line Ground Motor Ground be in separate conduit.
  • Page 40 RO1 Bypass Run 24 Vdc/8A 250 Vac/8A 125 Vdc/0.4A RO2 Drive Run RO3 Fault See Johnson Controls Network Communication End of Line Termination “MS-BACEOL-O” Installation Instructions (p/n: 24-10264-4) for N2 and BACnet MS/TP protocols. Terminal Block Layout 24 Vdc AO1+ AO1–...

  • Page 41: Control Board

    Installation Requirements Control Board The main VSD Series II VSD consists of a main control board, control I/O connections block and two slots for extra option boards. VSD Series II Variable Speed Drive Battery (Standard) Keypad (U.S. version shown) Analog Switch Control RJ45 CURRENT...

  • Page 42: Emc Installation

    Installation Requirements EMC Installation The responsibility to comply with the legally stipulated limit Install the frequency inverter as directly as possible (without values and thus the provision of electromagnetic spacers) on a metal plate (mounting plate). compatibility is the responsibility of the end user or system Route input and motor cables in the switch cabinet as close operator.

  • Page 43: Emc-Compliant Setup (Example: Vsd Series Ii)

    Installation Requirements EMC-Compliant Setup (Example: VSD Series II) W2 U2 V2 U1 V1 W1 24 Vdc 24 Vdc 115/120 Vac 11.81 in 115/120 Vac 230/240 Vac 230/240 Vac ( 300 mm) 400 Vac 400 Vac 460/480 Vac 460/480 Vac Notes Power cable: L1, L2, L3 and U/T1, V/T2, W/T3.

  • Page 44: Cable Description

    Installation Requirements International EMC Protection Cable Requirements 1st Environment 2nd Environment EMC Levels According to EN61800-3 (2004) Cable Type Category C2 Category C3 Level T Line voltage/mains Motor cable Control cable Cable Categories Description Recommended Cable Category (All cables are rated for the specific operating voltage) Cable Types Intended for fixed installation MCMK or similar...

  • Page 45: Locations Of The Emc-Jumpers In Frames Fs4 To Fs6

    Installation Requirements Installation in Corner-Grounded Network Installation in IT System Corner grounding is allowed for the drive types rating from If your supply network is an IT (impedance-grounded) system 72–310A at 380–480V supply and from 75–310A at but your AC drive is EMC-protected according to class C2 208–240V supply.

  • Page 46: Three-Phase Input Connection

    Installation Requirements Connection to Power Section The following figure shows the general connections for the frequency inverter in the power section. Three-Phase Input Connection Connection to Power Section Input Output U/T1 V/T2 W/T3 Motor Ground Connection 15 mm (0.59 in) 11.5 lb-in (1.3 Nm) 0.17 in...

  • Page 47: Removing The Jumper, Fs5 As Example

    Installation Requirements Disconnect the RFI-filters from ground by removing the Frames FS7 and FS8 EMC-jumpers using long-nose pliers or similar. See figure Follow the procedure described below to modify the EMC below. protection of the AC drive of frames FS7 and FS8 to EMC-level C4.

  • Page 48: Removing The Emc Jumper, Fs7 And Fs8

    Installation Requirements FS7 and FS8: Locate the EMC box under the cover. Remove FS7 only: Locate the DC grounding busbar between the screws of the box cover to expose the EMC-jumper. connectors R- and U and detach the busbar from the frame Detach the jumper and re-fix the box cover.

  • Page 49: Molex Connector Placement, Fs9

    Installation Requirements Frame FS9 Follow the procedure described below to modify the EMC Further remove the extension box cover, the touch shield protection of the AC drive of frame FS9 to EMC-level C4. and the I/O plate with I/O grommet plate. Locate the EMC jumper on the EMC board (see magnification in figure below) Find the Molex connector in the accessories bag.

  • Page 50: Checking The Cable And Motor Insulation

    Installation Requirements Checking the Cable and Motor Insulation Check the motor cable insulation as follows: Disconnect the motor cable from terminals U, V and W ● of the VSD Series II drive and from the motor Measure the insulation resistance of the motor cable ●...

  • Page 51: Technical Data

    Appendix A Appendix A Technical Data VSD Series II Technical Data Attribute Description Specification Mains connection Input voltage U in 208–240V, 380–480V, –10 to 10% Input frequency 50–60 Hz, –5 to 10% Connection to mains Once per minute or less Starting delay 4s (FS4 to FS6), 6s (FS7 to FS9) Motor connection...
  • Page 52 Appendix A VSD Series II Technical Data, continued Attribute Description Specification Ambient conditions, Vibration: 5–150 Hz continued • EN61800-5-1 Displacement amplitude: 1 mm (peak) at 5–15.8 Hz (FS4–FS9) • EN60668-2-6 Maximum acceleration amplitude: 1g at 15.8–150 Hz (FS4–FS9) Shock: UPS drop test (for applicable UPS weights) Storage and shipping: Maximum 15g, 11 ms (in •...

  • Page 53: Standard I/O Board

    Appendix A Technical Information on Control Connections Standard I/O Board Terminal Signal Description Reference output 10V, 3%: Maximum current 10 mA Analog input, voltage or current Analog input channel 1 0–10V (Ri 200 kohms) 4–20 mA (Ri 50 ohms) Resolution 0.1%, accuracy ±1% Selection V/mA with DIP switches Short-circuit protected Analog input common (current)

  • Page 54: Relay Board 1

    Appendix A Relay Board 1 Terminal Signal Description Relay output 1 Switching capacity 24 Vdc/8A 250 Vac/8A 125 Vdc/0.4A Minimum switching load 5V/10 mA Relay output 2 Switching capacity 24 Vdc/8A 250 Vac/8A 125 Vdc/0.4A Minimum switching load 5V/10 mA Relay output 3 Switching capacity 24 Vdc/8A...

  • Page 55: Cable Power And Motor Wiring Guidelines

    Appendix B Appendix B Cable Power and Motor Wiring Guidelines See Page 24 for cable stripping guidelines. North America Cable and Fuse Sizes—208–240 Vac Ratings Terminal NEC Wire Size Connection Size Motor Motor (AWG) (AWG) I(L) I(L) [kW] Rating Rating Amps Amps 230V...

  • Page 56: North America Cable And Fuse Sizes-380-480 Vac Ratings

    Appendix B North America Cable and Fuse Sizes—380–480 Vac Ratings Terminal NEC Wire Size Connection Size Motor (AWG) (AWG) I(L) I(L) [kW] Rating Amps Amps 230V Fuse Line Line Rating Frame Suffix 480 Vac 40°C 50°C 50 Hz (Class T) Motor Ground Motor...

  • Page 57: International Cable And Fuse Sizes 380-480 Vac Ratings

    Appendix B International Cable and Fuse Sizes 380–480 Vac Ratings Terminal Cable Size I(L) I(L) [kW] Mains and Amps Amps 400V Fuse Motor Main Earth Rating Cable Terminal Terminal Frame Suffix 40° C 50° C 50 Hz (gG/gL) Cu (mm Cu (mm Cu (mm 3*1.5+1.5...

  • Page 58: Dimension Drawings

    Appendix C Appendix C Dimension Drawings FS4 Dimension Drawing VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 59: Fs4 Dimension Drawing Flange Mount

    Appendix C FS4 Dimension Drawing Flange Mount VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 60: Fs5 Dimension Drawing

    Appendix C FS5 Dimension Drawing VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 61: Fs5 Dimension Drawing Flange Mount

    Appendix C FS5 Dimension Drawing Flange Mount VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 62: Fs6 Dimension Drawing

    Appendix C FS6 Dimension Drawing VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 63: Fs6 Dimension Drawing Flange Mount

    Appendix C FS6 Dimension Drawing Flange Mount VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 64: Fs7 Dimension Drawing

    Appendix C FS7 Dimension Drawing VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 65: Fs7 Dimension Drawing Flange Mount

    Appendix C FS7 Dimension Drawing Flange Mount VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 66: Fs8 Dimension Drawing Ip00

    Appendix C FS8 Dimension Drawing IP00 VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 67: Fs8 Dimension Drawing Ip2154 Flange Mount

    Appendix C FS8 Dimension Drawing IP2154 Flange Mount VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 68: Fs8 Dimension Drawing Flange Mount

    Appendix C FS8 Dimension Drawing Flange Mount VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 69: Fs9 Dimension Drawing

    Appendix C FS9 Dimension Drawing VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 70: Fs9 Dimension Drawing Ip2154

    Appendix C FS9 Dimension Drawing IP2154 VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...

  • Page 71: Fs9 Dimension Drawing Flange Mount

    Appendix C FS9 Dimension Drawing Flange Mount VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...
  • Page 72 Appendix C VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...
  • Page 73 Appendix C VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...
  • Page 74 Appendix C VSD Series II LIT-12011772—October 2012 www.johnsoncontrols.com...
  • Page 76 Eaton Technology Powered by © 2012 Johnson Controls Controls Group All Rights Reserved 507 E. Michigan Street Printed in USA P.O. Box 423 Publication No. LIT-12011772 / Z12051 Milwaukee, WI 53201 October 2012...

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