Trane Tr200 Users Manual BAS SVX49A EN 08/12/2011 Vertical Bypass/Non Bypass Panel / Operators Guide

Trane Heating System Vertical Bypass/Non Bypass Panel BAS-SVX49A-EN

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2015-01-21

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Operators Guide

TR200 Vertical Bypass/Non Bypass Panel

Trane optimizes the performance of homes and buildings around the world. A business of Ingersoll Rand, the
leader in creating and sustaining safe, comfortable and energy efﬁcient environments, Trane offers a broad
portfolio of advanced controls and HVAC systems, comprehensive building services, and parts. For more
information, visit www.Trane.com.

SAFETY WARNING
Trane has a policy of continuous product and product data improvement and reserves the right to change design and speciﬁcations without notice.
© 2011 Trane All rights reserved
BAS-SVX49A-EN 12 August 2011

Only qualiﬁed personnel should install and service the equipment. The installation, starting up, and servicing
of heating, ventilating, and air-conditioning equipment can be hazardous and requires speciﬁc knowledge and
training. Improperly installed, adjusted or altered equipment by an unqualiﬁed person could result in death or
serious injury. When working on the equipment, ovserve all precautions in the literature and on the tags,
stickers, and labels that are attached to the equipment.

August 2011
177R0253

MG14D122

*MG14D122*

Rev. 2011-08-12

BAS-SVX49A-EN

Safety

WARNING
EQUIPMENT HAZARD!
The vertical bypass/non bypass panel contains dangerous
voltages when connected to mains voltage. It is strongly
recommended that all electrical work conform to the
National Electrical Code (NEC) and all national and local
regulations. Installation, start-up and maintenance should
be performed only by qualified personnel. Failure to follow
the NEC or local regulations could result in death or
serious injury.
Motor control equipment and electronic controls are
connected to hazardous mains voltages. Extreme care
should be taken to protect against shock. The user must
be protected against supply voltage and the motor must
be protected against overload in accordance with
applicable national and local regulations. Be sure
equipment is properly grounded. Wear safety glasses
whenever working on electric control or rotating
equipment.

Grounding
Correct protective grounding of the equipment must be
established in accordance with national and local codes.
Ground currents are higher than 3mA.

Safety Guidelines
1.

Disconnect the drive and vertical bypass/non
bypass panel from mains before commencing
service work

DO NOT touch electrical parts of the vertical
bypass/non bypass panel or drive when mains is
connected. After mains has been disconnected,
wait 15 minutes before touching any electrical
components or read the label on vertical
bypass/non bypass panel.

The user must be protected against supply
voltage and the motor must be protected against
overload in accordance with applicable national
and local regulations.

While programming parameters, the motor may
start without warning. Activate the [Off] key on
the keypad when changing parameters.

The [Off] key on the keypad does not isolate the
drive from mains voltage and is not to be used as
a safety switch.

Warning against unintended start

WARNING
UNINTENDED START!
When the vertical bypass/non bypass panel is connected
to AC input power, the motor may start at any time. The
drive, panel, motor, and any driven equipment must be in
operational readiness. Failure to be in operational
readiness when panel and drive are connected to AC input
power could result in death, serious injury, or equipment
or property damage.
When the vertical bypass/non bypass panel is connected
to mains, the motor may be started by means of an
external switch, a serial bus command, an input reference
signal, or a cleared fault condition. Use appropriate
cautions to guard against an unintended start.

WARNING
GROUNDING HAZARD!
For operator safety, it is important to ground drive, vertical
bypass panel, and motor properly. Follow the grounding
guidelines of local and national codes. Failure to follow
grounding guidelines could result in death or serious
injury.

BAS-SVX49A-EN

Contents

Contents
1 Introduction
1.1.1 Purpose of the Manual

2-1

1.1.2 Overview

2-1

1.1.3 Typical Bypass Operation

2-1

1.2 Bypass Circuits

2-1

1.2.1 Three-contactor Bypass

2-1

1.3 Bypass Options

2-2

1.3.1 Common Run/Stop with Bypass

2-2

1.3.2 Automatic Bypass

2-2

1.3.3 Run Permissive in Bypass

2-2

1.3.4 Basic Fire Mode in Bypass

2-2

1.3.5 Advanced Fire Mode in Bypass

2-2

1.3.6 Overload Protection

2-2

1.4 Bypass Platform Configurations

2-3

1.5 Switch Mode Power Supply

2-3

1.5.1 Control Transformer

2-3

1.6 Disconnects

2-3

1.6.1 Main Disconnect

2-3

1.6.2 Mode Selector Switch

2-4

1.6.3 Panel Configurations

2-5

1.6.4 Panel Voltage and Frame Ratings

2-6

1.7 Power Component Functions

2-6

1.7.1 Power Fusing

2-6

2 Pre-installation

3-1

2.1.1 Receiving Inspection

3-1

2.1.2 Pre-installation Check

3-1

2.1.3 Installation Site Check

3-1

2.2 Harsh Environments

3-2

2.2.1 Airborne Liquids

3-2

2.2.2 Airborne Solids

3-2

2.2.3 Corrosive Chemicals

3-2

3 Installation

BAS-SVX49A-EN

2-1

4-1

3.1.1 Tools Required

4-1

3.1.2 Drive Fuses

4-1

3.1.3 Internal Main Panel Fuses

4-3

3.2 Mechanical Installation

4-3

Contents

3.2.1 Lifting

4-3

3.2.2 Hoist or Overhead Lift

4-3

3.2.3 Forklift

4-3

3.2.4 Shipping Weights

4-3

3.3 Cooling

4-4

3.4 Electrical Installation

4-5

3.4.1 Component Identification & Customer Connection

4-7

3.4.2 Wire and Cable Access

4-15

3.4.3 Wire Size

4-19

3.4.4 Wire Type Rating

4-20

3.4.5 Terminal Tightening Torques

4-20

3.4.6 Input Line Connection

4-25

3.4.7 Motor Wiring

4-25

3.4.8 Grounding (Earthing)

4-26

3.4.9 Control Wiring

4-26

3.4.10 Serial Communication Bus Connection

4-27

3.4.11 Drive Control Terminals

4-28

4 Start Up
4.1.1 Inspection Prior to Start Up

5-2

4.1.2 Start Up Procedure

5-2

5 Electromechanical Bypass (EMB2) Operation

6-1

5.1.1 Typical Control Connections for Common HVAC Applications

6-1

5.1.2 EMB2 Auto Bypass

6-3

5.1.3 EMB2 Common Run/Stop

6-3

5.1.4 EMB2 Run Permissive

6-4

5.1.5 EMB2 Overload

6-4

5.1.6 EMB2 Safety Interlock

6-5

5.1.7 EMB2 Fire Mode

6-5

5.1.8 EMB2 Fault Reporting

6-5

5.1.9 EMB2 Switches

6-6

6 Electronically Controlled Bypass (ECB) Operation

BAS-SVX49A-EN

5-1

7-1

6.1 Electronically Controlled Bypass (ECB) Operation

7-1

6.1.1 Overview

7-1

6.1.2 ECB Control Card

7-2

6.1.3 ECB Drive or Bypass Selection

7-5

6.1.4 ECB Programming

7-7

Contents

6.1.5 ECB Hand/OFF/Auto

7-8

6.1.6 ECB Mode of Operation

7-8

6.1.7 Bypass Status Word Bit Examples

7-10

6.1.8 ECB Auto Bypass

7-10

6.1.9 ECB Run Permissive

7-11

6.1.10 ECB Overload

7-11

6.1.11 ECB Safety Interlock

7-12

6.1.12 ECB Common Run/Stop

7-12

6.1.13 ECB Advanced Fire Mode

7-13

6.1.14 ECB Fault Reporting

7-13

7 Start Up Troubleshooting
7.1.1 Option Panel Alarm and Warnings

8 Appendix

BAS-SVX49A-EN

8-1
8-1
9-1

8.1.1 Dimensions

9-1

8.1.2 Mechanical Diagrams

9-2

8.1.3 Typical Wiring Diagrams

9-6

Contents

BAS-SVX49A-EN

Introduction

1 Introduction
1.1.1 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and operation of the option panel used in
conjunction with a Trane variable frequency drive (VFD or
drive). To enable efficient handling of the equipment,
requirements are provided for installation of mechanical,
electrical, control wiring, proper grounding, and environmental considerations. Pre-start and start up procedures
are detailed. Also included is a detailed overview of the
option panel bypass function. In addition, identification of
other optional components and their operation and start
up troubleshooting instructions are included. For the
electronically controlled bypass, additional programming
and operation information is provided.

1.1.2 Overview
A variable frequency drive regulates the speed and
operation of an electric motor. The drive is programmable
and offers many features and savings compared to
operating a motor from unregulated line voltage. The
option panel is a protective enclosure in which the drive
and various optional components are assembled and
mounted. The vertical non bypass panel is always
configured with a disconnect switch and fuses to protect
the drive. The vertical bypass panel allows switching
between running the motor from the drive (variable speed)
or across the line input power (constant speed).
The vertical bypass panel comes with one of two control
options:

•
•

The electromechanical bypass (EMB2)
Electronically controlled bypass (ECB)

The EMB2 is operated by a selector switch on the front of
the panel. The EMB2 controls a motor by switching
between drive control, operation in bypass, or off. In
addition, a test selection is available, which disengages the
motor from the drive but keeps the drive operational while
the motor runs in bypass. The switching function activates
contactors to provide power to the motor through the
drive or bypass circuitry, as required.

inputs, and status reporting. The VFD’s logic circuitry is
backed up by an independent panel-mounted power
supply so that, even if the drive loses power, control and
communication functions are maintained. Programming
and display are provided by the keypad. An important
feature of the ECB is the ability to accept commands from
a building automation system (BAS) and to report
operational status in return.
See more detailed descriptions of the EMB2 in 5 Electromechanical Bypass (EMB2) Operation and ECB in 6 Electronically
Controlled Bypass (ECB) Operation of this manual.

1.1.3 Typical Bypass Operation
With contactors M1 and M2 closed and contactor M3
open, the motor is running in drive control. Opening
contactor M2 removes power to the motor but allows the
drive to remain under power. This is referred to as test
mode. With contactors M1 and M2 open and contactor M3
closed, the motor is running in bypass from the line input
power.

1.2 Bypass Circuits
1.2.1 Three-contactor Bypass
The bypass circuit consists of a bypass contactor (M3)
interlocked with a drive output contactor (M2), a drive
input contactor (M1), and an overload relay. For the EMB2,
a door mounted Drive/OFF/Bypass/Test Selector switch is
used to electrically select whether the motor is powered
by the drive, connected to the full speed bypass, or
disconnected from both. The test position applies power
to the motor through the bypass (M3 closed) contactor but
removes power from the drive (M2 open) while keeping
the drive powered (M1 closed). A Pilot light indicates when
in bypass. For the ECB, control selection is made through
the drive keypad by pressing the DRIVE BYPASS key and
selecting from the available options shown. Display data
indicates when in bypass. The circuitry may be supplied
with either an input disconnect switch or an input circuit
breaker.

The ECB also uses contactors to provide power to the
motor through the drive or bypass circuitry. However, the
ECB contains a local processor that interacts with the
drive’s control logic for programmable options, remote

BAS-SVX49A-EN

1-1

Introduction

Contactor

Drive Mode OFF

Bypass

Test Mode

Mode
M1

Closed

Open

Closed

Open

Closed

Table 1.1 Contactor Operation

Figure 1.1 Basic Non Bypass Circuit

1.3.4 Basic Fire Mode in Bypass
1.3 Bypass Options
1.3.1 Common Run/Stop with Bypass
Allows a remote signal to initiate operation in either drive
control or bypass depending upon the position of the
bypass selector switch.

1.3.2 Automatic Bypass
This feature automatically transfers the motor from drive to
bypass without operator intervention when a fault
condition trips the drive, after a programmable time-out
period. The VFD’s internal fault circuitry controls this
action. The time delay permits all automatically resettable
faults to clear prior to transfer to bypass. Run permissive or
safety circuit signals override the auto bypass function and
may prevent or delay bypass operation.

This option switches the panel to bypass whenever a
remote fire mode signal is given to the VFD through the
input terminals. In either drive or bypass, fire mode is
intended to ignore common safety and overload inputs for
emergency situations. The motor will continue to run in
bypass until fire mode is removed or the drive, panel, or
motor fails. External safety signals and motor overload are
ignored when in fire mode.

1.3.5 Advanced Fire Mode in Bypass
The advanced fire mode allows for a variety of
programmable responses to an external fire mode
command signal. Bypass options are programmed through
the drive’s fire mode parameters. See 6.1.13 ECB Advanced
Fire Mode.

1.3.6 Overload Protection
1.3.3 Run Permissive in Bypass
With run permissive active, the drive sends a run request
and waits for a remote response before commanding the
motor to start. The response indicates the system is safe to
operate.

1-2

This thermally activated device provides mechanical
overload protection for the motor while in bypass
operation. It measures motor current and is set to the full
load amps (FLA) of the motor. A 1.2 x FLA service factor is
built-in and maintained, meaning that should the motor
current increase above that value, the overload will
calculate the level of increase to activate timing for the trip
function. The higher the current draw, the quicker the trip
response. The overload provides Class 20 motor protection.

BAS-SVX49A-EN

Introduction

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

Control Features

EMB2

Safety Interlock

ECB
X

Common Start / Stop

Automatic Bypass

Run Permissive

Basic Fire Mode

Advanced Fire Mode

Serial Communication

Table 1.2 Bypass Configurations

Figure 1.2 Basic Bypass Circuit

1.5.1 Control Transformer
1.5 Switch Mode Power Supply
The VFD’s logic circuitry is backed up by an independent
panel-mounted switch mode power supply so if the drive
loses power, control and communication functions are
maintained. The SMPS converts three-phase AC input
power to 24 V DC control power. Since the SMPS draws
power from all three phases, it offers immunity protection
from most phase-loss and brown-out conditions. The SMPS
is internally protected from short circuit on its output and
three board-mounted fuses provide additional protection.
The SMPS is not designed for external use and may take
up to 5 sec. to initialize at power-up. The SMPS will
maintain a 24 V DC output with a low input line voltage.
The 200 Volt SMPS will maintain the 24 V DC output with
a line voltage as low as 150 V AC and the 600 V SMPS to
335 V AC. Refer to Figure 1.2.

BAS-SVX49A-EN

A control transformer is included on larger horsepower
units where the contactor coils are AC. The control
transformer steps down the line input voltage to 120V AC.
The coils of AC contactors are isolated from the Switch
Mode Power Supply via relays.

1.6 Disconnects
1.6.1 Main Disconnect
The main disconnect removes line input power to the
drive and bypass. A main disconnect is available in four
options.

•

Fused disconnect. Two-position (ON/OFF) rotary
switch, padlock compatible, with three fuses, one
on each phase, built into the switch. For safety,
the switch must be in the OFF position before

1-3

Introduction

the option panel door can be opened. (Bypass
panel only.)

•

Disconnect without fuses. For user-supplied fuses
option. (Bypass panel only.)

•

Main circuit breaker. A thermal/ magnetic current
interrupt device using an ON/TRIP/OFF/RESET
switch. When in the ON position, a trip fault
removes power from the drive/bypass circuit and
the switch moves to the TRIP setting. The switch
must be moved to the RESET position
momentarily after the fault has been cleared to
reset the circuit breaker. (Bypass panel only.)

•

Main Disconnect with drive fuses. Non-bypass
panel two-position (ON/OFF) rotary switch that
disconnects the main AC line power to the drive
only.

1.6.2 Mode Selector Switch
The mode selector switch is used for 3-contactor bypass
on EMB2 units. The selector switch allows the operator to
select from four modes of operation.
Drive mode: When drive mode is selected, the M1 and M2
contactors are closed allowing power to flow in and out of
the drive to the motor.
Off mode: This mode opens all contactors removing any
power to the motor.
Bypass mode:When bypass mode is selected, the M3
contactor closes and allows the motor to run directly from
the input line power.
Test mode:Test mode closes the M1 and M3 contactors
and allows the motor to be powered by the input line
power. This also allows the drive to power up without
being connected to the motor. Refer to Figure 1.2.

1-4

BAS-SVX49A-EN

Introduction

1.6.3 Panel Configurations
The TR 200 Drive Series comes in two panel enclosure types. One is the non bypass and the other is the bypass. See
Table 1.3 for descriptions and available options.
Non bypass

Bypass

Drive plus both of the following:

Drive with bypass:

1. Fuses

2. Disconnect

2. Disconnect/Circuit Breaker
3. Contactors
4. Power Supply
5. Control Module

Table 1.3 Tier Definitions and Features

BAS-SVX49A-EN

1-5

Introduction

1.6.4 Panel Voltage and Frame Ratings
Table 1.4Table 1.4 defines the voltage and hp ratings of the frames sizes for the panel. See 8 Appendix for overall and
mounting dimensions.
Panel P2

Bypass

Non Bypass

(B3 - Drive)

TR200

Volts VAC

HP (KW)

208 & 230

7.5 (5.5) - 15 (11)

460 & 600

15 (11) - 25 (18.5)

Panel P3

Bypass

Non Bypass

(B4 - Drive)

TR200

Volts VAC

HP (KW)

208

20 (15)

230

20 (15) - 25 (18.5)

460 & 600

30 (22) - 50 (37)

Panel P4

Bypass

Non Bypass

(C3 - Drive)

TR200

20 (15) - 25 (18.5)

TR200

Volts VAC

HP (KW)

208

25 (18.5)

230

30 (22) - 40 (30)

460 & 600

60 (45) - 75 (55)

Panel P5

Bypass

Non Bypass

(C4 - Drive)

TR200

30 (22) - 40 (30)

TR200

Volts VAC

HP (KW)

208 & 230

50 (37) - 60 (45)

460 & 600

100 (75) - 125 (90)

Table 1.4 Panel Voltage and Frame Ratings

1.7 Power Component Functions
1.7.1 Power Fusing
For main panel power fuses, only use the specified fuse or
an equivalent replacement. For drive fuses only use the
specified fuse. See the fuse ratings label on the inside
cover of the unit or Table 3.2Table 3.2, Table 3.3Table 3.3,
Table 3.4Table 3.4 and Table 3.5Table 3.5.
Main fusing
Main fuses are located ahead of the drive and bypass.
Main fuses are designed to protect the circuitry within the
bypass panel but is not adequate to protect the drive.
Main fuses are dual-element, time-delay types and mount
inside the bypass enclosure.

1-6

Drive fusing
Drive fuses are located ahead of the drive and are a fastacting type. Drive fuses are standard in all bypass and nonbypass panels.
5,000 or 100,000 amp SCCR
The bypass panel supplied with a non fusible Main
Disconnect Switch is 5,000 amps short-circuit current rating
(SCCR). The bypass panel supplied with a Fusible
disconnect or circuit breaker is 100,000 amp SCCR. The
non bypass panel supplied with a non-fusible Main
Disconnect is 100,000 amp SCCR. See the panel label for
SCCR rating.

NOTE!
The 600 V circuit breaker option is 5,000 amp (SCCR).

BAS-SVX49A-EN

Pre-installation

2 Pre-installation
2.1.1 Receiving Inspection
Inspect the packaging and equipment closely when
received. Any indication of careless handling by the carrier
should be noted on the delivery receipt, especially if the
equipment will not be immediately uncrated. Obtain the
delivery person’s signed agreement to any noted damages
for any future insurance claims. Ensure that the model
number and power match the order and intended use for
the drive.
IMPORTANT LOST OR DAMAGED GOODS INSPECT THIS
SHIPMENT IMMEDIATELY UPON ARRIVAL If goods are
received short or in damaged condition, insist on a
notation of the loss or damage across the face of the
freight bill. Otherwise no claim can be enforced against
the transportation company. If concealed loss or damage is
discovered, notify your carrier at once and request an
inspection. This is absolutely necessary. Unless you do this
the carrier will not entertain any claim for loss or damage.
The agent will make an inspection and can grant a
concealed damage notation. If you give the transportation
company a clear receipt for equipment that has been
damaged or lost in transit, you do so at your own risk and
expense.
Trane is willing to assist you to collect claims for loss or
damage, but willingness on our part does not make us
responsible for collection of claims or replacement of
material. The actual filing and processing of the claim is
your responsibility.

2.1.2 Pre-installation Check
1.

Compare panel model number to what was
ordered.

Ensure each of the following are rated for the
same voltage:

•
•
•
•
3.

Drive
Panel
Power line
Motor

Ensure that the panel output rating is equal to or
greater than motor total full load current for full
motor performance.

•

Motor power size and panel must match
for proper overload protection.

•

If panel rating is less than motor; full
motor output cannot be achieved.

Check motor wiring:

•

Any disconnect between drive and
motor should be interlocked to drive
safety interlock circuit to avoid
unwanted drive trips.

•

Do not connect power factor correction
capacitors between the drive and motor.

•

Two speed motors must be wired
permanently for full speed.

•

Y-start, Δ-run motors must be wired
permanently for run.

2.1.3 Installation Site Check

•

Because the option panel relies on the ambient
air for cooling, it is important to observe the
limitations on ambient air temperature. Derating
concerns start above 104°F (40°C) and 3300 feet
(1000m) elevation above sea level.

•

It is important with multiple panels to check wall
strength. Make sure that the proper mounting
screws or bolts are used.

•

Ensure that the wall or floor area for installation
will support the weight of the unit.

•

If construction work continues after the
equipment is mounted, it is important to keep
the interior free from concrete dust and similar

Figure 2.1 Sample Panel Label

BAS-SVX49A-EN

2-1

Pre-installation

dirt. If the unit does not have power applied to it,
supply a protective covering. It is important to
ensure that the components stay as clean as
possible. It may be necessary to clean the interior
once construction is completed.

•

Keep drawings and manuals accessible for
detailed installation and operation instructions. It
is important that the manuals be available for
equipment operators.

2.2 Harsh Environments

NOTE!
The mechanical and electrical components within the
option panel can be adversely affected by the
environment. The effects of contaminants in the air, either
solid, liquid, or gas, are difficult to quantify and control.

2.2.1 Airborne Liquids
Liquids in the air can condense in components. Water
carried in the air is easily measured as relative humidity,
but other vapors are often more difficult to measure or
control. Steam, oil and salt water vapor may cause
corrosion of components. In such environments, use TYPE
12 enclosures to limit the exchange of outside air into the
option enclosure. Extremely harsh environments may
require a higher level of protection.

2.2.2 Airborne Solids
Particles in the air may cause mechanical, electrical or
thermal failure in components. A TYPE 1 enclosure
provides a reasonable degree of protection against falling
particles, but it will not prevent the fan from pulling dirty
air into the enclosure.

2.2.3 Corrosive Chemicals
In environments with high temperatures and humidity,
corrosive gases such as sulfur, nitrogen and chlorine
compounds cause corrosion to occur in components.
Indications of corrosion are blackened copper or rust on
steel or oxidized aluminum. In such environments, it is
recommended that the equipment be mounted in a
cabinet with fresh air ventilation and that corrosive
compounds be kept away. A non-ventilated cabinet fitted
with an air conditioner as a heat exchanger may be used.
Conformal coated circuit boards may be specified to
reduce the corrosive effects of a harsh environment.

2-2

BAS-SVX49A-EN

Installation

3 Installation
3.1.1 Tools Required

TOOLS
Spreader bar capable of lifting up to 750 lbs.

In addition to the standard tool kit, the tools in Table 3.1
are recommended for installation of the option panel.

Max diameter 0.5 in.
Forklift, crane, hoist or other lifting device capable of handling
up to 750 lbs. (Qualified device operator available for operating
the equipment.)
Metric Socket Set: 7 - 19mm
Socket Extensions: 4, 6, and 12 inch
Torx driver set: T10 - T40
Torque wrench: 6 - 375 lbs-in
Allen Wrenches:1/8, 3/16, 1/4, & 5/16 inches
Metric or English wrenches: 7 - 19mm
Table 3.1 Tools Required

3.1.2 Drive Fuses
To maintain UL, the drive fuses should be replaced only with the fuses specified in , , , and . If an alternate drive fuse is
desired please consult the factory. See the specifications label inside the cover of the unit for acceptable replacement drive
fuses. A sample of this data can be seen in Table 3.6
208 V AC
HP (KW)

UL Motor

Panel (TR200) Non Bypass

Main Fuse (TR200)

Drive Fuse (TR200)

Transformer Fuse (TR200)

Current

& Bypass

Bussman

LPJ-40-SP

JJN-50

LPJ-50-SP

JJN-50

7.5 (5.5)

24,2

10 (7.5)

30,8

15 (11)

46,2

20 (15)

59,4

25 (18.5)

74,8

30 (22)

40 (30)

114

50 (37)

143

60 (45)

169

P2
P3
P3 - Non Bypass P4 Bypass
P4
P5

LPJ-70-SP

JJN-60

LPJ-90-SP

JJN-80

LPJ-125-SP

JJN-125

LPJ-150-SP

JJN-125

LPJ-175-SP

JJN-150

LPJ-250-SP

JJN-200

FNQ-R-1.25

LPJ-250-SP

JJN-250

FNQ-R-1.25

Table 3.2 Drive Fuses 208 V

BAS-SVX49A-EN

3-1

Installation

230 V AC
HP (KW)

UL Motor

Panel (TR200) Non Bypass

Main Fuse (TR200)

Drive Fuse (TR200)

Transformer Fuse (TR200)

Current

& Bypass

Bussman

LPJ-35-SP

JJN-50

7.5 (5.5)

10 (7.5)

15 (11)

20 (15)

25 (18.5)

30 (22)

40 (30)

104

50 (37)

130

60 (45)

154

P3
P4
P5

LPJ-45-SP

JJN-50

LPJ-70-SP

JJN-60

LPJ-90-SP

JJN-80

LPJ-100-SP

JJN-125

LPJ-125-SP

JJN-125

LPJ-150-SP

JJN-150

LPJ-200-SP

JJN-200

FNQ-R-1.25

LPJ-250-SP

JJN-250

FNQ-R-1.25

Table 3.3 Drive Fuses 230 V
460 V AC
HP (KW)
15 (11)

UL Motor

Panel (TR200) Non

Main Fuse (TR200)

Drive Fuse (TR200)

Transformer Fuse (TR200)

Current

Bypass & Bypass

Bussman

LPJ-35-SP

JJS-40

20 (15)

25 (18.5)

30 (22)

40 (30)

50 (37)

60 (45)

75 (55)

100 (75)

124

125 (90)

156

P4
P5

LPJ-40-SP

JJS-40

LPJ-50-SP

JJS-50

LPJ-60-SP

JJS-60

LPJ-80-SP

JJS-80

LPJ-100-SP

JJS-100

LPJ-125-SP

JJS-125

LPJ-150-SP

JJS-150

LPJ-200-SP

JJS-200

FNQ-R-0.60

LPJ-250-SP

JJS-250

FNQ-R-0.60

Table 3.4 Drive Fuses 460 V
600 V AC
HP (KW)

UL Motor

Panel (TR200) Non

Main Fuse (TR200)

Drive Fuse (TR200)

Transformer Fuse (TR200)

Current

Bypass & Bypass

Bussman

LPJ-30-SP

JJS-35

LPJ-35-SP

JJS-35

15 (11)

20 (15)

25 (18.5)

LPJ-45-SP

JJS-45

30 (22)

LPJ-50-SP

JJS-50

40 (30)

LPJ-60-SP

JJS-60

50 (37)

LPJ-80-SP

JJS-80

60 (45)

LPJ-100-SP

JJS-100

75 (55)

LPJ-125-SP

JJS-125

100 (75)

125 (90)

125

P4
P5

LPJ-150-SP

JJS-150

FNQ-R-0.50

LPJ-200-SP

JJS-175

FNQ-R-0.50

Table 3.5 Drive Fuses 600 V

3-2

BAS-SVX49A-EN

Installation

3.1.3 Internal Main Panel Fuses
Use only the specified fuse or an equivalent replacement for the internal main fuses. See the specifications label inside the
cover of the unit for acceptable replacement main fuses. A sample of this can be seen in Table 3.6.
Fuse

Description

Manufacturer

Part Number/Size

F13A & C

Primary Transformer

Bussmann

FNQ-R-0.50
LPJ-30-SP

F15A, B, & C

Main Fuses

Bussmann

F16A, B, & C

Drive Fuses

Bussmann

JJS-35

F900, F901,F902

SMPS - Power Supply

Bussmann

FWH-020A6F, 500V

Table 3.6 Sample Fuse Rating Label

3.2 Mechanical Installation
3.2.1 Lifting

WARNING
Heavy Objects!
Do not use cables (chains or slings) except as shown. Each
of the cables (chains or slings) used to lift the unit must be
capable of supporting the entire weight of the unit. Lifting
cables (chains or slings) may not be of the same length.
Adjust as necessary for even unit lift. Other lifting
arrangements may cause equipment or property-only
damage. Failure to properly lift unit could result in death
or serious injury. See details below.

WARNING
Check the weight of unit to determine the safety of the
lifting method. Ensure that the lifting device is suitable for
the task. If necessary, plan for a hoist, crane or forklift with
appropriate rating to move the units.
Follow recommendations below. failure to do so could
result in death or serious injury.

3.2.3 Forklift

•

Only a competent lift operator with additional
support personnel should attempt moving the
unit.

•

Carefully position forklift and ensure stability prior
to lift.

3.2.4 Shipping Weights
Weights listed in Table 3.7 are approximate for base units.
Options can add or reduce weight of unit. Weights listed
are in lbs.
Frame

Non Bypass Panel

Bypass Panel
84

106

167

155

248

Table 3.7 Approximate Shipping Weights

3.2.2 Hoist or Overhead Lift

•

Use a solid steel spreader bar for lifting. Slide the
spreader bar through the two (2) lifting holes on
the panel. Lifting rings are 0.59in (15mm) in
diameter (see Figure 3.1). If VFD mounting screws
interfere with the spreader bar, lifting hooks can
be used instead of the lifting bar.

•

Connect the spreader bar to a hoist or other
lifting device.

•

Carefully lift the unit and secure it to the wall.
Refer to 8 Appendix for dimensional drawings to
determine fasteners size and location.

BAS-SVX49A-EN

3-3

Installation

Figure 3.2 Side Cooling Clearance
Figure 3.1 Proper Lifting Method

3.3 Cooling

•
•

Only mount the drive and panel vertically.

•

Most panels may be mounted side-by-side
without additional side clearance. However, the
P2 (B3 frame size) units require 1.5 in. minimum
clearance between units (see Figure 3.2).

•

Top and bottom clearance is required for cooling
(see Figure 3.3). Generally, 2 to 10 inches (50 to
250mm) minimum clearance is required,
depending upon the hp (kW) of the unit. See the
dimensional drawings in 8 Appendix for specific
requirements.

•

No additional back plate is required for drives
with the bypass and non bypass panels.

Panels rely on the ambient air for cooling. It is
important to observe the limitations on ambient
air temperature. The maximum ambient
temperature for all bypass panels is 40°C and
45°C for non bypass panels. Derating concerns
start above 3300 feet elevation above sea level.

Figure 3.3 Cooling Airflow

3-4

BAS-SVX49A-EN

Installation

3.4 Electrical Installation

WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects
before servicing. Follow proper lockout/tagout procedures
to ensure the power cannot be inadvertently energized.
Failure to disconnect power before servicing could result in
death or serious injury.

WARNING
Proper Field Wiring and Grounding Required!
All field wiring MUST be performed by qualified personnel.
Improperly installed and grounded field wiring poses FIRE
and ELECTROCUTION hazards. To avoid these hazards, you
MUST follow requirements for field wiring installation and
grounding as described in NEC and your local/state
electrical codes. Failure to follow codes could result in
death or serious injury.

WARNING
EQUIPMENT HAZARD!
Rotating shafts and electrical equipment can be hazardous.
It is strongly recommended that all electrical work conform
to all national and local regulations. Installation, start-up
and maintenance should be performed only by qualified
personnel. Failure to follow local regulations could result in
death or serious injury.

•

•
•
•

Motor control equipment and electronic controls
are connected to hazardous line voltages.
Extreme care should be taken to protect against
electrical hazard.
Correct protective grounding of the equipment
must be established. Ground currents are higher
than 3mA.
A dedicated ground wire is required.
Wear safety glasses whenever working on electric
control or rotating equipment.

NOTICE!
Make all power connections with a minimum of 60°C/
140°F rated copper wire.

BAS-SVX49A-EN

WARNING
INDUCED VOLTAGE!
Run output motor cables from multiple drives separately.
Induced voltage from output motor cables run together
can charge equipment capacitors even with the equipment
turned off and locked out. Failure to run output motor
cables separately could result in death or serious injury.

NOTE!
Run input power, motor wiring and control wiring in three
separate metallic conduits or raceways for high frequency
noise isolation. Failure to isolate power, motor and control
wiring could result in less than optimum drive and
associated equipment performance.
NOTE RUN INPUT POWER, MOTOR WIRING AND CONTROL
WIRING IN THREE SEPARATE METALLIC CONDUITS OR
RACEWAYS FOR HIGH FREQUENCY NOISE ISOLATION.
FAILURE TO ISOLATE POWER, MOTOR AND CONTROL
WIRING COULD RESULT IN LESS THAN OPTIMUM DRIVE
AND ASSOCIATED EQUIPMENT PERFORMANCE.

•

Because the motor wiring carries high frequency
electrical pulses, it is important that no other
wires are run together. If the incoming power
wiring is run in the same conduit as the motor
wiring, these pulses can couple electrical noise
back onto the building power grid.

At least three separate conduits must be connected to the
panel (Figure 3.4).

•

Power into the panel (and ground back to the
distribution panel)

•

Power from the panel to the motor and earth
insulated motor ground

•

Control wiring

Control wiring should always be isolated from the high
voltage power wiring.
Avoid getting metal chips into electronics.
Follow the connection procedures as illustrated in the
drawing provided with the unit.

3-5

Installation

Figure 3.4 Power Connections

3-6

BAS-SVX49A-EN

Installation

3.4.1 Component Identification & Customer Connection
Mechanical layout drawings are intended to provide the installer or equipment user with component identification and
location for that specific unit. Figure 3.5 represents a typical layout drawing. Table 3.8 provides definitions for drawing
reference designators. (Not all reference designators are shown.)

Figure 3.5 P2 Bypass Mechanical Layout Diagram

Device

24 V DC

Panel 24 V DC SMPS

Definition

Device

HPC

High Pot Connector

F13

T1 primary fuse

VFD

Definition
Auto Bypass Selector Switch
120 V AC control transformer
Variable frequency drive

CB1

Main Circuit Breaker

EMB2

Control Module

DS1

Main or Drive Disconnect

ECB

Control Module

F15

Main fuse

TB1-C

Terminal block 1 - Control

F16

Drive fuse

TB1-P

Terminal block 1 - Power

GND

Ground terminal

PR1

keypad

PR2

Control Relay for M2 Contactor

Drive Input contactor

PR3

Control Relay for M3 Contactor
Under voltage module

Control Relay for M1 Contactor

Drive Output contactor

UVM

Bypass contactor

Top Cover

OL1

Overload for Motor

Disconnect Handle

PL1

Bypass indicator light

Table 3.8 Reference Designator Definitions

BAS-SVX49A-EN

3-7

Installation

Figure 3.6 P2 Non Bypass Mechanical Layout Diagram.