form 160.

00-cl1 (909)

model – MV VSD OptiSpeed™

Installation & Start-up checklist
TO: _ ______________________________________________ JOB NAME: _______________________________________
_ ______________________________________________ LOCATION: _______________________________________
_ ______________________________________________ CUSTOMER ORDER NO. _______________________________
york tel. no._ __________________ york order no.__________________ york contract no.____________________
Medium Voltage Variable Speed Drive
model no.____________________________________ serial no._____________________________________________
_The work (as check below) is in process and will be completed by _____________ / _____________ / _____________
Month Day Year
The following work must be completed in accordance with installation instructions:
A. INSTALLATION CHECKLIST C-7 Note torque markings on bolts securing bus bars
1. Remove shipping materials and inspect and power connections, verify none of the bolts
cabinets for any physical damage......................................... have rotated from markings......................................
2. Position cabinets adjacent to chiller in C-8 Depress 2 green buttons in sliding rails and push
location that motor output wires will reach............................ Power Module assembly back into position in
3. Remove 2 cabinet bolts along front edge one smooth motion...................................................
allowing the cabinet sides to be within 1/4"........................... C-9 Re-install bolt to secure Power Module in place..........
4. Verify 2" x 3" openings in both cabinets line up C-10 Insert 2 electrical cables into sockets.....................
closely to allow power wiring to pass through....................... C-11 Re-install barrier cover............................................
5. Connect copper bus link between the 2 cabinets C-12 Repeat steps C-1 through C-11 for the
(air grill must be removed for access)................................... remaining 2 Power Module assemblies..................
6. Remove cover plate inside output section to D. Re-install neural bus bar across 3
permit entrance of output wires to motor.............................. Power Module assemblies...............................................
7. Remove inner cover plate to access E. Reconnect output wires for U, V, and W to
incoming power lugs............................................................. lugs on Power Module assemblies.................................
8. Remove 2 fan cover plates from top of 14. Re-install plastic cover over Power Module assemblies
cabinets and set aside.......................................................... in inverter cabinet.................................................................
9. Remove 2 clear plastic covers in transformer 15. Check bolt torque markings on all Diode
cabinet and one cover in inverter cabinet............................. Modules in the transformer cabinet......................................
10. Lift fans onto cabinet roof using sling and crane or 16. Inspect connections to transformer behind panels
forklift. Plug electrical connectors into sockets in fans.......... holding diode modules in the transformer cabinet...............
11. Bolt fans onto cabinets using the same 17. Inspect the Special Transformer which supplies
hardware removed from the cover plates............................. 3-phase 460 VAC and 1-phase 120 VAC.............................
12. Cut wire ties from control cables and plug the 3 cables 18 Inspect the 3 Pre-charge Inductors......................................
into the keyed sockets in the side of transformer cabinet.....
13. Inspect output Power Module assemblies ONLY perform the following when incoming
A. Remove 3 output cables from Power Module assembly lugs... power has NOT been wired to the unit!
B. Remove neutral bus bar across top of 3 assemblies...........
C. Power Modules are racked out one at a time to inspect 19. Check operation of Isolation Switch by lifting the
assemblies throroughly.................................................... cabinet door interlock and operating the switch...................
C-1 Remove front barrier cover....................................... 20. Check all power wiring to and from vacuum contactors.......
C-2 Remove electrical connectors - 21. Vacuum out all areas around transformer and
edge connector and 2-pin power connector............. on panels around outside of transformer.............................
C-3 Remove center bolt securing assemblies..................... 22. Re-install plastic covers over all diode assemblies..............
C-4 Pull Power Module assembly out from cabinet on 23. Inspect the internal cabinet location of output wiring
sliding track until track locks into extended position.... connections, behind the door in the logic section................
C-5 Inspect all ring-lugs, connectors, electrical 24. Check the GFI board, DCCT's, ground bus connection
connections for tightness, and pulling on between cabinets, and output bus lugs................................
wires to verify tightness............................................ 25. Vacuum out the internal output wiring enclosure.................
C-6 Inspect under Power Modules for tightness 26. Inspect all connections for tightness inside the
of fuses, connectors, etc........................................... logic section.........................................................................
27. Check adjustment of fan overloads......................................
B. PRE-ENERGIZATION CHECKLIST 44. Use Ohmeter to perform a point-to-point test of all
28. Visually confirm that there is NO power factor correction Current Transformers (CT & HCT), verifying phasing and
caps on the motor (the motor terminal box MUST be continually to all points. An open circuit can cause damage
opened for this check)............................................................. to the drive.................................................................................
29. Obtain the appropriate schematic drawings for reference............ 45. Check the impedance of power supply loads at power
30. Make an overall visual inspection to verify the drive supply outputs, investigate any circuits that are low.
system is NOT damaged............................................................... Check that there are NO ground connections to each
31. Verify that all parts are installed and match the type and power supply output, test Ohmeter-to-ground..........................
ratings shown on the schematic drawings 46. Verify all external unput signals to XIO terminal strip
(circuit boards, circuit breakers CT's, fuses, etc.)......................... TB2 by manually operating the feedback relays or
32. Verify suitable labelling for all unit devices and components........ switches, and checking the continually from terminal
Z24 (TB2-29) of XIO...................................................................
C. MECHANICAL INSPECTION & 47. Verify the analog input and output connections between
DEVICE OPERATION CHECK
XIO PWB and transducers...........................................................
33. Verify the cables and connector assemblies are routed neatly
48 Check the continuity of the transducer power input
and NOT pulled excessively. Check for cable termination and
connections from the CPT............................................................
bus bar hardware torque marks. Check for any shipping
49. Verify the transducer power and signal configuration
damage to transformer..................................................................
dip switch settings..........................................................................
34. Verify phase-to-phase and phase-to-ground wiring
50. Check for good tightness of fuse clips on PT's...........................
clearances from adjacent circuits..................................................
51. Verify correct connections of the remaining XIO interface
35. Check PCB's for component leads that may be touching,
terminals to external devices such as a resolver,
and all board connections seated properly. Perform "lug test"
speed sensor, or rotor temperature sensor................................
on all control circuit wiring..............................................................
36. Manually exercise all relays, switches, and other E. CONTROL POWER TEST
mechanical devices to ensure that they operate freely. 52. Check N25 (TB8 & 5) and P15 (TB1 & 4) voltage supply to
Operate the JK starter isolation switch handle several times to the Hall CT (HCT) terminal block (±14.25 - 15.75 VDC)..............
prove correct operation. Adjust and lubricate if necessary........... 53. Check 10VAC (CN1 pins 4 & 5) on the PDM PC8 for
37. Adjust timers, overload relays, etc. per project drawings.............. CPSF signal...................................................................................
38. Use vacuum cleaner to remove all metal chips from the cabinet. 54. Check 10VAC (CN1 pins 1, 2, & 3) on the PDM PC8
Metal chips may be present due to site wiring and cabling work. (acceptable value 20.6-27.4 VDC)...............................................
Any foreign metal can result in drive failure due to NOT enough 55. Check fan rotation. Apply 480VAC power to the control
clearance. Use vacuum at least for a half day, cleaning every power supply. Primary side 480V phase rotation must be
area of the cabinet thoroughly....................................................... clockwise at TB for correct fan operation......................................

D. POWER OFF OHMETER TEST F. VERIFY POWER SUPPLY VALUES

39. Visually inspect transformer secondary windings to the Record the actual values:
corresponding rectifier section....................................................
56. Power Supply (required value VDC)........................................
40. Visually inspect Power Module-to-Rectifier, and
Power Module-to-dv/dt filter interconnections............................ 57. P15 (required Value 14.25-15.75)............................................
41. Visually verify ACN buss bar to the ground fault circuit 58. N15 (required value -15.75 - -14.25)........................................
resistor, GDI board, and ground connections to board.............. 59. P5 (required value 4.8-5.2).......................................................
42. Visually inspect U, V, and W Power Module output to
VFD output terminals, bypass contactor, or other devices........
43. Check the input contactor fuses are correct................................

P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2009 ALL RIGHTS RESERVED
Form 160.00-CL1 (909)
Supersedes: Nothing