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Emerson FPCSK - User Manual

Emerson FPCSK
43 pages
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FPCSK and FPCBA
Electronic Bypass
Controller
INSTRUCTION MANUAL
START-UP GUIDE
Part Number: 027–2201
Issue: 1.1

Table of Contents

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Emerson FPCSK Specifications

General IconGeneral
BrandEmerson
ModelFPCSK
CategoryController
LanguageEnglish

Summary

Safety and Precautions

General Safety Warnings

Crucial warnings about installation, wiring, and handling to prevent hazards.

Introduction

Description

Welcome and overview of the Electronic bypass package and manual.

Installation Instructions

2.1 Receiving

Verifies part numbers, checks for shipping damage, and ensures internal hardware is secure.

2.2 Nameplate Information

Details the two nameplates for identification and the information they contain.

2.3 Part Number Identification

Explains how to identify product part numbers based on a coding system.

2.4 Mounting & Clearances

Provides guidelines for physical installation, including required clearances for heat dissipation.

2.5 Wiring and Precautions

Outlines general wiring practices and critical safety precautions during installation.

2.5.1 General

General safety rules for wiring, including not connecting/disconnecting while powered.

2.5.2 Input Wiring

Covers input wiring options and recommendations for connecting power supply.

2.5.3 Output Wiring

Details the output wiring options and recommended conduit locations for motor connections.

2.5.4 Control Circuit Wiring (FPCSK)

Describes analog output, digital inputs, and relay outputs for FPCSK models.

2.5.5 Control Circuit Wiring (FPCBA)

Details analog output, digital inputs, and relay outputs for FPCBA models.

2.5.6 Grounding

Provides instructions for proper grounding procedures, emphasizing separate conduits.

2.6 Inspection

Checklist for verifying wiring completion, cleanliness, and secure fastenings.

2.7 Checking Motor Rotation

Procedures for verifying correct motor rotation in VFD and Bypass modes.

2.7.1 Check #1: Rotation on VFD power

Step-by-step guide to check motor rotation while operating on VFD power.

2.7.2 Check #2: Rotation on Bypass power

Guide to check motor rotation when operating on bypass power.

Overview of the Electronic Bypass

3.1 Control Board

Describes the control board, DIP switches, and jumper settings for configuration.

3.2 Electronic Bypass Keypad Function Summary

Overview of the keypad buttons, LEDs, and their functions for operation.

3.3 Using the Electronic Bypass Configuration Switches

Explains the function of four configuration switches for tailoring bypass behavior.

3.4 Using the Additional Customer Inputs

Details additional customer inputs like Safety, Remote Bypass, and Remote VFD.

3.5 Alarm Displays

Lists the alarms that can be displayed, including motor overload and VFD faults.

3.6 Failure and Power Off Conditions

Explains how the system handles control card failure and power loss.

3.7 Control Modes of the Electronic bypass

Outlines the different operational modes: TEST, VFD, HAND, AUTO.

3.7.1 TEST mode

Describes the TEST mode for setting up and reading system characteristics.

3.7.2 VFD mode

Explains the VFD mode where input and output contactors are energized.

3.7.3 BYPASS mode

Details the BYPASS mode where the bypass contactor is energized.

3.7.4 HAND mode

Covers HAND mode for local control via keypads and pushbuttons.

3.7.5 AUTO mode

Explains AUTO mode for remote control via building automation systems.

3.8 Bypass Modes of the Electronic bypass

Describes three modes for bypassing the VFD and using full line power.

3.8.1 MANUAL Bypass

Explains manual bypass operation, initiated by HAND or AUTO mode selection.

3.8.2 AUTOMATIC Bypass on VFD Fault

Details automatic bypass activation upon sensing a VFD fault.

3.8.3 EMERGENCY Bypass

Describes emergency bypass activation via a jumper for control board failure.

Programming

4.1 Commander HSK Required Programming

Lists essential parameters for Commander HSK for proper bypass package operation.

4.2 Affinity BA Required Programming

Lists essential parameters for Affinity BA for proper bypass package operation.

4.3 Commander HSK Recommended Programming

Recommended parameters for Commander HSK during start-up, based on application.

4.4 Affinity Recommended Programming

Recommended parameters for Affinity during start-up, based on application.

Operation

General Precautions

Crucial safety and operational guidelines to prevent damage and injury.

5.1 Keypad Operation

Explains how to use the VFD and Electronic Bypass keypads for control.

5.1.1 VFD Keypad

Details the VFD keypad's primary use for speed control and monitoring.

5.1.2 Electronic Bypass Keypad

Describes the Electronic Bypass keypad's role in controlling the package.

5.1.3 Electronic Bypass Keypad Layout

Breaks down the Electronic Bypass keypad into its four main sections.

5.1.4 System Status LEDs

Explains the five system status LEDs indicating power, operation mode, and run status.

5.1.5 HAND; OFF; AUTO Buttons

Describes the three buttons for selecting the start mode (HAND, AUTO, OFF/RESET).

5.1.6 TEST; VFD; BYPASS Buttons

Details the three buttons for selecting the operation mode (TEST, VFD, BYPASS).

5.1.7 LED Alarm Display

Lists the four alarm LEDs indicating specific faults like Motor Overload or VFD Fault.

5.2 Starting Operation

Two-step process for initiating operation: selecting mode and start mode.

5.3 Ending Operation

Two options for ending operation: cancelling start mode or operation mode.

Alarm & Faults

6.1 Electronic Bypass Keypad Alarms and Faults

Details the four alarm LEDs on the keypad and their meanings.

Motor Overload

Indicates a tripped motor overload relay and checks for proper settings.

Safety

Indicates an open external safety interlock, checking for jumpers or contact closure.

Fire Alarm

Signals a fire condition, affecting operation based on purge or stop mode.

VFD Fault

Indicates a fault on the VFD, with codes displayed on the VFD keypad.

Appendix

7.1 Specifications

Lists technical specifications of the Electronic Bypass package.

7.1.1 Electronic bypass

Details design features, operating conditions, and approvals for the bypass.

7.2 Maintenance & Inspection

Describes periodic maintenance and inspection procedures for the bypass.

7.3 Start-up Checklist - Electronic Bypass

A checklist for pre-power checks, control wiring, and power-up verification.

7.4 Startup Checklist - VFD

Checklist for VFD startup, including connections, settings, and motor nameplate data.

Schematics

8.1 FPCSK Schematic

Wiring diagram for the FPCSK model of the Electronic Bypass Controller.

8.2 FPCBA Schematic

Wiring diagram for the FPCBA model of the Electronic Bypass Controller.

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