Q9 Plus Bypass ASD/Bypass Box I M - Toshiba · The Q9 Plus ASD is a very powerful tool, yet surprisingly simple to operate. The user-friendly Electronic Operator Interface (EOI) of

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Q9 Plus Bypass ASD/Bypass Box

INSTALLATION & OPERATION MANUAL

June, 2013

DN: 68251-000

Document Number: 68251-000

June, 2013

Q9 Plus Bypass ASD/Q9 Plus Bypass BoxInstallation & Operation Manual

TM

IntroductionCongratulations on the purchase of the Q9 Plus Bypass Adjustable Speed Drive (ASD)/Q9 Plus Bypass Box!

The bypass functionality of the Q9 Plus ASD allows for the three-phase input power to be routed around the ASD and applied directly to the motor. During bypass operation, the ASD is removed from the system electrically via contactors. This feature allows for uninterrupted system operation during ASD adjustment, modification, or repair. The Q9 Plus Bypass Box may be purchased either with or without an ASD included. See the section titled Mounting and Connections on pg. 21 for further information on the two versions of the Q9 Plus Bypass Box.

The Q9 Plus Adjustable Speed Drive is a solid-state AC drive that features Toshiba International Corporation’s (TIC) Virtual Linear Pump Technology, Time-Based Alternation, and Vector Control algorithms. These algorithms provide easy setup, enhanced reliability, and precise control under the most demanding conditions — all while enabling the motors of the system to develop high starting torque and providing compensation for motor slip. The result is smooth, quick starts and highly efficient operation. Additionally, as a BACnet®-compatible device, the Q9 Plus ASD supports monitoring and control of HVAC systems.

Virtual Linear Pump Technology was designed to remove the guesswork that is normally associated with the setup of pumping systems. It allows for pump curve responses that are direct, linear, and precise at any flow or pressure setting. Eliminating the normal concerns of the adverse effects of conventional pumping system control response curves, Virtual Linear Pump Technology allows the system to adapt seamlessly and easily to peak load demands while maintaining the same degree of high performance output and reliability across the entire load range — all without any user intervention!

Time-Based Alternation provides a more evenly-spread machine wear pattern for all motors and pumps of the system. This is accomplished by optimizing load sharing — all of the pumps of a multiple-pump system are allowed to alternatly act as the primary pump while the remaining pump(s) operate in an ancillary mode for time intervals that are determined by the user. Time-Based Alternation also offers a significantly decreased level of system down-time in the event of a failure of one or more pumps, when the system continues to operate seamlessly, albeit with a diminished capacity.

The Q9 Plus ASD is a very powerful tool, yet surprisingly simple to operate. The user-friendly Electronic Operator Interface (EOI) of the Q9 Plus ASD has an easy-to-read LCD screen and a high-intensity LED display. The EOI provides easy access to the many monitoring and programming features of the Q9 Plus ASD.

The Q9 Plus ASD uses digitally-controlled pulse width modulation. The programmable functions may be accessed via the easy-to-use menu, via the Direct Access Numbers, or using communications via a host PC. Easy system access to the monitoring and control features combined with high-performance software delivers unparalleled motor control precision and reliability.

This manual has been prepared to enable installers, users, and maintenance personnel to maximize the abilities of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. With this in mind, use this manual to develop a system familiarity before attempting to install or operate the device. This manual may also be used as a reference guide or for training.

Important NoticeThe instructions contained in this manual are not intended to cover all details or variations in equipment types. Nor may it provide for every possible contingency concerning the installation, operation, or maintenance of this equipment. Should additional information be required, contact the TIC Customer Support Center.

The contents of this manual shall not become a part of or modify any prior or existing agreement, commitment, or relationship. The sales contract contains the entire obligation of Toshiba International Corporation. The warranty contained in the contract between the parties is the sole warranty of Toshiba International Corporation and any statements contained herein do not create new warranties or modify the existing warranty.

Any electrical or mechanical modifications to this equipment without prior written consent of Toshiba International Corporation will void all warranties and may void the UL/CUL listing or other safety certifications. Unauthorized modifications may also result in a safety hazard or equipment damage.

About This ManualThis manual was written by the Toshiba International Corporation Technical Publications Group. This group is tasked with providing technical documentation for the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. Every effort has been made to provide accurate and concise information to you, our customer.

At TIC, we are continuously striving for better ways to meet the constantly changing needs of our customers. E-mail your comments, questions, or concerns about this publication to [email protected].

Manual’s Purpose and ScopeThis manual provides information on how to safely install, operate, maintain, and dispose of your Q9 Plus Bypass ASD/Q9 Plus Bypass Box. The information provided in this manual is applicable to the Q9 Plus Bypass ASD/Q9 Plus Bypass Box system only.

This manual is to be used in conjunction with the Q9 Plus ASD Installation & Operation Manual (D/N 68249).

This manual provides information on the various features and functions of this powerful cost-saving device, including

• Installation,

• System operation,

• Configuration and control options, and

• Mechanical and electrical specifications.

Included is a section on general safety instructions that describe the warning labels and symbols that are used. Read the manual completely before installing, operating, performing maintenance, or disposing of this equipment.

Throughout this manual the term Q9 Plus Bypass ASD will be used to describe the Q9 Plus ASD and its accompanying bypass circuitry all within one enclosure. The term Q9 Plus Bypass Box is used to describe the bypass box alone. Because the two operate in the same manner, they will be differentiated only when required.

This manual and the accompanying drawings should be considered a permanent part of the equipment and should be readily available for reference and review.

Because of our commitment to continuous improvement, Toshiba International Corporation reserves the right, without prior notice, to update information, make product changes, or to discontinue any product or service identified in this publication.

Toshiba International Corporation (TIC) shall not be liable for direct, indirect, special, or consequential damages resulting from the use of the information contained within this manual.

This manual is copyrighted. No part of this manual may be photocopied or reproduced in any form without the prior written consent of Toshiba International Corporation.

© Copyright 2013 Toshiba International Corporation.

TOSHIBA® is a registered trademark of the Toshiba Corporation. All other product or trade references appearing in this manual are registered trademarks of their respective owners.

All rights reserved.

Printed in the U.S.A.

mailto:[email protected]

Contacting TIC’s Customer Support CenterTIC’s Customer Support Center can be contacted to obtain help in resolving any Adjustable Speed Drive system problem that you may experience or to provide application information.

The Support Center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Center’s toll free number is US (800) 231-1412/Fax (713) 937-9349 CAN (800) 872-2192 MEX 01 (800) 527-1204. For after-hours support, follow the directions in the outgoing message when calling.

You may also contact Toshiba International Corporation by writing to:

Toshiba International Corporation

13131 West Little York Road

Houston, Texas 77041-9990

Attn: ASD Product Manager.

For further information on Toshiba International Corporation’s products and services or for any released system manuals, please visit our website at www.toshiba.com/ind/.

TOSHIBA INTERNATIONAL CORPORATION

Q9 Plus Bypass ASD/Q9 Plus Bypass Box

Please complete the Warranty Card supplied with your system and return it to Toshiba International Corporation by prepaid mail. This will activate the 12-month warranty from the date of installation; but, shall not exceed 18 months from the shipping date.

Complete the following information and retain for your records.

Model Number: ______________________________________________________________________

Serial Number:_______________________________________________________________________

Project Number (if applicable):__________________________________________________________

Date of Installation:___________________________________________________________________

Inspected By:________________________________________________________________________

Name of Application:_________________________________________________________________

Table of Contents

General Safety Information ....................................................................................................1

Safety Alert Symbol ...........................................................................................................1

Signal Words ......................................................................................................................1

Special Symbols .................................................................................................................2

Equipment Warning Labels ................................................................................................2

Qualified Personnel ............................................................................................................2

Equipment Inspection .........................................................................................................3

Handling and Storage .........................................................................................................3

Disposal ..............................................................................................................................3

Installation Precautions ...........................................................................................................4

Location and Ambient Requirements .................................................................................4

Mounting Requirements .....................................................................................................4

Conductor Routing and Grounding Precautions .................................................................5

Power Connections Precautions .........................................................................................5

Protection ............................................................................................................................6

System Integration Precautions ..............................................................................................7

Personnel Protection ...........................................................................................................7

System Setup Requirements ...............................................................................................8Dynamic Braking Precaution ...........................................................................................8

Operational and Maintenance Precautions ...........................................................................9

CE Compliance Requirements .............................................................................................11

Using RCD Protection ......................................................................................................11

EMC Installation Guidelines ............................................................................................11General EMC Guidelines for Consideration..................................................................11EMC Compliant Installation Guidelines........................................................................12

Theory of Operation ..............................................................................................................13

Stage 1 Function ...............................................................................................................13

Stage 2 Function ...............................................................................................................13

Stage 3 Function ...............................................................................................................13

Stage 4 Function ...............................................................................................................14

System Protection ..................................................................................................................16

ASD Protection .................................................................................................................16

Motor Protection ...............................................................................................................17Motor Circuit Protector Adjustment and Setting ...........................................................18Overload Circuit Protector Adjustment and Setting ......................................................19

Installation and Connections ................................................................................................20

Installation Notes ..............................................................................................................20Input Power ....................................................................................................................20

Q9 Plus Bypass ASD/Bypass Box Installation and Operation Manual i

Control Signal Isolation .................................................................................................20Jumper Requirements.....................................................................................................20Output Terminals ...........................................................................................................20

Mounting and Connections ...............................................................................................21Mounting the Q9 Plus Bypass ASD...............................................................................21Mounting the Bypass Box..............................................................................................22Connecting the Bypass Box ...........................................................................................23Startup and Test .............................................................................................................25

I/O Monitoring and Control .................................................................................................26

I/O Terminal Descriptions ................................................................................................27

Monitoring/Control Interface ............................................................................................30

Typical Connection Diagram ............................................................................................31

Control Panel Features ......................................................................................................35Panel Item Descriptions .................................................................................................35

Part Numbering Convention and System Components .....................................................37

Enclosure Dimensions/Weights ............................................................................................39

Cable/Terminal Specifications ..............................................................................................43

Current/Voltage Specifications .............................................................................................45

ii Q9 Plus Bypass ASD/Bypass Box Installation and Operation Manual

General Safety InformationDO NOT attempt to install, operate, maintain, or dispose of this equipment until you have read and understood all of the product safety information and directions that are contained in this manual.

Note: For all references to the National Electrical Code (NEC), see the latest release of the National Electrical Code.

Safety Alert SymbolThe Safety Alert Symbol indicates that a potential personal injury hazard exists. The symbol is comprised of an equilateral triangle enclosing an exclamation mark.

Signal WordsListed below are the signal words that are used throughout this manual followed by their descriptions and associated symbols. When the words DANGER, WARNING, and CAUTION are used in this manual, they will be followed by important safety information that must be carefully followed.

The word DANGER preceded by the safety alert symbol indicates that an imminently hazardous situation exists that, if not avoided or if instructions are not followed precisely, will result in serious injury to personnel or loss of life.

The word WARNING preceded by the safety alert symbol indicates that a potentially hazardous situation exists that, if not avoided or if instructions are not followed precisely, could result in serious injury to personnel or loss of life.

The word CAUTION preceded by the safety alert symbol indicates that a potentially hazardous situation exists that, if not avoided or if instructions are not followed precisely, may result in minor or moderate injury.

The word CAUTION without the safety alert symbol indicates that a potentially hazardous situation exists that, if not avoided or if instructions are not followed precisely, may result in equipment and property damage.

Q9 Plus Bypass ASD/Bypass Box Installation and Operation Manual 1

Special SymbolsTo identify special hazards, other symbols may appear in conjunction with the DANGER, WARNING and CAUTION signal words. These symbols indicate areas that require special and/or strict adherence to the procedures to prevent serious injury to personnel or loss of life.

Electrical Hazard Symbol

A symbol which indicates a hazard of injury from electrical shock or burn. It is comprised of an equilateral triangle enclosing a lightning bolt.

Explosion Hazard Symbol

A symbol that is comprised of an equilateral triangle enclosing an explosion indicates a hazard of injury from exploding parts.

Equipment Warning LabelsDO NOT attempt to install, operate, perform maintenance, or dispose of this equipment until you have read and understood all of the product labels and user directions that are contained in this manual.

Warning labels that are attached to the equipment will include the exclamation mark within a triangle. DO NOT remove or cover any of these labels. If the labels are damaged or if additional labels are required, contact the TIC Customer Support Center.

Labels attached to the equipment exist to provide useful information or to indicate an imminently hazardous situation that may result in serious injury, severe property and equipment damage, or loss of life if safe procedures or methods are not followed as outlined in this manual.

Qualified PersonnelInstallation, operation, and maintenance shall be performed by Qualified Personnel Only. A Qualified Person is one that has the skills and knowledge relating to the construction, installation, operation, and maintenance of the electrical equipment and has received safety training on the hazards involved (refer to the latest edition of NFPA 70E for additional safety requirements).

Qualified Personnel shall:

• Have carefully read the entire manual.

• Be familiar with the construction and function of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box, the equipment being driven, and the hazards involved.

• Be able to recognize and properly address hazards associated with the application of motor-driven equipment.

• Be trained and authorized to safely energize, de-energize, ground, lock-out/tag-out circuits and equipment, and clear faults in accordance with established safety practices.

• Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves, hard hats, safety glasses, face shields, flash clothing, etc., in accordance with established safety practices.

For further information on workplace safety visit www.osha.gov.

2 Q9 Plus Bypass ASD/Bypass Box Installation and Operation Manual

Equipment Inspection• Upon receipt of the equipment, inspect the packaging and equipment for shipping damage.

• Carefully unpack the equipment and check for parts that may have been damaged during shipping, missing parts, or concealed damage. If any discrepancies are discovered, it should be noted with the carrier prior to accepting the shipment, if possible. File a claim with the carrier if necessary, and immediately notify the TIC Customer Support Center.

• DO NOT install the ASD if it is damaged or if it is missing any components.

• Ensure that the rated capacity and the model number specified on the nameplate conform to the order specifications.

• Modification of this equipment is dangerous and is to be performed by factory-trained personnel. When modifications are required, contact the TIC Customer Support Center.

• Inspections may be required after moving equipment.

• Contact the TIC Customer Support Center to report discrepancies or for assistance if required.

Handling and Storage• Use proper lifting techniques when moving the Q9 Plus Bypass ASD/Q9 Plus Bypass Box;

including properly sizing up the load, getting assistance, and using a forklift if required.

• Store in a well-ventilated covered location and preferably in the original packaging if the equipment will not be used upon receipt.

• Store in a cool, clean, and dry location. Avoid storage locations with extreme temperatures, rapid temperature changes, high humidity, moisture, dust, corrosive gases, or metal particles.

• The storage temperature range of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box is -13° to 149° F (-25° to 65° C).

• DO NOT store in places that are exposed to outside weather conditions (i.e., wind, rain, snow, etc.).

• Store in an upright position.

DisposalNever dispose of electrical components via incineration. Contact your state environmental agency for details on disposal of electrical components and packaging in your area.


Installation Precautions

Location and Ambient Requirements• The TIC Q9 Plus Bypass ASD/Q9 Plus Bypass Box is intended for permanent installations only.

• Installation shall conform to the National Electrical Code (NEC) — Article 110 (Requirements

for Electrical Installations), all regulations of the Occupational Safety and Health

Administration, and any other applicable national, regional, or industry codes and standards.

• Select a mounting location that is easily accessible, has adequate personnel working space, and

adequate illumination for adjustment, inspection, and maintenance of the equipment (refer to NEC

Article 110-13).

• DO NOT mount the Q9 Plus Bypass ASD/Q9 Plus Bypass Box in a location that would produce

catastrophic results if it were to become dislodged from its mounting location (equipment damage

or injury).

• DO NOT mount the Q9 Plus Bypass ASD/Q9 Plus Bypass Box in a location that would allow it

to be exposed to flammable chemicals or gases, water, solvents, explosive/corrosive mists or gases,

or other fluids.

• The ambient operating temperature range of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box is 14°

to 104° F (-10° to 40° C).

• The installation location shall not be exposed to direct sunlight.

• Avoid installation in areas where vibration, heat, humidity, dust, fibers, metal particles, explosive/

corrosive mists or gases, or sources of electrical noise are present.

• Allow proper clearance spaces for installation. DO NOT obstruct the ventilation openings. Refer to

the section titled Installation and Connections of the Q9 Plus ASD Installation & Operation

Manual (D/N 68249) for further information on installation and ventilation requirements.

Mounting Requirements• Only Qualified Personnel are to install this equipment.

• Install the unit in a secure and upright position in a well-ventilated area.

• As a minimum, the installation of the equipment shall conform to the NEC — Article 110 (NEC),

OSHA, as well as any other applicable national, regional, or industry codes and standards.

• Installation practices shall conform to the latest revision of NFPA 70E Electrical Safety

Requirements for Employee Workplaces.

• It is the responsibility of the person installing the Q9 Plus Bypass ASD/Q9 Plus Bypass Box or

the electrical maintenance personnel to ensure that the unit is installed into an enclosure that will

protect personnel against electric shock.


Conductor Routing and Grounding Precautions

• Use separate metal conduits for routing the input power, output power, and control circuits; and each shall have its own ground cable.

• A separate ground cable shall be run inside the conduit with the input power, output power, and control circuits.

• DO NOT connect the CC terminal of the Terminal Board to earth ground.

• Always ground the unit to prevent electrical shock and to help reduce electrical noise.

• It is the responsibility of the person installing the Q9 Plus Bypass ASD/Q9 Plus Bypass Box or the electrical maintenance personnel to provide proper grounding and branch circuit protection in accordance with the NEC and any applicable local codes.

— T h e M e t a l O f C o n d u i t I s N o t A n A c c e p t a b l e G r o u n d —

Power Connections Precautions

C o n ta c t W i t h E n e r g i z e d W i r i n g W i l l C a u s e S e v e r e I n j u r y O r D e a t h .

• Turn off and lock-out/tag-out all power sources before proceeding to connect the power wiring to the equipment.

• Ensure the correct supplied voltage, wiring used, and system type for the application (refer to the NEC Article 300 – Wiring Methods and Article 310 – Conductors For General Wiring). Size the branch circuit conductors in accordance with NEC Table 310.16.

• Ensure that all power sources are turned off and isolated in accordance with established lock-out/tag-out procedures before connecting the three-phase power source wiring to the ASD input terminals, and connect the ASD output terminals to a motor of the correct voltage and type for the application (refer to the NEC Article 300 - Wiring Methods and Article 310 - Conductors for General Wiring). Size the branch circuit conductors in accordance with the NEC Table 310.16.

• Adhere to the recommended conductor sizes listed in the section titled Cable/Terminal Specifications on pg. 43. If multiple conductors are used in parallel for the input or output power, each branch of the parallel set shall have its own conduit and not share its conduit with other parallel sets (i.e., place U1, V1, and W1 in one conduit and U2, V2, and W2 in another) (refer to the NEC Article 300.20 and Article 310.4). National and local electrical codes should be referenced if three or more power conductors are run in the same conduit (refer to the NEC Article 310 adjustment factors).

• Ensure that the three-phase input power is NOT connected to the output of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. This will damage the system and may cause injury to personnel.

• DO NOT install the Q9 Plus Bypass ASD/Q9 Plus Bypass Box if it is damaged or if it is missing any component(s).

• DO NOT connect resistors across terminals PA – PC or PO – PC. This may cause a fire.

• Ensure the correct phase sequence and the desired direction of motor rotation in the Bypass mode.

• Turn the power on only after attaching and/or securing the front cover.


Protection• Ensure that primary protection exists for the input wiring to the equipment. This protection must be

able to interrupt the available fault current from the power line. The equipment may or may not be equipped with an input disconnect (option).

• All cable entry openings must be sealed to reduce the risk of entry by vermin and to allow for maximum cooling efficiency.

• If using multiple motors, provide separate overload protection for each motor, and use V/f control.

• It is the responsibility of the person installing the Q9 Plus Bypass ASD/Q9 Plus Bypass Box or the electrical maintenance personnel to setup the Emergency Off braking system of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. The function of the Emergency Off braking function is to remove output power from the drive in the event of an emergency. A supplemental braking system may also be engaged in the event of an emergency. For further information on braking systems, see DC Injection Braking in the Q9 Plus ASD Installation & Operation Manual.

Note: A supplemental emergency stopping system should be used with the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. Emergency stopping should not be a task of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box alone.

• Follow all warnings and precautions, and DO NOT exceed equipment ratings.


System Integration PrecautionsThe following precautions are provided as general guidelines for the setup of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box system.

• The TIC Q9 Plus Bypass ASD/Q9 Plus Bypass Box is a general-purpose product. It is a system component only, and the system design should take this into consideration. Please contact the TIC Customer Support Center for application-specific information or for training support.

• The TIC Q9 Plus Bypass ASD/Q9 Plus Bypass Box is part of a larger system, and the safe operation of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box will depend on observing certain precautions and performing proper system integration.

• Improperly designed or improperly installed system interlocks may render the motor unable to start or stop on command.

• The failure of external or ancillary components may cause intermittent system operation (i.e., the system may start the motor without warning).

• A detailed system analysis and job safety analysis should be performed by the systems designer and/or systems integrator before the installation of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box component. Contact the TIC Customer Support Center for options availability and for application-specific system integration information if required.

Personnel Protection• Installation, operation, and maintenance shall be performed by Qualified Personnel Only.

• A thorough understanding of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box will be required before the installation, operation, or maintenance of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box.

• Rotating machinery and live conductors can be hazardous and shall not come into contact with personnel. Personnel shall be protected from all rotating machinery and electrical hazards at all times.

• Insulators, machine guards, and electrical safeguards may fail or be defeated by the purposeful or inadvertent actions of workers. Insulators, machine guards, and electrical safeguards are to be inspected (and tested where possible) at installation and periodically after installation for potential hazardous conditions.

• DO NOT allow personnel near rotating machinery. Warning signs to this effect must be clearly posted at or near the machinery.

• DO NOT allow personnel near electrical conductors. Contact with electrical conductors can be fatal. Warning signs to this effect must be clearly posted at or near the machinery/hazard.

• Personal Protection Equipment (PPE) shall be provided and used to protect the installer, user, maintenance personnel, and all employees from any hazards inherent to system operation.


System Setup Requirements• When using the Q9 Plus Bypass ASD/Q9 Plus Bypass Box as an integral part of a larger system, it

is the responsibility of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box installer or maintenance personnel to ensure that there is a fail-safe in place (i.e., an arrangement designed to switch the system to a safe condition if there is a fault or failure).

• System safety features should be employed and designed into the integrated system in a manner such that system operation, even in the event of system failure, will not cause harm or result in personnel injury or system damage (i.e., E-Off, Auto-Restart settings, System Interlocks, etc.).

• The programming setup and system configuration of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box may allow it to start the motor unexpectedly. A familiarity with the Auto-Restart and Retry settings is a requirement to use this product.

• Improperly designed or improperly installed system interlocks may render the motor unable to start or stop on command.

• The failure of external or ancillary components may cause intermittent system operation (i.e., the system may start the motor without warning).

• There may be thermal or physical properties, or ancillary devices, integrated into the overall system that may allow for the Q9 Plus Bypass ASD/Q9 Plus Bypass Box to start the motor without warning. Warning signs to this effect must be clearly posted at or near the equipment installation.

• If a secondary magnetic contactor (MC) is used between the ASD and the load, it should be interlocked to halt the ASD before the secondary contact opens. If the output contactor is used for bypass operation, it must be interlocked such that commercial power is never applied to the ASD output terminals (T1, T2, T3).

• Power factor improvement capacitors or surge absorbers MUST NOT BE INSTALLED on the three-phase output of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box.

• Use of the built-in system protective features is highly recommended (i.e., E-Off, Overload Protection, etc.).

• The operating controls and system status indicators shall be clearly readable and positioned where they may be viewed without obstruction.

• Additional warnings and notifications shall be posted at the equipment installation location as deemed required by Qualified Personnel.

• Follow all warnings and precautions, and DO NOT exceed equipment ratings.

Dynamic Braking Precaution

• The Dynamic Braking function is NOT used with the Q9 Plus Bypass ASD/Q9 Plus Bypass Box.

• DO NOT attempt to configure or connect the DBR function to the Q9 Plus Bypass ASD/Q9 Plus Bypass Box.

• Attempts to configure or adapt the Q9 Plus Bypass ASD/Q9 Plus Bypass Box to use the Dynamic Braking function may result in system damage or injury to personnel.


Operational and Maintenance Precautions

• Turn off and lock-out/tag-out the main power, the control power, and instrumentation connections before inspecting or servicing the ASD, removing any enclosure panels, or connecting/disconnecting the power wiring to the equipment.

• Turn the power on only after attaching (or closing) the front cover. DO NOT open or remove the front cover or any of the enclosure panels of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box during normal operation.

• During system setup, calibration, testing, or troubleshooting, it may be required to access live circuits. DO NOT leave the system unattended and powered with the door(s) and/or covers removed.

• If/when taking a live reading is required (equipment is powered), it is to be performed by Qualified Personnel ONLY. Proper and approved personal protection equipment is to be used by trained personnel for all electrical measurements.

• The capacitors of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box maintain a residual charge for a period of time after the Q9 Plus Bypass ASD/Q9 Plus Bypass Box is powered off. The required time for each system typeform is indicated with a cabinet label and a Charge Indicator LED. Wait at least the minimum time indicated on the enclosure-mounted label and ensure that the Charge Indicator LED has turned off once the ASD power has been turned off before coming into contact with any circuits.

• DO NOT attempt to disassemble, modify, or repair the system. Contact the TIC Customer Support Center for repair information.

• DO NOT place any objects inside of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box.

• If the system should emit smoke or an unusual odor or sound, turn off the power immediately.

• The heat sink and other components may become extremely hot to the touch. Allow the unit to cool before coming into contact with these items.

• Remove power from the Q9 Plus Bypass ASD/Q9 Plus Bypass Box during extended periods of non-use.

• Inspect the system annually (as a minimum) for damaged or improperly functioning parts, cleanliness, and to ensure that the connectors are tightened securely. Inspect more frequently when operating in a harsh environment or when used on a high-output-demand application.

• Ensure that the Run functions (F, R, Preset Speed, etc.) of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box are off before performing a Reset. The post-reset settings may allow the motor to start unexpectedly.

• The Auto-Restart and Retry programmable functions of the ASD may allow for the system to start or stop unexpectedly. Warning signs to this effect must be clearly posted at or near the machinery/hazard.

• In the event of a power failure, the motor may restart after power is restored.


• Use caution when setting the output frequency. Over speeding a motor decreases its ability to deliver torque and may result in damage to the motor and/or the driven equipment.

• The Q9 Plus Bypass ASD/Q9 Plus Bypass Box is designed to operate NEMA B motors. Consult with the TIC Customer Support Center before using the Q9 Plus Bypass ASD/Q9 Plus Bypass Box for special applications such as with an explosion-proof motor or applications with a piston load.

• DO NOT install, operate, perform maintenance, or dispose of this equipment until you have read and understood all of the product warnings and user directions. Failure to do so may result in equipment damage, operator injury, or loss of life.


CE Compliance RequirementsIn addition to the local and regional safety requirements, this section describes additional criteria that must be met to qualify for European Conformity (CE) certification. All relevant apparatus placed on the European market is required to comply to the European Community directive on electromagnetic compatibility (EMC). The following instructions provide a means of compliance for the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. A Technical Construction File (TCF) indicates the rationale used to declare compliance and is on file at Toshiba International Corporation, Houston, Texas, U.S.A.

Using RCD ProtectionWhere a residual-current-operated protective device (RCD) is used to guard against direct or indirect contact, only an RCD of Type B is allowed on the supply side of this Electronic Equipment.

Otherwise, another protective measure shall be applied. Other measures include separation of the Electronic Equipment from the environment by double or reinforced insulation and isolation of the Electronic Equipment and supply side by a transformer.

EMC Installation GuidelinesAll systems placed on the European market are required to comply with the European Community directive regarding electromagnet compatibility (EMC). TIC ensures that all systems deployed in the European market have been screened and are in 100% compliance.

General EMC Guidelines for Consideration• Input filters of the appropriate rating shall be used.

• Proper grounding is a requirement.

• Grounds shall be kept to the minimum length to accomplish the connection.

• Grounds shall have low RF impedance.

• A central ground shall be employed in a complex system.

• Paint or corrosion can hamper good grounding; remove as required.

• Keep control and power cabling separated. Minimize exposed (unscreened) cable.

• Use 360° shielded connections where possible.


EMC Compliant Installation GuidelinesThe Q9 Plus Bypass ASD/Q9 Plus Bypass Box shall be installed in accordance with the following guidelines.

1. Filtering — An input filter shall be used with the ASD. A Schaffner FN258 series input filter of the appropriate rating shall be used and mounted adjacent to the ASD.

2. Mechanical — The ASD and the associated equipment shall be mounted on a flat metallic backplane. A minimum space of 5 cm (2 inches) shall exist between the ASD and the filter to allow for ventilation. The filter output cable is to be connected from the bottom of the filter to the ASD power input and is to be the minimum length required for a connection.

Units received as an Open Chassis shall not be placed into operation until being placed into an approved enclosure that will protect personnel against electrical shock.

Opening and closing of enclosures or barriers shall be possible only with the use of a key or a tool.

3. Cabling — The cables of the input power, filter, and motor shall be of the appropriate current rating. The cables shall be connected in accordance with the guidelines of the manufacturer and the applicable local and national agencies. A 4-core screened cable (such as RS 379-384) is to be used for the power and earth connections to minimize RF emissions. Control cabling must be screened using P/N RS 367-347 or a similar component.

4. Grounding — The mains (input) ground shall be connected at the ground terminal provided on the filter. The filter and motor shall be grounded at the ground terminals provided in the ASD.

5. Screening — The mains (input) screen is to be connected to the metallic back-plane at the filter; remove any finish coating as required. The screen over the filter output cables, the motor cable screen, and the control wire screens must be connected to the ASD case using glands or conduit connectors. The motor cable screen shall be connected to the motor case. When using a braking resistor, the cabling between the resistor and ASD shall also be screened. This screen shall connect to both the ASD enclosure and the resistor enclosure.

See the Q9 Plus Bypass ASD/Q9 Plus Bypass Box Filter Selection below for the recommended input filters for a given typeform.

Q9 Plus Bypass ASD/Q9 Plus Bypass Box Filter Selection Table

230VVT130

FilterNumber

460VFilter

Number460V

FilterNumber

Q9+2015I FN258-7 Q9+4015I

FN258-7

Q9+4500FN258-100

Q9+2025IFN258-16

Q9+4025I Q9+4600

Q9+2035I Q9+4035I Q9+4750 FS5236-130

Q9+2055IFN258-30

Q9+4055IFN258-16

Q9+410K FS5236-180

Q9+2080I Q9+4080I Q9+412K FS5236-300

Q9+2110I FN258-42 Q9+4110IFN258-30

BYP4-070EFN258-100

Q9+2160I FN258-75 Q9+4160I BYP4-080E

Q9+2220IFN258-100

Q9+4220I FN258-42 BYP4-100E FN258-130

Q9+2270I Q9+4270IFN258-55

BYP4-125E FN258-180

Q9+2330I FN258-130 Q9+4330I BYP4-160E FS5236-300

Q9+2400I FN258-180 Q9+4400I FN258-75

BYP2-100E FN258-130

BYP2-125E FN258-180


Theory of OperationThe Q9 Plus Bypass ASD/Q9 Plus Bypass Box system is available in three primary configurations. The system configuration type is defined by the suffix A, C, or E as shown in the part numbering convention on pg. 37.

The description below targets the E configuration. System operation for the A and C types differ from the E type where the referenced function is not supported by the A or C typeform.

Note: Reference Figure 1 on pg. 15 and Figure 7 on pg. 31 for the following explanation.

Note: The 200-volt 30 HP and 40 HP systems are designed with the ASD component and the Bypass Box provided and mounted as separate items (e.i., the ASD is sold separately; see Table 4 on page 41). The same is true for the 400-volt 50 – 125 HP systems.The Integrated Enclosure and the BYP Series systems operate in the same manner — as described below.

Initially, all switches are open and the normal states of all relays are as indicated in Figure 1 on pg. 15.

Stage 1 FunctionPower is applied in Stage 1 via the Control Power Transformer (CPT). The 120 VAC signal is applied to the Shunt Trip circuit and LED 5 (Control Power). LED 5 illuminates, and if the LS switch is open (enclosure door is closed), the system is enabled for normal operation.

If the LS switch is closed (enclosure door is open), the Motor Circuit Protector (MCP) is opened via the Shunt Trip function (see Motor Protection on pg. 17), and the three-phase input voltage to the system is terminated. The LS switch may be connected to an ancillary circuit that can perform a system shutdown in the event of a system malfunction or an ancillary circuit status change (e.g., door opens, over temp, etc.). The LS switch is used as a door interlock in this example.

Stage 2 FunctionStage 2 has two operating modes: Test operation and INV operation (K2 energized).

If the Test switch (SW1) is closed or if K2 is energized via SW2 (SW2 to INV, OL closed [open = overload], and CIA-to-B closure required), the K1 relay is energized and the states of the K1 contacts change.

LED1 illuminates (if in the Test mode) and the 1M contactor energizes, which closes the 1M contacts (three-phase power is applied to the ASD input; see Figure 7 on pg. 31).

Stage 3 FunctionThe closures of the OL contacts of the motor overload relay and the CIA/B (Customer Interface) contacts are required to provide 120 VAC to Stage 3.

The CIA/B contacts are configured by the user such that the system is disabled in the event that any user-selected function should undergo a state change (i.e., alarm is initiated, door is opened, etc.). CIA/B contacts may be jumpered if unused.


The three positions of SW2 (Off, INV, and BYP) are described below.

Off — K2 and K3 remain in the normal state.

INV — Energizes K2 which turns off LED 1 (Test Mode) (if on), illuminates LED 2 (INV Mode), opens K2 at Stage 3, closes K2 at Stage 4, and completes the ST terminal path via PCB 11. The resulting closure of K2 at Stage 4 energizes the 2M contactor (jumper or open-damper signal at DRA/B required), which allows the ASD output to be applied to the motor (see 2M at Figure 7 on pg. 31).

BYP — Energizes K3 which turns off LED 2 (INV Mode) (if on), illuminates LED 3 (Bypass Mode), opens K2 at Stage 4 (which opens 2M if closed), and closes K3 at Stage 4. The resulting closure of K3 at Stage 4 energizes the 3M contactor (jumper or open-damper signal at DRA/B required), which allows the utility power to be applied directly to the motor bypassing the ASD (see 3M at Figure 7 on pg. 31).

Note: Ensure that the phase relationship of the L1, L2, and L3 connections to the motor for the Bypass mode of operation and for the ASD-driven operation are consistent. The Reverse and Forward functions will be reversed if not properly connected (see diagram in Figure 7 on pg. 31).

The Damper Response feedback circuit (DRA/DRB) may be used to prevent a motor from attempting to force air flow through a duct that has a closed damper.

Damper motor power (120 VAC) is provided from an external source and is applied via the switched DSA/DSB circuit (OUT1 contacts). The 120 VAC is switched via the OUT1 contacts while operating in the INV mode or switched via the K3 contacts while operating in the Bypass mode.

Note: OUT1 contacts are labeled DSA and DSB on the Terminal Board.

Stage 4 FunctionIn the INV mode, the OUT1 closure (set to Damper Command) occurs upon receiving a Run command and allows power to be applied to the damper motor. Once the damper-mounted DRA-to-DRB contacts are closed (open damper required), K4 is energized.

LED 4 (System Interlock) illuminates and the K4 contacts close the S3-to-CC connection (JP1 jumper required), completing the Damper Feedback circuit requirement for ASD operation. The DRA-to-DRB closure also provides power to the 2M coil allowing for the ASD output to be applied to the motor while operating in the INV mode.

If no discrete input terminal is assigned the function Damper Feedback, this permissive will not be a requirement for normal system operation.

With all other permissives configured to run, the motor will run without activating a Damper Feedback discrete input terminal.

In the Bypass mode, K3 is energized via SW2. The K3 contact closure at PCB 11 applies power to the damper motor (Terminal Board jumpers JPDS1 and JPDS2 are required). Once the damper-mounted DRA-to-DRB contacts are closed (open damper required), the 3M coil is energized and provides utility power to the motor, bypassing the ASD.

The DRA-to-DRB contacts are provided via a reversible damper-mounted switch. The switch terminates power to the damper motor once the damper is fully opened or closed (reversible means that only the opposite function is available once reaching the fully opened or closed position).


Figure 1. Simplified Depiction (Ladder Logic) of the Q9 Plus Bypass ASD Bypass Operation.

See the section titled Theory of Operationon pg. 13 for a description of the simplified depiction.


System ProtectionThe Q9 Plus Bypass ASD/Q9 Plus Bypass Box has protection features that are designed to protect the ASD and the motor from overload/over-current damage and from the undesirable effects of under-voltage operation. Because of the different types of over-current conditions that may occur (i.e., inrush current, short circuit current, extended overloads, etc.), the Q9 Plus Bypass ASD/Q9 Plus Bypass Box is equipped to protect the system from start-up over-current and running over-current damage. Both protection mechanisms require an application-specific adjustment to optimize performance and minimize nuisance tripping.

There are two system operating modes: Q9 Plus Bypass ASD-driven and Bypass operation. When the motor is being driven by the ASD, the primary over-current protection and extended overload protection for the ASD is accomplished via the Electronic Thermal Protection setting of the ASD. This parameter should be set to the FLA of the motor (see F631).

The power unit of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box is rated for 100,000 Amps Interrupting Capacity (AIC). The bypass circuit is rated for 100,000 Amps Interrupting Capacity also.

Overload protection for the Bypass mode of operation is accomplished via the Motor Circuit Protector shown on pg. 18 and the Overload Circuit Protector shown on pg. 19 (both shown schematically in Figure 7 on pg. 31).

ASD ProtectionThe Q9 Plus Bypass ASD/Q9 Plus Bypass Box is designed and manufactured to accommodate a wide range of voltage and current requirements (typeforms). Each typeform is designed to operate at 100% output continuously and can operate at 110% for up to 60 seconds. A trip will be incurred if the design specifications are exceeded for a given typeform. Greater than 110% overload will have an inverse affect on the overload time allowed.

ASD overload protection is accomplished via the ASD software which can be configured to disable the system in the event of an overload. Using the Electronic Thermal Protection setting, the ASD may be properly matched to the motor being driven and to the application (see F631).

The short-circuit protection, which is provided by hardware and software, disables the system in the event of a fault.

The installer is to provide input fuses for the 230-volt Q9 Plus ASDs. The 460-volt Q9 Plus ASDs are equipped with internal primary power input fuses as a standard feature.

When connecting two or more drive systems to the same power line as shown in Figure 2, it will be necessary to select a circuit-breaking configuration that will ensure that only MCCB2 (not MCCB1) trips if a short circuit occurs in system 1. If it is not feasible to use this configuration, insert a fuse between MCCB2 and system 1.

Figure 2. Circuit Breaker Configuration.


Read and understand all safety warnings before operating this equipment!

Motor ProtectionMotor circuit protection is accomplished using circuit breakers that have adjustable trip thresholds. The circuit breakers are set to the minimum current value of the circuit breaker at the factory and must be adjusted for the motor being driven and the requirements of the application.

The motor protection hardware is comprised of a Motor Circuit Protector (MCP) at the three-phase system input and an Overload Circuit Protector (OCP) connected to the motor (see Figure 7 on pg. 31). Overload settings are application-specific and should be set and/or adjusted by Qualified Personnel ONLY.

The MCP that is used on the L1, L2, and L3 input power lines has a Shunt Trip feature that may be used to further enhance the system protection function of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. The Shunt Trip feature may be connected such that the L1, L2, and L3 MCP may be opened by a state change of the LS switch. The LS switch may be operated by an ancillary circuit or relay. If an ancillary circuit is experiencing a condition that warrants a system shutdown (e.g., door is opened), the L1, L2, and L3 MCP will be opened by the completed Shunt Trip circuit. During normal operation, the Shunt Trip circuit is open.

Should the Shunt Trip circuit activate and terminate the three-phase input power, a manual reset is required to resume normal system operation.


Motor Circuit Protector Adjustment and Setting

The trip threshold of the MCP is set to the lowest setting when the product ships from the factory. Refer to the NEC Table 430-152 for recommendations and guidelines on establishing the proper MCP setting for a given application. With the vast number of application system variables, the MCP may have to be set as a reference, tested, and adjusted up or down until the desired result is achieved.

When using a Design E motor, the setting for the instantaneous trip circuit breaker shall not be more than 1100% of the full-load input current. The maximum setting for a motor, other than Design E, shall be 800% of the input current. This is done to ensure that the protection does not activate while starting the motor but is able to provide adequate protection for a fault condition.

Overload settings are application-specific and should be set and/or adjusted by Qualified Personnel ONLY (see Qualified Personnel on pg. 2).

Figure 3. MCP Adjustment.

Set to minimum at the factory. Application-specific adjustment is required.


Overload Circuit Protector Adjustment and Setting

The trip threshold of the OCP is set to the lowest setting when the product ships from the factory. The OCP setting should allow for the high inrush current of startup and the short-time overload current of high-inertia loads but not be set so high as to provide inadequate overcurrent protection. The OCP should be set to a level that is just above the maximum level of the application’s normal operating requirements.

A motor starter is recommended for larger motors.

Overload settings are application-specific and should be set and/or adjusted by Qualified Personnel ONLY (see Qualified Personnel on pg. 2).

Figure 4. Motor OCP Adjustment and OCP Contactor.

The Normally Open (NO) and Normally Closed (NC) contacts remain in their normal states during normal operation. Both contacts change states during an overload trip.

The contacts may be used with ancillary circuitry to annunciate an overload trip or to control other system features.

Set to minimum at the factory. Application-specific adjustment is required.


Installation and ConnectionsThe Q9 Plus Bypass ASD/Q9 Plus Bypass Box is categorized into three system configurations that are identified by the part number suffixes A, C, and E. See Figure 8 on pg. 32, Figure 9 on pg. 33, and Figure 10 on pg. 34 for electrical depictions of the A, C, and E variations, respectively.

The Q9 Plus Bypass ASD/Q9 Plus Bypass Box may be ordered with or without the optional system protection hardware and the bypass circuitry designed to facilitate system diagnostics and maintenance operations. The available Q9 Plus Bypass ASD/Q9 Plus Bypass Box HP ranges for the 230- and 460-volt units are listed in the section titled Current/Voltage Specifications on pg. 45.

Installation NotesInput Power

The Q9 Plus Bypass ASD/Q9 Plus Bypass Box input voltage should remain within 10% of the specified input voltage range. Input voltages approaching the upper or lower limit settings may require that the overvoltage and undervoltage stall protection level parameters be adjusted. Voltages outside of the permissible tolerance should be avoided.

The input power frequency should be ±2 Hz of the specified input frequency.

DO NOT use an ASD with a motor that has a higher power rating than the rated output of the ASD.

Control Signal IsolationInterface problems may occur when some ASDs are used in conjunction with process controllers. Signal isolation may be required to prevent controller and/or ASD malfunctions. The Q9 Plus Bypass ASD/Q9 Plus Bypass Box option, the ASD-ISO-1, provides isolation of the Control Board output circuit from the AM/FM output and from the I input (for further information on the ASD-ISO-1 option contact the TIC Customer Support Center or contact the manufacturer of the process controller for additional information on controller compatibility and signal isolation). See the section titled I/O Monitoring and Control on pg. 26 for more information on control input signals.

Jumper RequirementsThe Q9 Plus Bypass ASD/Q9 Plus Bypass Box is shipped with jumpers connected to the following terminals:

ST to CC (coasts to stop if removed),S4 to CC (Emergency Off trip if removed),CIA to CIB (Customer Interlock; user-specific), andDRA to DRB (system disabled if open).

All four jumper connections are required for normal operation of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box while in the default settings configuration (see the Q9 Plus ASD Installation & Operation Manual [D/N 68249] for information on changing the default settings).

Output TerminalsDO NOT apply commercial power to the output terminals T1, T2, or T3.

Isolate (disconnect) the Q9 Plus ASD from the motor before megging the motor.

When a brake-equipped motor is connected to the Q9 Plus Bypass ASD/Q9 Plus Bypass Box, it is possible that the brake may not release at startup because of insufficient voltage. To avoid this condition, DO NOT connect the brake or the brake contactor to the output of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box.


Mounting and ConnectionsThe Q9 Plus Bypass ASD/Q9 Plus Bypass Box is available in two typeform-specific versions: the one-part system (the ASD and the Bypass system in one enclosure) and the two-part system (the ASD and the Bypass Box as two separate components).

The mounting and connection requirements vary when discussing the one-part and the two-part systems. The two-part system is identified as the BYP Series or Bypass Box in this publication. The term Q9 Plus ASD/Q9 Plus Bypass Box will be used throughout this publication to address both types unless addressing specifics of the BYP Series. The systemic functionality is identical for both system versions, and no differentiation is required. Mechanical enclosure differences are specified as required.

The Q9 Plus Bypass ASD/Q9 Plus Bypass Box may be set up initially by performing a few simple system configuration connections and settings. To operate properly, the Q9 Plus Bypass ASD/Q9 Plus Bypass Box must be securely mounted and connected to a power source (three-phase AC input at the L1, L2, and L3 terminals). The control terminals of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box may be used by connecting the terminals of the Terminal Board to the proper sensors or signal input sources (see the section titled I/O Monitoring and Control on pg. 26 for an expanded description of the system control options).

The output terminals of the system (T1, T2, and T3) must be connected to the motor that is to be controlled. See Figure 7 on pg. 31 for the connection diagram.

As a minimum, the installation of the ASD shall conform to Article 110 of the NEC, the Occupational Safety and Health Administration requirements, and any other local and regional industry codes and standards.

Mounting the Q9 Plus Bypass ASD

The ambient operating temperature rating for the Q9 Plus Bypass ASD/Q9 Plus Bypass Box is from 14° to 104° F (-10° to 40° C).

The process of converting AC to DC and then back to AC produces heat. During normal ASD operation, up to 5% of the input energy to the ASD may be dissipated as heat.

Install the Q9 Plus Bypass ASD securely onto a vertical surface using the four mounting holes on the top and bottom of the enclosure.

Mount the system in a location that is in a well-ventilated area that is not in the path of direct sunlight.

When installing multiple ASDs, ensure that there is a clearance space of at least 8 inches (20 cm) from the top and the bottom of adjacent units. Ensure that the ventilation openings are not obstructed. There should be at least 5 cm (2 inches) on either side of adjacent units. For the models below 50 HP, the top and bottom clearance specifications may be reduced to 4 inches (10 cm). This space ensures that adequate ventilation is provided (see the section titled Enclosure Dimensions/Weights on pg. 39 for additional information on mounting space requirements).

DO NOT operate the ASD with the enclosure door open.

ASDs produce high-frequency noise — steps must be taken during installation to avoid the negative effects of noise. Listed below are some examples of measures that will help to combat noise problems.

• Separate the input and output power conductors of the main circuit. DO NOT install the input and output wires in the same duct or in parallel with each other, and DO NOT bind them together.

• DO NOT install the input or output power conductors of the main circuit and the wires of the control circuit in the same duct or in parallel with each other, and DO NOT bind them together.


• Use shielded wires or twisted wires for the control circuits.

• Ensure that the grounding terminals (G/E) of the ASD are securely connected to ground.

• Connect a surge suppressor to every electromagnetic contactor and relay installed near the ASD.

• Install noise filters as required.

Connecting the Q9 Plus Bypass ASD

L1, L2, and L3 are the three-phase input supply terminals for the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. An AC Reactor may be installed to provide filtering of the three-phase input power to the Q9 Plus Bypass ASD/Q9 Plus Bypass Box.

T1, T2, and T3 are the output terminals of the ASD that connect to the motor. A DC Reactor may be connected across terminals PA and PO to provide additional filtering. When not used, a jumper is connected across these terminals (see Figure 7 on pg. 31).

Filtering provides an increased line transient immunity and a lower harmonic current.

Connect the input and output power lines of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box in accordance with the type of system being used as shown in Figure 8 on pg. 32, Figure 9 on pg. 33, or Figure 10 on pg. 34.

Connect the three-phase input power to the input terminals of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box at the L1, L2, and L3 terminals. Connect the output terminals T1, T2, and T3 of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box to the motor. The input and output conductors and terminal lugs used shall be in accordance with the requirements listed in Cable/Terminal Specifications on pg. 43.

Note: In the event that the motor rotates in the wrong direction when powered up, reverse any two of the three leads connected to the motor.

If conductors smaller than the recommended sizes are used in parallel for the input or output power, each branch of the parallel set shall have its own conduit and not share its conduit with other parallel sets (i.e., place T1A, T2A, and T3A in one conduit and T1B, T2B, and T3B in another conduit).

Note: National and local codes should be referenced when running more than three conductors in the same conduit.

Install a molded case circuit breaker (MCCB) or fuse between the three-phase power source and the ASD in accordance with the NEC Article 430-102 through 430-111 and the Fault Current setting of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box (see F631).

Mounting the Bypass Box

The Bypass Box of the BYP Series is provided as a separate item from the ASD — the two are shipped from the factory neither mechanically nor electrically connected. The Q9 Plus ASD and the Bypass Box are installed independently and then connected together.

Install the Bypass Box securely onto a vertical surface using the four mounting holes on the top and bottom of the enclosure as shown in Table 5 on page 42.

The Q9 Plus ASD is then installed as described in the Q9 Plus ASD Installation and Operation Manual (D/N 68249). The Q9 Plus ASD is attached to the Bypass Box using the two screws of the Bypass Box wire chase resulting in the configuration shown in Figure 5 on pg. 24.

The ambient operating temperature rating for the Bypass Box is from 14° to 104° F (-10° to 40° C).

DO NOT operate the system with the enclosure door open.


Connecting the Bypass Box

The Bypass Box input and output power lines connect to the Q9 Plus ASD via the wire chase of the upper section of the Bypass Box as shown in Figure 5 on pg. 24.

The wire size used shall be in accordance with the specifications listed in the section titled Cable/Terminal Specifications on pg. 43.

Connect the Q9 Plus ASD to the Bypass Box as follows:

1. Connect the L1, L2, and L3 terminals of the Q9 Plus ASD to the L1, L2, and L3 terminals of the Bypass Box, respectively, via terminal block PDB1.

2. Connect the T1, T2, and T3 terminals of the Q9 Plus ASD to the T1, T2, and T3 terminals of the Bypass Box, respectively, via terminal block PDB1.

Note: The Bypass Box version of the Q9 Plus requires that the control Interface Board be used to connect the Terminal Board to the Control Board via the 25-pin ribbon cable (P/N 76295) as described below and shown in Figure 5 on pg. 24.

3. Open the front door of the Q9 Plus ASD and remove the lower front cover.

4. Loosen the Torx screw at the upper-right corner of the Terminal Board.

5. Slide the factory-installed Terminal Board downward to remove it from the Q9 Plus ASD.

6. Insert the Interface Board (P/N 58100) into the Q9 Plus ASD (slide upwards). Ensure that the male S106 connector of the Interface Board seats securely into the female connector of the Q9 Plus ASD.

7. Secure the Interface Board using the Torx screw at the upper-right corner of the Terminal Board.

Note: The Torx screw at the upper-right side of the Interface Board does not require much torque to secure the Interface Board into the 9-Series ASD. Once the Torx screw begins to resist turning, less than ½ of a turn is required to tighten securely.

8. Connect one end of the 25-pin ribbon cable (P/N 76295) to CN7 of the Interface Board.

9. Route the cable through the wire chase of the Bypass Box towards the lower section of the Bypass Box. Ensure that the cable is routed away from power circuits as much as possible.

10. Connect the other end of the 25-pin ribbon cable to CN7A of the Terminal Board.

11. Replace the lower front cover of the Q9 Plus ASD and close the door.

12. Close the door of the Bypass Box.

System GroundingProper grounding helps to prevent electrical shock and to reduce electrical noise. The ASD is designed to be grounded in accordance with Article 250 of the NEC or Section 10/Part One of the Canadian Electrical Code (CEC).

The grounding conductor shall be sized in accordance with Article 250-122 of the NEC or Part One-Table 6 of the CEC.

The input, output, and control lines of the system shall be run in separate metal conduits, and each shall have its own ground conductor.

Ensure that the Torx screw of the Interface Board is securely in place to prevent arcing, intermittent operation, or system failure.

— T h e M e t a l O f C o n d u i t I s N o t A n A c c e p t a b l e G r o u n d —


Figure 5. Q9 Plus ASD-to-Q9 Plus Bypass Box Typical Connection Diagram.

Note: The connection diagram of this figure applies to the C and E system types.


Startup and Test

Before turning on the unit, the following checks are to be performed by Qualified Personnel.

• L1, L2, and L3 are connected to the three-phase input power.

• T1, T2, and T3 are connected to the motor.

• The three-phase input voltage is within the ASD setup tolerances.

• There are no shorts and all grounds are secured.

• With the previous checks confirmed, ensure that the direction of the motor rotation in the Bypass mode and in the ASD-driven mode is consistent.

• Ensure that all personnel are clear of the motor and the motor-driven equipment.


UT1

I/O Monitoring and ControlThe Q9 Plus Bypass ASD/Q9 Plus Bypass Box can be controlled by several input types and combinations thereof, as well as operate within a wide range of voltage levels. This section discusses the control methods and supported I/O functions.

The Terminal Board (shown on pg. 30) of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box supports discrete and analog I/O functions. Table 1 lists the names, descriptions, and the default settings (if programmable) of the input and output terminals of the Terminal Board. See the section I/O Terminal Descriptions on pg. 27 for more information on the listed terminals.

Table 1. Terminal Board Terminal Names and Functions.

Terminal Name

Circuit TypeFunction

(Default setting if programmable)

ST

Discrete Input

Connect to CC to activate (Sink

mode).

Standby — Multifunctional programmable discrete input. Activation required for normal ASD operation.

RESReset — Multifunctional programmable discrete input. Activation resets ASD when Faulted — ignored when not Faulted.

F Forward — Multifunctional programmable discrete input.

R Reverse — Multifunctional programmable discrete input.

S1 Fire Speed — Multifunctional programmable discrete input.

S2 Preset Speed 2 — Multifunctional programmable discrete input.

S3 Damper Feedback — Multifunctional programmable discrete input.

S4 Emergency Off — Multifunctional programmable discrete input.

CIA/CIB InterlockCustomer Interlock — The CIA-to-CIB interlock connection is accomplished via a jumper, a relay, etc., and is required for normal system operation.

DRA/DRB Damper InputDamper Response — The DRA-to-DRB connection is accomplished via limit switches at the opened damper and is required for normal system operation.

DSA/DSB (OUT1)

Switched Output

Damper Command — Multifunctional programmable dry contact that is used to open/close the 120 VAC damper motor power circuit when the motor is ASD-driven.

OUT2 A/BAcc/Dec Complete — Multifunctional programmable output that changes state when the programmed acceleration or deceleration ramp is reached.

FLC Fault relay (common).

FLB Fault relay (N.C.).

FLA Fault relay (N.O.).

RR

Analog Input

Frequency Mode 1 — Multifunction programmable analog input (0.0 to 10 volt input — 0 Hz to Maximum Frequency).

RX Unassigned — Multifunctional programmable analog input (-10 to +10 VDC input).

IFrequency Mode 2 (default setting) — Multifunctional programmable analog current input (4 [0] to 20 mADC input — 0 Hz to Maximum Frequency).

V Unassigned — Multifunctional programmable analog voltage input (0 to 10 VDC input).

AM

Analog Output

Output Current — Multifunctional programmable voltage output that is proportional to the output current of the ASD or to the magnitude of the function assigned to this terminal.

FMOutput Frequency — Multifunctional programmable Current or Voltage output that is proportional to the output frequency of the ASD or to the magnitude of the function assigned to this terminal. Select Current or Voltage at F681.

P24DC Output

24 VDC (200 mA max.) output.

PP 10.0 VDC (10 mA max.) voltage source for the external potentiometer.

FP Pulsed OutputOutput Frequency — Multifunctional programmable output pulse train of a frequency based on the output frequency of the ASD or of the magnitude of the function assigned to this terminal.

CC — Return for all input and output terminals (DO NOT connect to Earth Gnd).


I/O Terminal DescriptionsNote: The programmable terminal assignments may be accessed and changed from their

default settings as described in the Q9 Plus ASD Installation & Operation Manual.

ST — The default setting for this terminal is the Standby mode controller. As the default setting, this terminal must be activated for normal system operation. The ST terminal is activated by connecting CC to this terminal (Sink mode). When deactivated, OFF is displayed at the Frequency Command screen. This input terminal may be programmed to any of the discrete terminal functions that are listed in the Q9 Plus ASD Installation & Operation Manual.

RES — The default setting for this terminal is Reset. The RES terminal is activated by connecting CC to this terminal (Sink mode). A momentary connection to CC resets the ASD and any fault indications from the display. Reset is effective when faulted only. This input terminal may be programmed to any of the discrete terminal functions that are listed in the Q9 Plus ASD Installation & Operation Manual.

F — The default setting for this terminal is Forward Run. The Forward Run terminal is activated by connecting CC to this terminal (Sink mode). Forward Run runs the motor in the Forward direction for the duration of the activation. This input terminal may be programmed to any of the discrete terminal functions that are listed in the Q9 Plus ASD Installation & Operation Manual.

R — The default setting for this terminal is Reverse Run. The Reverse Run terminal is activated by connecting CC to this terminal (Sink mode). Reverse Run runs the motor in the Forward direction for the duration of the activation. This input terminal may be programmed to any of the discrete terminal functions that are listed in the Q9 Plus ASD Installation & Operation Manual.

S1 — The default setting for this terminal is Fire Speed. The Fire Speed terminal is activated by connecting CC to this terminal (Sink mode). The function of this input as Fire Speed is to run the motor at the Preset Speed 1 setting for the duration of the activation and is typically initiated by a fire/smoke sensing device. This input terminal may be programmed to any of the discrete terminal functions that are listed in the Q9 Plus ASD Installation & Operation Manual.

S2 — The default setting for this terminal is Preset Speed 2. The S2 terminal is activated by connecting CC to this terminal (Sink mode). The function of this input as Preset Speed 2 is to run the motor at the Preset Speed 2 setting for the duration of the activation. This input terminal may be programmed to any of the discrete terminal functions that are listed in the Q9 Plus ASD Installation & Operation Manual.

S3 — The default setting for this terminal is Damper Feedback. The Damper Feedback terminal is activated by connecting CC to this terminal (Sink mode). The function of this input as Damper Feedback is to complete the requirements for normal system operation as described in the section titled Theory of Operation on pg. 13. This input terminal may be programmed to any of the discrete terminal functions that are listed in the Q9 Plus ASD Installation & Operation Manual.

S4 — The default setting for this terminal is Emergency Off (normally closed). The Emergency Off terminal is activated by opening the connection to CC (Sink mode). The function of this input as Emergency Off is to remove power from the output of the ASD and may apply a supplemental braking system using the method selected at the Emg Off Mode selection parameter (F603). This input terminal may be programmed to any of the functions that are listed in the Q9 Plus ASD Installation & Operation Manual.

CIA/CIB — These terminals are used to complete the Customer Interlock function. The CIA-to-CIB connection is a requirement for normal Q9 Plus Bypass ASD/Q9 Plus Bypass Box operation. These terminals may be connected using a jumper or are used to Enable/Disable the system as a function of a user-selected event or condition that will open or close this circuit. See the section titled Theory of Operation on pg. 13 for further information on these terminals.


DRA/DRB — These terminals are used to complete the Damper Response function. The DRA-to-DRB connection is a requirement for normal Q9 Plus Bypass ASD/Q9 Plus Bypass Box operation. These terminals may be connected using a jumper or used to Enable/Disable the system as a function of an event or condition that will open or close this circuit. See the section titled Theory of Operation on pg. 13 for further information on these terminals.

DSA/DSB (OUT1) — The default function assigned to this output contact is Damper Command. As such, it is used to switch an externally-supplied 120 VAC to the damper motor. This output terminal may be programmed to provide an indication (open or closed) that a user-selected function has occurred or is active. Once the ASD receives a run command, any terminal that is set to the Damper Command function changes state. This function may be used to signal external equipment (e.g., switch power to the damper motor). The OUT1 contact is rated at 2 A/120 VAC and 2 A/30 VDC. See the section titled Theory of Operation on pg. 13 and the Q9 Plus ASD Installation & Operation Manual for further information on this terminal.

OUT2 A/B — The default function assigned to this output contact is ACC/DEC Complete. This output terminal may be programmed to provide an indication (open or closed) that a user-selected function has occurred or is active. This function may be used to signal external equipment (e.g., activate the brake). The OUT2 contact is rated at 2A/250 VAC. See the Q9 Plus ASD Installation & Operation Manual for further information on this terminal.

FLC — FLC is the common leg of a single-pole double-throw form C relay. The FL relay is the Fault Relay by default but may be programmed to any of the selections listed in the Q9 Plus ASD Installation & Operation Manual.

FLB — The normally-closed leg of the FL relay.

FLA — The normally-open leg of the FL relay.

Note: The FLA, FLB, and FLC contacts are rated at 2A/120 VAC and 2A/30 VDC.

RR — The default function assigned to this terminal is the Frequency Mode 1 setting. The RR terminal accepts a 0 – 10 VDC input signal that is used to control the function assigned to this terminal. This input terminal may be programmed to control the speed or torque of the motor via an amplitude setting or regulate by setting a limit. The gain and bias of this terminal may be adjusted for application-specific suitability. See the Q9 Plus ASD Installation & Operation Manual for further information on this terminal.

RX — The RX terminal accepts a ±10 VDC analog input signal and controls the function assigned to this terminal. This input terminal may be programmed to control the speed, torque, or direction of the motor. It may also be used to regulate (limit) the speed or torque of the motor. The gain and bias of this terminal may be adjusted for application-specific suitability. See the Q9 Plus ASD Installation & Operation Manual for further information on this terminal.

I — The default function assigned to this terminal is to carry out the Frequency Mode 2 setting. The function of the I terminal is to receive a 4 – 20 mA input signal that controls a 0 – 80 Hz output (or the user-selected function). This input terminal may be programmed to control the speed or torque of the motor and may not be used when using the V input terminal. It may also be used to regulate (limit) the speed or torque of the motor. The gain and bias of this terminal may be adjusted for application-specific suitability. See the Q9 Plus ASD Installation & Operation Manual for further information on this terminal.

V — The function of the V terminal is to receive a 0 – 10 VDC analog input signal that is used to control a user-selected function. This input terminal may be programmed to control the speed or torque of the motor and may not be used when using the I input terminal. It may also be used to regulate (limit) the speed or torque of the motor. The gain and bias of this terminal may be adjusted for application-specific suitability. See the Q9 Plus ASD Installation & Operation Manual for further information on this terminal.


AM — The default function assigned to this output terminal is Output Current. This output terminal produces an output voltage that is proportional to the magnitude of the Output Current of the Q9 Plus Bypass ASD (or the function assigned to this terminal). This output terminal may be programmed to provide an output that is a function of any of the functions listed in the Q9 Plus ASD Installation & Operation Manual.

FM — The default function assigned to this output terminal is Output Frequency. This output terminal produces an output current or voltage that is proportional to the magnitude of the Output Frequency of the Q9 Plus Bypass ASD (or the function assigned to this terminal). The Voltage/Current output selection is performed at F681. This output terminal may be programmed to provide an output that is a function of any of the functions listed in the Q9 Plus ASD Installation & Operation Manual.

P24 — +24 VDC @ 200 mA power supply for customer use.

PP — The function of output PP is to provide a 10 VDC/10 mADC output that may be divided using a potentiometer. The tapped voltage is applied to the RR input to provide manual control of the RR programmed function.

FP — The default function assigned to this open collector output terminal is Output Frequency. This output terminal produces an output pulse train with a frequency that is proportional to the magnitude of the Output Frequency of the ASD (or the function assigned to this terminal). This output terminal may be programmed to provide an output pulse train of a frequency that is a function of the user-selected function in the Q9 Plus ASD Installation & Operation Manual.

CC — Control Common (DO NOT connect to Earth Gnd).


rminal Board
Monitoring/Control InterfaceThe Terminal Board serves as a monitoring and control interface of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. The Terminal Board receives input from ancillary devices, transducers, or from the user via the EOI. The Terminal Board also provides output signals that may be used to control ancillary devices, close/open a contact, annunciate, or monitor system variables.
Connect the available input and output monitoring/control lines of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box in accordance with the type of system being used as shown in Figure 8 on pg. 32, Figure 9 on pg. 33, or Figure 10 on pg. 34.

Note: See the Q9 Plus ASD Installation & Operation Manual for more information on Q9 Plus Bypass ASD control.

Figure 6. Q9 Plus Bypass ASD/ Bypass Box Terminal Board (P/N 53750 — PCB 13).


Typical Connection DiagramThree expanded depictions of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box systems are shown in figures 8, 9, and 10.

Figure 7. Q9 Plus Bypass ASD/Q9 Plus Bypass Box Typical Connection Diagram.

L3

T3

L3

T3

MOTOR

T1 T2

T2T1

L2L1

L1 L2

OL95 96 98

T3

97

L3

T3T23M T1

M

L1

T1

G

T2

L2

2M

13

25

CNCPT1

CNOL

4

L3

T3

321

T2T1

L1 L2

L2 L3L1

T3

L3

AC

RE

AC

TOR

L2L1

T2T1

PO PA

CN

7

1M

Fuse

MC

P

Fuse

Fuse

115VAC

DC

RE

AC

TOR

ASD

PCB12

CPT

G

CN2ACN1A

CN7A

3 25 4 1 7 3 125 46

7 6 5 34 2 15 4 2 13

CN1 CN2

PCB11

Q9 Terminal Board

Extender Box Control Board

S

LS

16 DSB

- CC

TB5

TB6 +-

+-

TB4 +-

TB3 +-

CCFP

CCV

CCI

CCAM

22

25

TB2 +

2423

19

2120

1817

F

P24

FM

RRRES

S2

RS1

S3S4

3 CC

10

131415

1112

789

56

4

FLC

OUT2A

DSAOUT2B

FLAFLB

CIB

DRBDRA

RX

CIAPP

TB1

21

CCST

Factory-InstalledJumpers

CHARGEINDICATORLED

PCB13

RS485

S4

460-

Vol

t Inp

utFu

ses

Sta

ndar

d

P/N 53750

(Door-mounted)

Plus

Note: When connecting multiple wires to the PA, PB, PC, or PO terminals, DO NOT connect a solid wire and a stranded wire to the same terminal.


Figure 8. Q9 Plus Bypass ASD/Bypass Box-IA Typical Connection Diagram — No Bypass or Contactors.

2

CC0-

1 m

A

CN

7A

MOTOR

25 Conductor Ribbon Cable

T3T1 T2G

1

2

CNOL13

34

CN1M

CN23M

2

1

1

2

CNLS

ST

AC

Rea

ctor

BLBKRD

3FU

1FU

2FU

T3T1 T2

MCP L3L1 L2

G

CP

T

5FU

Charge Indicator LEDL3L1 L2 PO

DC

Rea

ctor

PA

K4

4

CNCPT

41

CN1A

PCB121 2 3 5 1

CN2A

X1

X2H2

H4

4FUH1

H3

115VAC

6FU

16

JPDS2

DSB

- CC

TB5

SW1 (AM)

4-20

mA

SW2 (FM)

TB6 +-

+-

TB4 +-

TB3 +-

CCFP

CCV

CCI

CCAM

22

25

TB2 +

2423

JP1 19

2120

1817

F

P24

FM

RRRES

S2

RS1

S3S4

3 CC

10

JPDS1131415

1112

789

56

4

FLC

OUT2A

DSAOUT2B

FLAFLB

CIB

DRBDRA

RX

CIAPP

TB1

21

53 4 6 7

CCST

LEGENDG-

BL--BK-RD

-LS

MCPASD-

-

--

-DAMPER SEND

ADJUSTABLE SPEED DRIVEMTR CIRCUIT PROTECTOR

DAMPER RESPONSECUSTOMER INTERLOCK

DOOR SWITCH

RED

BLUEBLACK

GROUND

DS(A,B)DR(A,B)CI(A,B)

(OUT1)

K4


OptionalReactances

R3 RD

OPTIONAL AC REACTOR-R3OPTIONAL DC REACTORRD -

S

LS

CN

7

ASD

Q9PCB13

RS485S4

460-

Vol

t Inp

utFu

ses

Sta

ndar

d

Plus


Figure 9. Q9 Plus Bypass ASD/Bypass Box-IC Typical Connection Diagram — Two-Contactor. Bypass.

K2

LED2

102

2

CC0-

1 m

A

CN

7A

96

MOTOR

3M

T1 T2 T3

T3T1 T2 95

L3L1 L2

L3L1 L2

M

25 COND

3M

2M22

22

T3T1 T2

2M

9897

A2 A13M

A2 A12M

L3L1 L2

T3T1 T2G

1

2

CNOL13

34

CN1M

CN23M

2

1

1

2

CNLS

ST

AC R

EAC

TOR

BLBKRD

3FU

1FU

2FU

T3T1 T2

L3L1 L2

G

CPT5FU

CHARGEL3L1 L2 PO

DC

REA

CTO

R

PA

K4

4

4

CNCPT

41

CN1A

PCB12

CN1

1 2 3

21 3

5

5

1CN2A

CN21

X1

X2H2

H4

4FUH1

H3

115VAC

6FU

R

TYPICAL LED CIRCUIT

R

LED

DLED5

BYP

K3

SW2

2OFF

3

K3

1INV 12

4

PCB11

14

16

JPDS2

DSB

- CC

TB5

SW1 (AM)

4-20

mA

SW2 (FM)

TB6 +-

+-

TB4 +-

TB3 +-

CCFP

CCV

CCI

CCAM

22

25

TB2 +

2423

JP1 19

2120

1817

F

P24

FM

RRRES

S2

RS1

S3S4

3 CC

10

JPDS1131415

1112

789

56

4

FLC

OUT2A

DSAOUT2B

FLAFLB

CIB

DRBDRA

RX

CIAPP

TB1

21

53 4

3 548

6 7

767

CCST

5

9K3

K26 12 11K2

K2

10

2

LED4

K3

LED3

13 13 14

LEGEND

(OUT1)

K4


Contactors

MC

P

ReactancesOptional

RDR3

OPTIONAL DC REACTOROPTIONAL AC REACTOR

MECHANICAL INTERLOCKADJUSTABLE SPEED DRIVEMTR CIRCUIT PROTECTOR

DAMPER RESPONSECUSTOMER INTERLOCK-CI(A,B)

DOOR SWITCHLS-

DAMPER SEND

-ASD

DS(A,B)DR(A,B)

MCP---

-BLUEBLR3-

BKRD

MG

-

BLACK

GROUNDRED-

-

- BYPASS MODEINVERTER MODE

SYSTEM INTERLOCKCONTROL POWERLED5-

RD -

LED4

LED2LED3-

-

-

Protection(OCP)

Circuit

LS

S

INDICATORLED

CN

7

ASD

Q9PCB13

RS485

S4

460-

Volt

Inpu

tFu

ses

Stan

dard

Overload

Plus


Figure 10. Q9 Plus Bypass ASD/Bypass Box-IE Typical Connection Diagram — Three-Contactor Bypass.


Control Panel FeaturesThere are three types of Q9 Plus Bypass ASD/Q9 Plus Bypass Box control panels available. The type of panel used is configuration-specific to the typeform being used (A, C, or E typeforms).

Panel A is used as a cover and has no active features.

Panels C and E provide the user with access to the Q9 Plus Bypass ASD/Q9 Plus Bypass Box monitoring and control features. Each feature is discussed below and expanded upon in the section titled Theory of Operation on pg. 13.

Figure 11 shows the three Q9 Plus Bypass ASD/Q9 Plus Bypass Box panel types.

Figure 11. Q9 Plus Bypass ASD/Q9 Plus Bypass Box A-, C-, and E-Configuration Panels.

Panel Item Descriptions1. Control Power LED (LED 5) — ON when the control circuit power is applied.

2. System Interlock LED (LED 4) — ON when the following conditions are met:

• Control Power is applied,

• Door switch (LS) is open,

• Protective Overload contactor (OL) is closed,

• Customer Interface contact (CI) is closed, and

• The damper is fully open (DRA connected to DRB).

The Inverter and Bypass operating modes are enabled for normal operation as selected by the Inverter Mode Switch.

3. Inverter LED (LED 2) — ON when the following conditions are met:




• Customer Interface contact (CI) is closed, and

• The Inverter Mode switch is set to INV.

Upon receiving a Damper Response signal (DRA/DRB), the 2M contactor closes to allow for normal Inverter Mode operation.

2-Contactors

No ContactorsA

C

3-ContactorsE


4. Bypass LED (LED 3) — ON when the following conditions are met:




• Customer Interface contact (CI) is closed,

• The damper is fully open (DRA connected to DRB), and

• The Inverter Mode switch is set to BYP.

Upon receiving a Damper Response signal (DRA/DRB), the 3M contactor closes to allow for normal Bypass Mode operation.

5. Inverter Mode Switch — With the System Interlock LED criteria being met (item #2), the Inverter Mode switch is used to select Inverter Mode, Bypass Mode, or Off.

6. Inverter Test Mode Switch — With the CPT input power applied and the door closed, the Inverter Test Mode switch (when on) closes the 1M contactor (via K1) to test the ASD section of the system without providing an ASD output to the connected motor.

7. Test LED (LED 1) — ON during Inverter Test Mode operation.


Part Numbering Convention and System Components

Figure 12. Q9 Plus Bypass ASD Part Numbering Convention.

Figure 13. Q9 Plus Bypass Box (only) Part Numbering Convention.

Note: The Type 1 enclosed versions of the Q9 Plus Bypass ASD/Q9 Plus Bypass Box meet or exceed the specification UL 1995, the Standard for Heating and Cooling Equipment, and complies with the applicable requirements for installation in a compartment handling conditioned air.


Figure 14. Typical Q9 Plus ASD/ Q9 Plus Bypass Box Components.

Note: Size 1 shown.


Enclosure Dimensions/WeightsTable 2. Q9 Plus Bypass ASD Series Enclosure Size 1 (inches/mm).

Model Number

Shipping Weight Approx.(Lbs/kg.)

Q9+2015

95/43.1

Q9+2025

Q9+2035

Q9+2055

Q9+2080

Q9+4015

Q9+4025

Q9+4035

Q9+4055

Q9+4080

Q9+4110

Q9+4160


Table 3. Q9 Plus Bypass ASD Series Enclosure Size 2 (inches/mm).

Model Number


Q9+2110

180/81.5

Q9+2160

Q9+2220

Q9+2270

Q9+4220

Q9+4270

Q9+4330

Q9+4400


Table 4. Q9 Plus Bypass ASD Series Enclosure Size 3 (inches/mm).

Model NumberShipping Weight

Approx.(Lbs/kg.)

Q9+2330 182/82.6

Q9+2400

282/128Q9+4500

Q9+4600

Q9+4750324/147

Q9+410K

Q9+412K 356/161.5

Note: Part number suffix = (E) + A, C, or E (i.e., EA, EC, or EE).

Note: Part number suffix = (R) + 3, 5, or D (i.e., R3, R5, or RD).

See Figure 12. on pg. 37 for more on the part numbering convention.

Model Number

Q9+

Dimension A

Dimension B

2330(E) 54.4/1382 53.13/1350

2330(E)(R)59.75/1518 58.5/1486

2400(E)

2400(E)(R) 64.88/1648 63.63/1616

4500(E)

59.75/1518 58.5/14864500(E)(R)

4600(E)

4600(E)(R)

4750(E) 63.0/1600 61.75/1569

4750(E)(R) 68.0/1727 66.75/1696

410K(E) 63.0/1600 61.75/1569

410K(E)(R)68.0/1727 66.75/1696

412K(E)


Table 5. Q9 Plus Bypass Box Series Enclosure Size 3 (inches/mm).

Model Number


— ASD SOLD SEPARATELY FOR THIS TYPEFORM —

BYP2-100 127/57.6BYP2-125

BYP4-070 102/46.3

BYP4-080127/57.6

BYP4-100

BYP4-125 142/64.4

BYP4-160 174/78.9

Model Number A B C D E F G

BYP2-100-EX 32.10/815 30.12/765 31.23/7939.38/238 3.79/96.3 4.14/105 4.55/116

BYP2-100-EXRX 37.10/942 35.12/892 36.23/920

BYP2-125-EX 32.10/815 30.12/765 31.23/79312.50/318 4.41/112 4.62/117

5.30/135

BYP2-125-EXRX 37.10/942 35.12/892 36.23/920

BYP4-070-EX

32.10/815 30.12/765 31.23/7939.38/238 4.58/116 4.48/114

BYP4-070-EXRX

BYP4-080-EX

BYP4-080-EXRX

BYP4-100-EX

12.50/318 4.41/112 6.89/175

BYP4-100-EXRX 37.10/942 35.12/892 36.23/920

BYP4-125-EX 32.10/815 30.12/765 31.23/793

BYP4-125-EXRX37.10/942 35.12/892 36.23/920

BYP4-160-EX

The listed items have an X placed into the part number indicating that they may be further characterized as indicated on pg. 37.


Cable/Terminal SpecificationsThe following ratings are guidelines and shall not be the sole determining factor of the lug or wire size used with the Q9 Plus Bypass ASD/Q9 Plus Bypass Box. Application-specific variables, wire insulation type, and conductor material are but a few of the considerations necessary when selecting the actual lug and wire type to be used.

As a minimum, the installation of the ASD shall conform to the requirements of the NEC Article 110 and Article 430, the Occupational Safety and Health Administration requirements, and to any other local and regional industry codes and standards.

Note: Use only 75° C copper wire/cable for motor and power connections.

Table 6. Q9 Plus Bypass ASD/Q9 Plus Bypass Box 230- and 460-Volt Drive Cable/Terminal Specifications.

Model No.MCP

Rating (Amps)

Typical Wire/Cable Size Lug Size/Wire Capacity

AWG/kcmil

Input/Output Power

TB1 TB2 – TB6ASD

Input/OutputOL Relay Output

Circuit Breaker Input

Q9+2015 714

18(2-core shield)

20(3-core shield)

14 – 1/08 – 18

14 – 1/0

Q9+202515

Q9+2035 12

Q9+205530

10

Q9+20808

12 – 8

Q9+2110 50 10 – 4

10 – 1/0Q9+2160

756

8 – 2Q9+2220 4

Q9+2270 1002

4 – 1/0Q9+2330

250

14 – 2/0

4 – 4/0Q9+2400 1/0

BYP2-100 26 – 3/0

BYP2-125 1/0 2 – 300

Q9+4015

714

18(2-core shield)

20(3-core shield)

14 – 1/0

8 – 18

14 – 1/0

Q9+4025

Q9+4035

Q9+405515

Q9+4080 12

Q9+411030

10 12 – 8

Q9+41608 10 – 4

Q9+4220

50Q9+42706 8 – 2

10 – 1/0Q9+4330

Q9+440075 4 4 – 1/0

Q9+4500


Q9+4600 150 3

18(2-core shield)

20(3-core shield)

3 – 1/0 8 – 3/0

Q9+4750 150 1

2 – 3006 – 3/0

8 – 3/0

Q9+410K250

1/04 – 4/0

Q9+412K 3/0 6 – 300

BYP4-070 75 44 – 1/0 10 – 1/0

14 – 1/0

BYP4-080150

38 – 3/0

BYP4-100 1

2 – 3006 – 3/0

BYP4-125250

1/04 – 4/0

BYP4-160 3/0 6 – 300

Table 6. Q9 Plus Bypass ASD/Q9 Plus Bypass Box 230- and 460-Volt Drive Cable/Terminal Specifications.

Model No.MCP

Rating (Amps)

Typical Wire/Cable Size Lug Size/Wire Capacity

AWG/kcmil

Input/Output Power

TB1 TB2 – TB6ASD

Input/OutputOL Relay Output

Circuit Breaker Input


Current/Voltage Specifications

Table 7. 230- and 460-Volt NEMA Type-1 Chassis Standard Ratings.

Model No.

Use With ASD

Model VT130

HPInput Voltage

3-Ph 50/60±2 Hz

Output Voltage

3-Ph Variable

Frequency

Output Current 100%

Continuous

Overload Current

110% for 60 Secs.

Q9+2015

N/A

1.0

200 – 240 VAC(±10%)

Input Voltage Level (Max.)

4.8 A 5.3 A

Q9+2025 2.0 7.8 A 8.6 A

Q9+2035 3.0 11.0 A 12.1 A

Q9+2055 5.0 17.5 A 19.3 A

Q9+2080 7.5 25.3 A 27.8 A

Q9+2110 10 32.2 A 35.4 A

Q9+2160 15 48.3 A 53.1 A

Q9+2220 20 62.1 A 68.3 A

Q9+2270 25 78.2 A 86.0 A

Q9+2330 30 92.0 A 101.2 A

Q9+2400 40 120.0 A 132.0 A

BYP2-100 Q9+2330 30 92.0 A 101.2 A

BYP2-125 Q9+2400 40 120.0 A 132.0 A

Q9+4015

N/A

1.0

380 – 480 VAC(±10%)


2.1 A 2.3 A

Q9+4025 2.0 3.4 A 3.7 A

Q9+4035 3.0 4.8 A 5.3 A

Q9+4055 5.0 7.6 A 8.4 A

Q9+4080 7.5 11.0 A 12.1 A

Q9+4110 10 14.0 A 15.4 A

Q9+4160 15 21.0 A 23.1 A

Q9+4220 20 27.0 A 29.7 A

Q9+4270 25 34.0 A 37.4 A

Q9+4330 30 40.0 A 44.0 A

Q9+4400 40 52.0 A 57.2 A

Q9+4500 50 65.0 A 71.5 A

Q9+4600 60 77.0 A 84.7 A


Q9+4750

N/A

75

380 – 480 VAC(±10%)


96.0 A 105.6 A

Q9+410K 100 124.0 A 136.4 A

Q9+412K 125 156.0 A 171.6 A

BYP4-070 Q9+4500 50 65.0 A 71.5 A

BYP4-080 Q9+4600 60 77.0 A 84.7 A

BYP4-100 Q9+4750 75 96.0 A 105.6 A

BYP4-125 Q9+410K 100 124.0 A 136.4 A

BYP4-160 Q9+412K 125 156.0 A 171.6 A

Table 7. 230- and 460-Volt NEMA Type-1 Chassis Standard Ratings.

Model No.

Use With ASD

Model VT130

HPInput Voltage

3-Ph 50/60±2 Hz

Output Voltage

3-Ph Variable

Frequency

Output Current 100%

Continuous

Overload Current

110% for 60 Secs.


Index

Numerics1M contactor, 13230 Volt NEMA Type-1 Chassis, 452M contactor, 14, 353M contactor, 14, 36

AAM, 26, 29Amps Interrupting Capacity (AIC), 16ASD protection, 16

BBYP, 14BYP Series, 21Bypass LED, 36Bypass operation, 15

CCable/Terminal Specifications, 43CC, 26, 29CE Compliance Requirements, 11CIA to CIB, 20CIA/B contacts, 13CIA/CIB, 26, 27Connecting the Bypass Box, 23Connecting the Q9 Plus Bypass ASD, 22Control Power LED, 35Control Power Transformer, 13Current/Voltage Specifications, 45Customer Interface, 13Customer Interlock, 20, 26Customer Support Center, 2

DDamper Command, 14Damper Feedback, 14Damper Feedback (DRA/B circuit), 14Damper Response, 14, 26Default Terminal Setting, 26Discrete Input, 26Disposal, 3DRA, 26DRA to DRB, 20DRA/DRB, 28DRA-to-DRB, 14

DSA and DSB, 14DSA/DSB, 14, 28Dynamic Braking, 8Dynamic Braking Precaution, 8

EEnclosure Components, 38Enclosure Dimensions/Weight, 39Enclosure Size 1, 39Enclosure Size 2, 40Enclosure Size 3, 41, 42Enclosure Weights, 39Equipment Inspection, 3Equipment Warning Labels, 2

FF, 26, 27Filter Selection Table, 12FLA, 26, 28FLB, 26, 28FLC, 26, 28FM, 26FP, 26, 29

GGeneral Safety Information, 1

HHandling and Storage, 3

II terminal, 28I/O Control and Monitoring, 26Important Notice, 4Input Voltage, 45Installation, 20Installation Precautions, 4Introduction, 3INV, 14Inverter LED, 35Inverter Mode Switch, 36


JJPDS1, 14JPDS2, 14

LLS switch, 13Lug Size, 43

MMCP Adjustment and Setting, 18MCP Rating, 43Mode Switch, 36Monitoring/Control Interface, 30Motor HP/Kw, 45Motor protection, 17motor rotates in the wrong direction, 22Mounting and Connections, 21Mounting the Bypass Box, 22

OOCP Adjustment and Setting, 19OL contacts, 13Operational and Maintenance Precautions, 9OUT1, 26, 28OUT2 A/B, 26, 28Output Current, 45Output Voltage, 45Overload Current, 45

PP24, 26, 29Part Numbering Convention, 37phase relationship of the L1, L2, and L3 connections, 14PP, 26, 29

QQ9 Plus Bypass ASD/Q9 Plus Bypass Box Connection

Diagram, 31Q9 Plus Bypass ASD/Q9 Plus Bypass Box-A, 32Q9 Plus Bypass ASD/Q9 Plus Bypass Box-C, 33Q9 Plus Bypass ASD/Q9 Plus Bypass Box-E, 34Q9 Plus Bypass Box Enclosure, 38

Qualified Personnel, 2

RR, 26, 27

RES, 26, 27

Reverse and Forward functions, 14

RR, 26, 28

RX, 26, 28

SS1, 26, 27

S2, 26, 27

S3, 26, 27

S4, 26, 27

S4 to CC, 20

Shipping Weight, 39, 41, 42

Shunt Trip, 13, 17

Special Symbols, 2

ST, 26, 27

ST to CC, 20

Startup and Test, 25

SW2 Off Position, 14

System Grounding, 23

System Integration Precautions, 7

System Interlock LED, 35

System Protection, 16

TTerminal Board, 21, 26, 30

Terminal Descriptions, 27

Terminal Specifications, 43

Test LED, 36

Test Mode Switch, 36

Theory of Operation, 13

Typical Wire/Cable Size, 43

VV terminal, 28

Voltage Specifications, 45

WWarranty Card, 2


Documents

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