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IOMM 1159 Variable Frequency Drives

1. BLACK WIRE WHITE WIRE TERMINAL BAR REF i Use 3 8 in dia cadmium plated steel bolt N KUKON ec ce nut and lockwasher Torque to 20 ft lbs Copper wire and lugs must be used 901 SEE DETAIL B FOR LOCATIOI Used on Wye Delta starters only VFD Terminals For field wiring freestanding VFDs the outgoing terminals and incoming power block terminals are determined by the VFD size listed in Table 10 NOTE X is the number of terminals per phase For factory mounted VFDs the outgoing terminals are factory connected to the compressor motor When wiring to a VFD with a disconnect switch or circuit breaker the incoming lug size is determined by the device size as shown in Table 11 NOTE X is the number of terminals per phase Table 9 LiquiFlo 2 0 Terminal Size Range Incoming Terminals Outgoing High Int CB Ultra Hi Int CB Terminals 3 3 0 400 MCM 3 3 0 400 MCM 2 200 500 MCM 4 500 1000 MCMI 4 500 1000 MCM 4 200 500 MCM NOTE X is the number of terminals per phase IOMM 1159 Table 10 Air Cooled amp LiquiFlo Incoming Outgoing Terminal Size Range Incoming Power Block Connection Range VFD Size Model Family Outgoing Terminals Metric Stud Size Air Cooled VFD 011 1 14 2 0 MCM Bolt M8X1 25 VFD 014 1 14 2 0 MCM Bolt M8X1 25 VFD 016 1 4 500 MCM VFD 022 1 4 500 MC
2. Installation Operation amp Maintenance Manual oem Variable Frequency Drives Air Cooled LiquiFlo and LiquiFlo 2 0 For Centrifugal Chillers With MicroTech 200 or MicroTech II Control LI mh A McQuay Internationa Table of Contents Introduction sccccsssssssssssssssesesenes 3 VED Sizes Mounting Cooling Type 4 Short Circuit Current Ratings SSCR 5 Environmental Conditions 6 Harmonic Distortion coccoooccncnononononanonononnnnno 6 General Description 6 Codes Standards ooooonncccconooonnnncnoconanananononcnnnnos T Quality Assurance eene 7 Air Water Cooled Nomenclature 7 LiguiFlo 2 0 Nomenclature 7 Installation sicci teorie cerchio D Cooling Requirements for VFDS 11 Cooling Module LF VFD 090 120 all LF 2 014 Wiring General eee 17 Power WiriN8 ooooonoccccncccnnoncnoncnnnconcconocnnccnnonnss 18 Terminal Sizes sss 20 Optional Line Reactor Installation 22 Remote Line Reactor Dimensions 24 VFD Chiller Interconnection Wiring Diagram27 Power Factor Correction ssss 28 VED Dimensions 29 Air Cooled eere 29 IaquiElo Oia 35 Controls il Definition of TerIoS ccoconc
3. Indication Flashing red status light None Flashing yellow status light and Digln CflctB indication on LCD HIM Drive Status 2 shows type 2 alarm s Indication Corrective Action Clear fault e Press Stop Cycle power Set Fault Clear to 1 Clear Faults on the HIM Diagnostic menu Wire inputs correctly and or install jumper Program Digital Inx Sel for correct inputsStart or Run programming may be missing Program Digital Inx Sel to resolve conflicts Remove multiple selections for the same function Install stop button to apply a signal at stop terminal Corrective Action If 2 wire control is required no action needed If 3 wire control is required program Digital Inx Sel for correct inputs Drive does not respond to changes in speed command Indication Corrective Action Cause s No value is coming from the source of the command Incorrect reference source has been programmed Incorrect Reference source is being selected via remote device or digital inputs LCD HIM Status Line indicates At Speed and output is 0 Hz None 1 If the source is an analog input check wiring and use a meter to check for presence of signal 2 Check Commanded Speed for correct source 3 Check Speed Ref Source for the source of the speed reference 4 Reprogram Speed Ref A Sel for correct source 5 Check Drive Status 1 bits 12 and 13 for
4. 00 A IOMM 1159 33 Figure 19 VFD 090LW 120LW Water Cooled Free Standing Only POWER ON 41 0 5 fae 24 3 mja 11 9 w 11 9 i 3 38 TYP gt E E N E gt DRIVE FAULT PII fd O PUMP F MOTOR RUNNING T Y B LINE LEAD ACCESS MOTOR LEAD ACCESS COVER PLATE COVER PLATE n 32 4 WATER RESERVOIR 72 1 CUSTOMER INLET OUTLET 3 4 NPT CLOSED LOOP FAN COOLING SYSTEM AIR FLOW 4 NOTE The closed loop cooling module is factory installed adjacent to the VFD Unit Weights Weight Ib kg 1800 817 1800 817 IOMM 1159 34 LiquiFlo 2 0 Figure 20 VF 2037 2055 Free Standing ON 940 OUTPUT WIRING 11 875 INPUT WIRING 16 181 PANEL PANEL FO e e e O 17 208 17 208 INPUT TN OUTPUT WIRING PANEL 10 6 X 15 3 OPENING WITH 13 8 X 13 8 OPENING WITH COVER REMOVED COVER REMOVED 60 000 911 A0 ONLY 15 104 SEE DETAIL B 14 124 a 27 445 7 FOR Al E 5 1 125 00 i E ER Ek lt TM 6 6
5. About the Alarm Oueue The drive automatically retains a history of alarms that have occurred in the alarm gueue The alarm gueue is accessed using the OIM or PC software The alarm gueue holds the eight most recent alarms The last alarm to occur is indicated in queue entry 1 As new alarms are logged into the queue existing alarm entries are shifted for example entry 1 will move to entry 2 Once the queue is full older alarms are discarded from the gueue as new alarms occur All entries in the alarm queue are retained if power is lost Alarms are automatically cleared when the alarm condition goes away The alarm queue can be cleared using the OIM by selecting Clr Alarm Queue or by using a PC software tool IOMM 1159 75 Alarm Descriptions Table 35 Alarm Descriptions LF 2 0 NOTE Type 1 Auto resettable 2 Non resettable 3 User configurable Description An analog input is configured for alarm on signal loss and signal loss has Analog In L aog SSB occurred Parameter 190 Direction Mode is set to Bipolar or Reverse Dis and one of more Bipolar Conflict of the following digital input functions is configured Fwd Rev Run Fwd Run Rev Jog Fwd or Jog Rev Digital input functions are in conflict Combinations marked with a will cause an alarm Acc2 Dec2 Jog Jog Fwd R Accel2 Cecel2 Jog Fwd R v i Acc2 Dec2 x x Accel2 Dig In ConflictA Cecel2 Jog Jog Fwd Jo
6. IOMM 1159 78 Resetting faults will clear the faulted status indication If any fault condition still exists the fault will be latched and another entry made in the fault queue Note that performing a fault reset does not clear the fault queue Clearing the fault queue is a separate action See the Fault Clear 240 parameter description The table beginning on the following page describes drive faults and corrective actions It also indicates the fault type as 1 Auto resettable 2 Non resettable 3 User configurable Table 37 LF 2 0 Fault Descriptions and Corrective Actions Fault No Type Description Action Verify proper input voltage Check line sync board and fuse AC Line Lost 227 Input power Lost Check AC line I O board 4 Verify connection between boards An analog input is configured to fault on signal loss A signal Check parameters Analog In Loss 29 13 loss has occurred Configure 2 2 Check for broken loose with Anlg In 1 2 Loss 324 connections at inputs 327 Drive unsuccessfully attempted to reset a fault and resume running for the programmed Correct the cause of the fault and manually AUTO SUE AES m number of Auto Rstrt Tries clear 174 Enable disable with Fault Config 1 238 AutoTune 80 The autotune procedure was Restart procedure Aborted canceled by the user Auxiliary Input 2 1 Input is open Check remote wiring 1 Verify input voltage is within drive The orive is
7. 83 Table 40 No Indication None Start From OIM Cause s Drive is programmed for 2 wire control and Logic Source Sel 89 All Ports OIM start and network start are disabled for 2 wire control Corrective Action If 2 wire control is required no action is necessary If 3 wire control is required program Digital Inx Sel 361 366 for correct inputs Flashing or steady red Ready LED Active fault Reset fault Enable input is open Close terminal block enable input Flashing yellow Ready LED The terminal block stop input is open and control source is set to All Ports Close terminal block stop input Start inhibit bits are set Check status in Start Inhibits 214 Drive Status 1 209 indicates logic control source Table 41 No Indication LCD OIM Status Line indicates At Speed and output is 0 Hz Logic Source Sel 89 is not equal to the desired OIM Local OIM DPI Port 2 or DPI Port 3 DPI Port 2 is Verify setting of Logic Source Sel 89 The OIM Control digital input effectively sets the control source to required for remote OIM Response to Changes in Spee Cause s No value is coming from the source of the command the lowest attached OIM port d Command Corrective Action 1 If the source is an analog input check wiring and use a meter to check for presence of signal 2 Check Commanded Freq 2 for correct source
8. Incorrect input wiring 2 wire control requires Run Run Forward or Run Reverse input s 3 wire control requires Start and Stop inputs Jumper from terminal 7 to 8 is required Wire inputs correctly and or install jumper Incorrect digital input programming Mutually exclusive choices have been made 2 wire and 3 wire programming may be conflicting e Exclusive functions i e direction control may have multiple inputs configured Stop if factory default and is not wired or is open Start or Run programming may be missing Program Digital In x Sel 361 366 for correct inputs Logic Source Sel is not set to Terminal BIk Set Logic Source Sel to Terminal Blk Table 39 No Start from Terminal Block Logic Continued Indication s Flashing yellow Ready LED and DigIn CflctB indication on LCD OIM Drive Status 2 210 shows type 2 alarm s Cause s Incorrect digital input programming e Mutually exclusive choices have been made 2 wire and 3 wire programming may be conflicting Exclusive functions i e direction control may have multiple inputs configured Stop if factory default and is not wired or is open Start or Run programming may be missing Corrective Action Program Digital In x Sel 361 366 to resolve conflicts Remove multiple selections for the same function Install stop button to apply a signal at stop terminal IOMM 1159
9. Rigging Extreme care must be used when rigging the equipment to prevent damage See the certified dimension drawings included in the job submittal for the center of gravity of the unit Consult the local McQuay International sales office for assistance if the drawings are not available Air Cooled The unit can be lifted by fastening the rigging hooks to the two lifting eyes located on the top of the unit LiquiFlo The unit can be lifted by fastening the rigging hooks to the four lifting eyes located on the top of the unit LiquiFlo 2 0 IOMM 1159 10 Figure 2 LF 2 0 Lifting Points Litt Points A Use the following procedure to lift and mount the LiquiFlo 2 0 drive Step 1 Using an overhead or portable hoist minimum 2 ton rated capacity attach a free fall chain to the chain secured to the drive Take up any vertical slack in the chain Step 2 Using the hoist lift the drive from the horizontal shipping pallet Step 3 Position the drive Step 4 Machine or floor mount the drive enclosure using 1 2 inch bolts grade 3 or better with compression washers Location and Mounting Location Consider the following guidelines Verify that NEMA 1 enclosure drives can be kept clean and dry The area chosen should allow the space required for proper air flow A minimum of 6 inch clearance is required wherever vents are located Be sure that the NEMA 1 enclosure is installed away from oil coolants or other airb
10. E A Password T Technician Level M Manager Level O Operator Level __ Description No Default Range Password Comments dE SEE 15 40 F 30 to 60 F Temp lift at 100 speed cond sat evap sat temp 14 E Lift O min speed as a of 100 lift SP 10 has VFD Speed Q 0 Lift 5096 0 to 100 priority over this setting VFD Minimum Speed 70 60 to 100 Min VFD speed has priority over SPs 11 8 12 No Yes VFD on unit or not Oil No Start Diff 30 to 60 F Minimum Delta T between oil sump temperature and above Evap Temp saturated evaporator temperature 0 to 9999 Determines when to shut off a compressor factory Tons set 0 1 to 5 0 Inhibits loading if LWT change exceed the setpoint F min value 0 0 to 5 0 Additional compressor can start if LWT change is F min below setpoint Time period to go from initial load point RLA set in SP 5 to 100 RLA Initial amps as of RLA Used with SP 4 and SP 6 Soft load on using SP 5 and SP 6 or off Not used on these chillers RLA above which loading is inhibited Load Limit Nominal Capacity Maximum LWT Rate 0 5 F min Minimum LWT Rate 0 1 F min Soft Load Ramp Time 1 to 60 min Initial Soft Load Amp 20 to 100 Limit Soft Load Enable OFF ON Nameplate RLA A N A Maximum Amps 40 10100 Unloading is forced at 5 above this value 20 to 80 RLA below which unloading is inhibited imi ON sets RLA at 0 for 4 mA external sign
11. N A 104 LF 3 4 NPT 3 4 NPT 3 4 NPT Notes 1 Cooling water must be from the closed chilled water circuit with corrosion inhibitors for steel and copper and must be piped across the chilled water pump 2 The pressure drop is given for the maximum coolant temperature maximum flow The water regulating valve will reduce the flow when the coolant temperature is below the maximum in the table The pressure drop includes the drop across the solenoid valve heat exchanger and water regulating valve 3 Models VFD 090and 120 and all LF 2 0 models have a separate self contained cooling loop with a recirculating water pump and heat exchanger but have the same chilled water cooling source water piping as all water cooled VFDs McQuay Drive Model Number Copper Tube Size Table 7 Chiller Cooling Water Connection Sizes Chiller Unit Free Standing VFD LF and LF 2 0 Factory Mounted VFD LF Only To Oil Cooler To VFD All Others 1 in FPT 3 4 in MPT 1 in FPT Cooling Module LF VFD 090 120 all LF 2 0 NOTE The cooling module is factory mounted on VFD 090 120 bases to the right of the VFD and does not require field piping to the VFD The cooling module for the LF models VDF 090 and 120 has a self contained coolant temperature control system and no associated programming of the VDF is required All cooling modules used with LF 2 0 VFD models are controlled by the VFD and require VFD programming as shown on page 16 This is done
12. drops below the recorded Startup Delta T minus the user adjustable offset and the LEWT is below the active setpoint minus the control band plus user defined offset the user adjustable lag compressor shutdown timer same time as the lag start timer is activated When the timer times out and the above conditions still exist the lag compressor will be shut down MicroTech 200 Controller VFD Menu Screens The MicroTech controller screens are modified from standard when VFD software is loaded into the microprocessor in the factory VFDs require special software as described in this section The screens are grouped by menus that are further broken down to screen numbers Fields noted with an are only active when a VFD is used Arrows indicate that addition related screens are located above or below Menu 1 Screen 2 Unit Status This entire screen only appears when a VFD is used 1 Unit Status hh mm mon dd yy VFD Off etc Cmnd VFD Speed XXX Vanes Not Open Open Lift Ctl Speed XXX IOMM 1159 41 42 Menu 2 Screen 2 Water Temps and Flows 2 Water Temps Flow hh mm mon dd yy PulldwnRate X X M EvapFlow XXXgpm Ent Ht Revy N A F Cond Flow XXXgpm Lvg Ht Revy N A F Menu 3 Screen 2 Refrigerant Temps Press 3 Refrig Temps Press hh mm mon dd yy Lift Press XX Xpsi Lift Temp XX X F Calc Lift Speed XXX Menu 9 Screen 1 Network Status 9 Network Status hh mm
13. 060 120 Cooling Water Piping for Free Standing VFD STOP 4 CHILLED VALVE BALANCING WATER G VALVE i VALVE WATER REGULATING VALVE T d Factory Mounted STOP A VALVE x i STRAINER l MAX 40 MESH j DRAIN E posa Field Supplied Piping Components Field Piping ET Connection Point Factory Mounted REGULATING VALVE Factory Mounted ES NOTES 1 For VFD 060 072 the chilled water piping goes directly to a heat exchanger in the VFD For VFD 090 120 the chilled water piping goes to a VFD mounted cooling module that contains a heat exchanger and closed loop recirculating pump 2 See page 14 for the chilled water supply quantity 3 Dual compressor chillers Models WDC and WCC have one factory combined oil cooler inlet and outlet connection Each compressor has its own dedicated VFD with onboard heat exchanger which are piped in parallel 4 The VFDhas an on board water regulating valve on the chilled water system side Fittings shown in the dotted field piping are by the customer Basic fittings are shown local codes and or job conditions may reguire additional components IOMM 1159 13 14 Table 6 Cooling Requirements Combined Comp Oil and N E VFD Cooling Only Copper Coolant Entering Entering VFD Cooling Max Min Piessurg Max Pressure Tube Size Method Coolant Coolant Drop Water Type K or L Temp F Temp F Side psi Air Cooled
14. 10 so 7 MODE e SWITCH see 180444 alt NOTES FOURTH A M Tre 1 STAGE ES STARTER ES E ep2 e E NOTE CHILLED n NOTE 10 a A EWI 2 WATER COOLING t gt PUMP TOWER ifs 46 73 Eta STARTERS JE STAGE A Q Cie STARTER Ur m gei e 77 NOTE 112 NOTE 10 EWM H 76 COOLING gt ha o f TOWER 115 a f e 75 A N SECONDH 2 ig STAGE NOTE6 NOTE 6 STARTER Ly SWITCH SWITCH NOTE9 DELTAT DELTAT d FLOW FLOW 0 ITE M NOTE 10 OREVAP OR COND l Ee 2 o Ho Sy sous ca ps mr west FIRST PA STAGE ni Cw e STARTER Ly cF e SONON 81 CONDENSER 82 NO N ALARM RELAY WATER 2 W NOTE 4 PUMP NC o STARTERS POWER E NOTE9 52 A o COOLING TOWER E t 1 BYPASS VALVE L_ 355750 A opi A TOv NOTE 11 S COOLING TOWER VFD 53 CWIA MICROTECH i ia ie COMPRESSOR CONTROL BOX TERMINALS CTB1 NOTE 2 Fis VAC GND STARTER LOAD SIDE TERMINBALS COMPRESSOR CONTROL le s ii i i SCHEMATIC 330342201 CP1 e gt CP2 e o 12 LEGEND 330343001 23 5A e 9 23 UT Te T2 T4 T3 T5 COMPRESSOR 245 e 24 COMPRESSOR TERMINALS FIELD SUPPLIED ITEM MOTOR 25 e U e 25 STARTER NOTE 1 v rs 2 e 2 3 e e 3 4 o 4 11 6 amp 11 11 e 11 12 e o 12 22 e 22 LOAD cwad ss 330387901 0A THAN So XA 30V OR 24VAC See notes on following page IOMM 1159 27 NOTES for Wiring 1 Compressor motor VFDs are either factory mounted and wired or shipped separate for field mounting and wiring VFD
15. AutoT Rs Stat AutoT Lm Rot Description Programmed Current Lmt Val has been exceeded Enable Disable with Fault Config 1 Option board removed One or more of the output transistors were operating in the active region instead of desaturation This can be caused by excessive transistor current or insufficient base drive voltage The communications card has a fault on the network side DPI port stopped communicating A SCANport device was connected to a drive operating DPI devices at 500k baud Enable signal missing from control terminal block Autotune Rs Static Test failed Autotune Lm rotate test failed Action if appropriate Check load requirements and Current Lmt Val setting 1 Clear fault 1 Check DPI device event queue and corresponding fault information for the device 1 If adapter was not intentionally disconnected check wiring to the port Replace wiring port expander adapters Main Control Board or complete drive as required 2 Check HIM connection 3 If an adapter was intentionally disconnected and the Logic Mask bit for that adapter is set to 1 this fault will occur To disable this fault set the Logic Mask bit for the adapter to 0 1 Check control wiring 2 Check position of hardware enable jumper 3 Check digital input programming 1 Verify that motor is not rotating when autotune is enabled 2 Check motor connections 1 Check motor nameplate
16. Compr set La COMPRESSOR STATE Vanes Open Switch gt H VFD Running Adj Speed Closed or VFD Running Hold Min BUN Uniad Vanes While holding Open Vanes Loading Speed Adj Vanes DR Speed Modulating to chilled water Kea VFD Speed equals Minimum Speed RUN Hold Vanes Pull down Rate ull Vanes Vanes modulating to LEWT RUN Unload Vanes Max Amps Vanes Loaded continuously Load timer Capacity Overrides Corrective action RUN Hold Vanes Max Amps Capacity Overrides Corrective action seer nes RA Told aros Max Amps i applies to Vanes Unload Vanes Evap Press applies to Speed 5min T RUN Hold Vanes Evap Press COMPRESSOR STATE VFDSpeed RUN Load Speed MinSpeed l RUN Unload Speed Unit Status RUN Hold Speed AND PEW TS Spt is ahy Shutdown RUN Unload Speed Evap Press RUN Hold Speed Evap Press Unit Status RUN Hold Speed Pull down Rate is any Shutdown RUN Unload Speed Max Amps BLN Hold Speed Mar Amps a LU LEWT leaving evap water temperature CB Control Band COMPRESSOR STATE SHUTDOWN Unload POSTLUBE Timer 30 30sec Compressor Shutdown Command Speed held 0 vanes continuosly pulsed closed Vane Closed Switch isOpen Notes 1 The above pressures must be set at unit design conditions 2 Low evaporator pressure shutdown alarm setpoint is 26 0 psi default 3 If the discharge temperature is higher than 170 F pulse the load solenoid
17. Cooling Power Loss Fatal App XX lt X lt X X X X X lt gt X lt Power Unit Ground Fault PrechargeActv Hardware Enbl PwrBrd Chksum x HeatsinkOvrTp Shear Pin gt HeatsinkUndTp Sleep Config I O Change I O Comm Loss SpdRef Cnflct Start AtPwrUp I O Removed System Fault IGBT OverTemp Input Phase TB Man Conflict UnderVoltage IntDB OvrHeat UserSet Timer InverterFault VHz Neg Slope Load Loss Waking MaxFreqCnfict Zero Divide IOMM 1159 67 Troubleshooting Table 22 No Start Drive does not Start from Start or Run Inputs wired to the terminal block Cause s Drive is Faulted Incorrect input wiring See Installation Manual for wiring examples 2 wire control requires Run Run Forward Run Reverse or Jog input 3 wire control requires Start and Stop inputs Jumper from terminal 25 to 26 is required Incorrect digital input programming Mutually exclusive choices have been made i e Jog and Jog Forward 2 wire and 3 wire programming may be conflicting Exclusive functions i e direction control may have multiple inputs configured Stop is factory default and is not wired Table 23 No Start from HIM Drive does not Start from HIM Cause s Drive is programmed for 2 wire control HIM Start button is disabled for 2 wire control Table 24 No Speed Change
18. Diagnostics menu is if primary interest to the operator When selected press the Enter key to select it Then use the scroll keys up down right or left to select the item of interest IOMM 1159 72 Using the LEDs Determining Precharge Board Status Using the LED Indicators Frames 5 amp 6 Only Precharge is an internal function that is used automatically when powering up the control There is no operator function required Precharge LEDs give the status of the board They are located above the Line Type jumper shown in Figure 40 In addition to the LED signal a fault in the precharge function will also show on the display Figure 41 Location of Precharge Status LED C IBTOP Line Type QOO Spare Ood Spare Table 31 Precharge Board LED Indicators Description Power ON Indicates when pre charge board power supply is operational Indicates one of the following alarms occurred causing the pre charge to momentarily stop firing Line Loss Low Phase single phase dropped below 80 of line voltage Input frequency out of range momentarily Note An alarm condition automatically resets when the condition no longer exists Indicates one of the following faults DC Bus short DC Bus not charged Input frequency out of range Overtemperature Note A fault indicates a malfunction that needs to be corrected prior to restarting A fault condition is only reset
19. O Board Mismatch Incorrect I O board identified Restore I O board to original configuration or If new configuration is desired reset fault Incompat MCB PB Input Amp Imbalance 106 225 Drive rating information stored on the power board is incompatible with the Main Control board Input phase current imbalance exceeded limits Load compatible version files into drive Check for loose connection in input power wiring Input Volt Imbalance Inverter Dsat U V W Inverter OverCurrent U V W Invtr Base Temp 226 200 201 202 203 204 205 Input voltage imbalance exceeded limits High current was detected in an IGBT High current was detected in an IGBT Base temperature exceeded limit Check for problem in input power distribution 1 Check for loose connection in IGBT wire harness 2 Check IGBTs 1 Verify proper motor data is entered 2 Reduce current limit Check for proper temperature and flow rate of coolant Invtr Gate Kill Invtr IGBT Temp IR Volts Range Line Frequency Inverter gate kill contact is open Output transistors have exceeded their maximum operating temperature The drive autotuning default is Calculate and the value calculated for IR Drop Volts is not in the range of acceptable values Line frequency not in the range of 47 63 Hz Close gate kill contact Check for proper temperature and flow rate of coolant Re enter moto
20. accordance with local codes and the National Electric Code NEC A CAUTION Voltage unbalance not to exceed 2 with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG 1 1998 Standard This is an important requirement to avoid excessive motor or drive heating A WARNING Oualified and licensed electricians must perform wiring Shock hazard exists Power wiring to compressors must be in proper phase seguence Motor rotation is set up for clockwise rotation facing the lead end with phase seguence of 1 2 3 Care must be taken that the proper phase seguence is carried through the VFD to the compressor With the phase sequence of 1 2 3 and LI connected to T1 and T6 L2 connected to T2 and T4 and L3 connected to T3 and T5 rotation is proper See diagram in terminal box cover The McQuay International start up technician will check the phase sequence Z CAUTION Connections to terminals must be made with copper lugs and copper wire Care must be taken when attaching leads to compressor terminals Note Do not make final connections to motor terminals until wiring has been checked and approved by a McQuay International technician Under no circumstances should a compressor be brought up to speed unless proper sequence and rotation have been established Serious damage can result if the compressor starts in the wrong direction Such damage is not covered by product warranty Power Factor
21. after cycling power Yellow IOMM 1159 73 LED Drive Status Figure 42 Location of the Ready LED Ready LED 7 Table 32 Ready LED Status Functions Flashing Description Drive ready but not running and no faults are present Green Steady Drive running no faults are present Flashing The drive is not ready Check parameter 214 Start Inhibits Yellow Steady An alarm condition exists Check parameters 211 Drive Alarm 1 and 212 Drive Alarm 2 Red Flashing An alarm condition exists Check parameters 211 Drive Alarm 1 and 212 Drive Alarm 2 Stead Determining Drive Status Using the Status LEDs Two status LEDs are located on the DPI Communications Interface board on the front of the power module The LEDs indicate of the status of the inverter and the rectifier Note that if the LEDs are off it indicates it is not receiving power A fault has occurred DPI eo 4 i 1 Interface Board 4 front surface of 5 power module Inverter Status LED Rectifier Status LED 74 Table 33 Status LED Definitions Flashing Drive ready but not running and no faults are present Steady Drive running no faults are present Flashing The drive is not ready Check parameter 214 Start Inhibits Green Yellow Stead An alarm condition exists Check parameters 211 Drive Alarm 1 y and 212 Drive Alarm 2 Flashi
22. alarm types Description Action if appropriate Drive received a start command while in PrechargeActv Auxiliary In Power Loss Table continued next page the DC bus precharge state Auxiliary input interlock is open DC bus voltage remained below Power Loss Volts for longer than Power Loss Time Enable Disable with Fault Config 1 Check remote wiring Monitor the incoming AC line for low voltage or line power interruption IOMM 1159 62 UnderVoltage Description DC bus voltage fell below the minimum value of 333V for 400 480V drives and 461V for 600 690V drives Enable Disable with Fault Config 1 Action if appropriate Monitor the incoming AC line for low voltage or power interruption OverVoltage Motor Stall MotorOverload HeatsinkOvrTp IGBT OverTemp System Fault OverCurrent Ground Fault InverterFault Load Loss Motor Therm DC bus voltage exceeded maximum value Motor is operating at high current and low frequency and is not accelerating Internal electronic overload trip Enable Disable with Fault Config 1 Heatsink temperature exceeds maximum allowable value 85 degrees C Alarm 90 degrees C Fault Output transistors have exceeded their maximum operating temperature due to excessive load Hardware problem exists in the power structure The drive output current has exceeded the hardware current limit A cur
23. between run and jog when in local control REMOTE LED is off When run is selected pressing the START key results in continuous drive operation When JOG is selected pressing the START key results in drive operation only until the START key is released Note Do not run in local control Do not JOG Compressor may run without lubrication This key is ignored if the control source is not local REMOTE LED is on See the RUN and JOG LED descriptions for more information START Use the START key to apply power to the motor in local control REMOTE LED is off See the RUNNING LED description for more information Note Local control is not allowed on McQuay Centrifugal Chillers Compressor may run without lubrication STOP RESET If the drive is running RUNNING LED is on the STOP RESET key stops the drive If the drive is not running RUNNING LED is off pressing this key resets drive faults Using the LEDs The keypad contains eight LEDs that show the present drive status The following table describes what each drive status LED means 90 Table 46 Drive Status LEDs LED RUNNING REMOTE JOG FORWARD REVERSE PROGRAM PASSWORD Meaning Output power is being applied to the motor On Output power is not being applied to the motor The drive is being controlled START RUN JOG FORWARD REVERSE speed reference from a source other than the keypad Off The drive is being control
24. by McQuay International at startup Closed loop cooling system operation e Apump circulates a glycol water mixture coolant through the VFD heat sink a coolant reservoir and a small plate heat exchanger Heat is removed from the VFD heat sink and rejected to the plate heat exchanger e The pump and control valve are controlled by the VFD control system on LF 2 0 VFD models and self contained on LF models e The module s plate heat exchanger is cooled by water from the chilled water system Installation steps e Place cooling module in desired location on a flat well ventilated area Provide a minimum of three feet clearance and 8 feet overhead e Attach coolant piping from the chilled water system and the recirculation fluid hoses from the module to the VFD See Figure 5for connection locations an size Include service isolation valves in the coolant and chilled water inlet and outlet piping e Charge the module with the coolent shipped with the module IOMM 1159 The following is required from the customer s chilled water supply for the McQuay VFD cooling loop to perform properly Water Quality Water must be compatible with components supplied in the cooling loop brass copper stainless steel and neoprene rubber seals Supply water circulates through a copper brazed stainless steel plate type heat exchanger by way of a stainless steel and brass ball valve and associated stainless steel brass and copper piping Water Sou
25. if the vanes are not fully open IOMM 1159 53 Operation VFD011 043 PF755 Using the Interface The Human Interface Module HIM is located on the VFD enclosure front door The display is divided into three zones as shown below 1 Status Bar 2 Data Area 3 Soft Key Labels Figure 31 HIM Display Zones Status Bar The Status Bar provides information about the operating condition of the drive Figure 32 Status Bar on the Display Screen Element Description A small image of the connected Host Drive g Host Icon Indicates current Host Drive operating Stopped Status Text status Text flashes when a fault is present Indicates drive output feedback for HORE kastuisi example Hz RPM amps etc AUTO MAN Mode Indicates Auto or Manual HIM status Indication ja Alarm Bell icon indicates that an alarm is Indication present Rotation Indicates direction of Host Drive FORO Indication operation IOMM 1159 54 Soft Keys Up to five soft keys shown shaded in Figure 30 may be available A soft key changes its function name based on the HIM screen or data entry mode When a soft key is active its present function is shown on the LCD screen in its corresponding soft key label Figure 33 Soft Keys EN E E mm ed Cs ble me cm E 6 Navigation and Number Keys The five blue multi function keys 2 4 5 6 and 8 shown in Figure 33 are used to scroll menus screens
26. is a 8B listing and description of drive faults with possible solutions il when applicable and alarms set fo 46 i n al n n Faults and Alarms A fault is a condition that stops the drive There are three fault types Table 18 Fault Types When this type of fault occurs and Auto Rstrt Tries is set to a value greater than 0 a user configurable timer Auto Rstrt Delay begins When the timer reaches zero the drive attempts to automatically reset the fault If the condition that caused the fault is no longer present the fault will be reset and the drive will be restarted This type of fault normally requires drive or motor repair The cause of the fault must be corrected before the fault can be cleared The fault will be reset on power up after repair User These faults can be enabled disabled to annunciate or ignore a fault Configurable condition Auto Reset Run Non Resettable An alarm is a condition that if left untreated may stop the drive There are two alarm types Table 19 Alarm Types Type Alarm Description User These alarms can be enabled or disabled through Alarm Config 1 It Configurable is recommended that factory setting not be changed Non Configurable Drive Status These alarms are always enabled The condition or state of the drive is constantly monitored Any changes will be indicated through the LEDs and or the Human Interface module HIM C
27. may cause equipment damage Coolant Volume Approx 1 gallon is required with side by side connection of cooling module to the drive cabinet More coolant volume will be required if coolant loop is located up to 20 feet away from drive Coolant Maintenance The coolant liquid should be checked and refreshed as needed on a yearly basis The pH should be maintained between 8 0 and 10 0 A 50 solution of sodium hydroxide or potassium hydroxide can be used to raise pH if falls below 8 0 Any time the coolant falls below a pH of 7 0 the loop should be flushed and coolant replaced Any time the coolant appears other than white it should be replaced Remote Mounted Cooling Loop The maximum distance the cooling loop can be installed away from the drive cabinet connections is 20 feet Careful planning of remote mounting is required to minimize coolant flow restrictions introduced by piping connections Cooling Module Parameters Set in LF 2 0 VFD models LF 2 0 drives control the operation of the cooling module The parameters are set by McQuay International at chiller commissioning IOMM 1159 How to Monitor Cooling Loop Operation FX 05 Screen Navigation see Figure 7 After power up the process temperature will be displayed Alarms When an alarm is present the alarm LED will blink fast and the error code will flash The following is a list of the error code E0 OK El Low Level Fault E2 Fluid Over Temperature Fault E3 Fluid
28. nONTONoWINg a 2 ie impedance Decel Inhibit 24 3 E deceleration ve follows proper grounding techniques ecause it is attempting to limit 3 Disableb lati d or add bus voltage isable bus regulation and or a dynamic brake resistor and or extend deceleration time Drive rating of 110 for 1 Drive OverLoad 64 minute or 15096 for 3 seconds Reduce load or extend Accel Time 140 has been exceeded Motor did not come up to speed 1 Uncouple load from motor The value for flux amps FluxAmpsRef determined by the autotune 1 Reprogram Motor NP FLA 42 with Rang 78 procedure exceeds the the correct motor nameplate value programmed Motor NP FLA 2 Repeat Autotune 61 in excess of 7 of drive rated Check the motor and external wiring to the Ground Fault amps has been detected at one drive output terminals for a grounded or more of the drive output condition terminals R L E Reduce input voltage to meet specification High AC Line Input line voltage is too high of 480 10 Check programming Check for excess 1 The drive output current has A HW exceeded the hardware curre t load improper DC boost setting DC brake OverCurrent limit volts set too high or other causes of excess i current I O Board Loss of communication to I O Continued next page IOMM 1159 79 Fault I O Board Fail Board failure 1 Cycle power 2 If fault repeats replace I O board Type Description Action I
29. perform corresponding functions displayed in the Data Area or enter numeric values The five gray numbers keys 1 1 3 7 and 9 are used only to enter their respective numeric value Figure 34 Navigation and Number Keys O OU AU JES ie uo O m EN m2 EN 1 m E jo Key Name Description Enters the numeric value 2 m S O Arrow Scrolls down to select an item Enters the numeric value 4 qe 4 Left Arrow Scrolls left to select an item Enters the numeric value 5 5 Enter Displays the next level of a selected menu item qm Enters new values Performs intended actions a Enters the numeric value 6 6 Right Arrow Scrolls right to select an item Enters the numeric value 8 ge 9 8 Up Arrow Scrolls up to select an item IOMM 1159 55 Single Function Keys Each or the four single function keys always performs only its dedicated function Al BL H g Name Description Start Start the drive Folder Access parameters diagnostics memory functions preferences and other tasks such as Start Up Control Access jog direction auto manual and other control Bar functions on we gt Used to stop the drive or clear a fault This key is Stop always active Controlled by parameter 370 Stop Mode A Faults and Alarms A fault is a condition that stops the unit or prevents it from starting There are three types T
30. screen Corrective Action 1 See Attention statement 2 Reprogram parameters 161 162 to eliminate any Adjust Freq selection 3 Disable bus regulation parameters 161 amp 162 and add a dynamic brake 4 Correct AC input line instability or add an isolation transformer 5 Reset drive Excess bus voltage is normally due to excessive regenerated energy or unstable AC line input LCD Status voltages Line indicates Internal timer has halted drive operation Faulted Diagnostics Menu When a fault trips the drive use this menu to access detailed data about the drive Table 28 Fault menu Option Faults View fault queue or fault information clear faults or reset drive Description Status Info View parameters that display status information about the drive Device Version View the firmware version and hardware series of components HIM Version View the firmware version and hardware series of the HIM Parameter Menu Refer to Viewing and Editing Parameters Device Select Menu Use this menu to access parameters in connected peripheral devices IOMM 1159 69 Memory Storage Menu Drive data can be saved to or recalled from User and HIM sets User sets are files stored in permanent nonvolatile drive memory HIM sets are files stored in permanent nonvolatile HIM memory Table 29 Memory Storage Option Description HIM Copycat Device gt HIM Save data to a HIM set l
31. systems and require no field work for cooling Water cooled factory mounted VFDs Models VFD 060 and 072 only VFD cooling water piping is factory connected to the chiller s oil cooling system Cooling water piping is to the normal chiller oil cooling system connections Water cooled freestanding VFDs cooling water piping must be field connected to freestanding VFDs See Figure 3 and Figure 4 Cooling water is connected directly to LF models 060LA and 072LW LF models 090LW and 120LW have a cooling module factory mounted and piped All LF 2 0 units have a separate cooling module that must be field piped to the chilled water circuit and also interconnected to the VFD The cooling module provides an intermediate heat exchanger between the cooling source chilled water and the heatsink of the VFD See page 14 for detailed installation instructions IOMM 1159 11 12 VFD Cooling Summary LF Models VFD 060 and 072 when unit mounted free standing is optional cooling water is factory connected When free standing chilled water as a cooling source is field connected directly to the VFD LE Models VED 090 and 120 available as free standing only Cooling module is factory mounted piped and wired and requires chilled water field piped to it as a cooling source All LF 2 Models VF2037 through 2110 Free standing only Cooling module is required and is field mounted and field piped and wired to the VFD Figure 3 LF 2
32. than 65 000 rms symmetrical amperes at 480 volts when protected by Bussman type JJS KTK KTK R PP or T class fuses A WARNING Input and output power wiring to the reactor must be performed by authorized personnel in accordance with the NEC and all local electrical codes and regulations IOMM 1159 Verify that the power source to which the reactor is to be connected is in agreement with the nameplate data on the reactor A fused disconnect switch or circuit breaker should be installed between the reactor and its source of power in accordance with the requirements of the NEC and all local electrical codes and regulations Refer to the drive inverter or other electrical equipment user manual for selection of the correct fuse rating and class Reactors are designed for use with copper conductors with a minimum temperature rating of 15 C Refer to Figure 11 for a typical electrical diagram of a reactor in its proper location upstream of a VED Where desirable a flexible conduit connection to the reactor enclosure should be made to reduce audible noise A WARNING Failure to connect reactors supplied as a component part of a drive system or other power electronic system according to the system interconnection diagram supplied by the System Engineer will result in eguipment damage injury or death A WARNING If a line reactor or a line reactor and a load reactor are used with a drive eguipped with a bypass ci
33. the mode immediately switches to VFD OFF Rapid Shutdown also occurs by changing the front panel Stop Auto switch on the MicroTech to Stop WDC WCC Dual Compressor VFD Operation The MicroTech 200 controller has the capability to control a dual compressor VFD chiller or two stand alone VFD chillers with interconnecting network communications including all lead lag load balance functions The lead compressor starts and runs the same as a single VFD compressor controlling speed and vane position based on Leaving Evaporator Water Temperature LEWT When the capacity of the lead compressor reaches an equivalent user defined speed LEWT offset and pull down rate it indicates to the master control panel that it is time to enable the lag second compressor to satisfy additional cooling requirements When the master control panel sees the enable lag indication it checks the LEWT and if it is greater than the active setpoint plus the lag Start UP S U Delta T it will start the lag delay timer keypad adjustable At this time the MicroTech control will record the evaporator chilled water Delta T for reference to determine lag compressor shutdown NOTE Operation assumes constant chilled water flow for dual compressor VFD units The MicroTech is constantly looking at the recorded startup evaporator Delta T the user adjustable offset from the delta T and the active setpoint As the load decreases and the evaporator Delta T
34. to insure that speed is not limited by programming IOMM 1159 84 Table 43 Motor Operation is Unstable Motor data was incorrectly entered or autotune was not 1 Correctly enter motor nameplate data 2 Perform static or rotate performed autotune procedure 61 Table 44 Stopping the Drive Results in a Decel Inhibit Fault Indication Decel Inhibit fault screen LCD status line indicates Faulted Troubleshooting the Drive w the LCD OIM Cause s The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage Excess bus voltage is normally due to excessive regenerated energy or AC line input voltages Internal timer has halted drive operation unstable Corrective Action Reprogram bus regulation parameters161 and 162 to eliminate any Adjust Freq selection Disable bus regulation parameters 161 and162 and add a dynamic brake Correct AC input line instability or add an isolation transformer Reset drive The LCD OIM provides immediate visual notification of alarm or fault conditions as well as the following diagnostic information e Entries in the fault queue e Fault parameters e Drive status parameters o Selected device version and status information o OIM version information Accessing the Fault Oueue The drive automatically retains a history of the last eight faults that have occurred in the fault gueue To acce
35. unexpected source selections 7 Check Dig In Statusto see if inputs are selecting an alternate source 8 7 Reprogram digital inputs to correct Speed Sel x option 68 Table 25 No Acceleration Motor and or drive will not accelerate to commanded speed Cause s Indication Corrective Action Acceleration time is excessive Excess load or short acceleration times force the drive into current limit slowing or stopping acceleration Speed command source or value is not as expected Programming is preventing the drive output from exceeding limiting values Reprogram Accel Time x Check Drive Status 2 bit 10 to see if the drive is in Current Limit Remove excess load or reprogram Accel Time x Check for the proper Soeed Command using Steps 1 through 7 above Check Maximum Speed and Maximum Freq to assure that speed is not limited by programming Table 26 Unstable Operation Motor operation is unstable ooo Causes Indication Corrective Action 1 Correctly enter motor nameplate data 2 Perform Static or Rotate Autotune procedure 3 Set gain parameters to default values Motor data was incorrectly entered or Autotune was not performed Table 27 Stopping Gives Decel Fault Stopping the drive results in a Decel Inhibit fault Cause s Indication The bus regulation feature is enabled and is Decel halting deceleration due to excessive bus voltage Inhibit fault
36. waveform 3 High frequency components of voltage distortion can interfere with signals transmitted on the AC line for some control systems The harmonics of concern are the 5 7 11 and 13 Even harmonics harmonics divisible by three and high magnitude harmonics are usually not a problem Current Harmonics An increase in reactive impedance in front of the VFD helps reduce the harmonic currents Reactive impedance can be added in the following ways 1 Mounting the drive far from the source transformer 2 Adding line reactors 3 Using an isolation transformer IOMM 1159 3 3 0 400 MCM 1 P 600 MCM 3 3 0 400 MCM 1 P 600 MCM PF700H 1 P 600 MCM 4 500 1000 MCM 4 500 1000 MCM 4 500 1000 MCM 1 P 600 MCM PF700H 1 P 600 MCM 4 500 1000 MCM 4 500 1000 MCM 4 500 1000 MCM 1 P 600 MCM Optional Line Reactor Installation Voltage Harmonics Voltage distortion is caused by the flow of harmonic currents through a source impedance A reduction in source impedance to the point of common coupling PCC will result in a reduction in voltage harmonics This may be done in the following ways 1 Keep the point of common coupling PCC as far from the drives close to the power source as possible Increase the size decrease the impedance of the source transformer Increase the capacity of the busway or cables from the source to the PCC Put the added reactance downstream close
37. yellow LED indicates the presence of an alarm a red LED indicated a fault Viewing Faults and Alarms The primary area of interest to the operator is viewing drive alarms and faults Alarms are problems that do not shut down the drive compressor They may eventually turn into faults which do stop the compressor From the main menu use the Up or Down arrows A or V to select Diagnostics See Figure 35 Press the Enter key to select this menu Then use these navigating keys to reach a desired menu as shown in Figure 36 IOMM 1159 59 Figure 37 HIM Menu Structure User Display N PowerFlex 700H O Connected DPI Devices Him CopyCat Memory Storage ES Device User Sets Drive User 00005 Yy View Alarm Queue Alarms Clr Alarm Queue O Faults Fault Info Status Info Drive Status 1 View Fault Queue OO Device Items Drive Status 2 Clear Faults Device Version PowerFlex 700H Drive Alarm 1 Clr Fault Queue HIM Version Product Data Drive Alarm 2 Reset Device Control Board Speed Ref Source Power Board Slot A E Start Inhibits v Last Stop Source LCD HIM Product Data Dig In Status LCD HIM Control Board Dig Out Status Keyboard Numeric Drive Temp Motor OL Count O View selected through OD ED VAAKA HISP S ah 4 Y Param Access Lv gt Basic oo File Group Par FGP File Advanced Numbered List File 1 Name FGP Group Changed Params File 2 Nam
38. 53 PF700H VFD037 VFD059 PF700H VFD043 VFD068 PF700H VFDO74 PF700H VFD106 PF700H Rated Model Family Amps Model Family Table 2 PF755 and LF Family Mounting Options R Vintage L Shipped loose Remote mounted M Mounted A Air cooled W Water cooled Optional Line Reactor VFD Note 1 VFD Model Cooling Mounting Mounting Air Cooled VED OTTAMA DIS VFD 011RLA VED OT4RMA NOE VED 014RLA VED O16AMA PaRa VFD O16RLA VED 022RMA a VFD 022RLA VFD 027RMA mn VFD 027RLA VED 033RMA sa VFD 033RLA VEDO37RMA o VFDO37RLA VED 043RMA samas VFD 043RLA i Water Cooled VFD 060LW 600 VFD 060MW VFD 072LW See Page 25 VED 072MW ANE VFD 090LW VFD120LW NOTES 1 Line reactors 3 are optional on all sizes Electrical characteristics 380 460 VAC 10 3 phase 50 60 Hertz 5 Hz 2 Optional line reactors are 3 impedance IOMM 1159 Table 3 575V Air Cooled Mounting Options VFD Mounting VFD053 PF700H Remote VFD059 PF700H Remote VFD068 PF700H Remote VFD074 PF700H Remote VFD 106 PF700H Remote Table 4 LiquiFlo 2 0 Mounting Options VF 2037 LF 2 0 Frame 3 Remote VF 2055 VF 2080 LF 2 0 w Cooling Module VF 2110 Frame4 1105 Short Circuit Current Ratings SSCR 1 Units with Power Block Terminal Block 10kA SCCR except LF2 0 N 2 and 3 only 2 Units with 65kAIC Circuit Breaker 65
39. 75 begins When the timer reaches zero the drive attempts to automatically reset the fault If the condition that caused the fault is no longer present the fault will be reset and the drive will be restarted Reset Run Not used on McQuay units This type of fault normally requires drive or motor repair The cause of the fault must be corrected before the fault can be cleared The fault will be reset on power up after repair Non Resettable User These faults can be enabled disabled to either annunciate or ignore a Configurable fault condition using Fault Config 1 238 The drive indicates faults in the following ways Ready LED on the drive cover see section 12 3 Drive status parameters Drive Status 1 209 and Drive Status 2 210 Entries in the fault queue see section 12 5 1 Pop up screen on the LCD OIM See figure 12 4 The screen displays e Fault number e Fault name e Time that has elapsed since fault occurred IOMM 1159 77 Figure 43 Sample Fault Screen on the LCD OIM Fault Fxxxxx Fault Text String Time Since Fault XXXX XX XX ACKNOWLED GE NOTES 1 Press any F Key to acknowledge the fault 2 The fault screen is displayed until it is acknowledged by pressing any F key or cleared in the drive by other means About the Fault Queue The drive automatically retains a history of faults that have occurred in the fault queue The fault queue is accessed using the OIM or VS Utiliti
40. Correction Capacitors Do not use power factor correction capacitors with centrifugal chillers with a compressor VFD Doing so can cause harmful electrical resonance in the system Correction capacitors are not necessary since VFDs inherently maintain high power factors Compressor Motor Terminal Insulation The installing contractor must insulate the compressor motor terminals as described below on units over 600 volts and when the unit is installed in a high humidity location that could cause condensate to form on the motor terminals The terminals are cooled to 45 F to 50 F as a result of the motor cooling The required material can be ordered and shipped in as a kit 775123601 This is to be done after the McQuay International start up technician has checked for proper phase sequence and motor rotation Following this verification by the McQuay International technician the contractor should apply the following items Materials required available at most electrical supply outlets 1 Loctite brand safety solvent 12 oz package available as Daikin part number 350A263H72 IOMM 1159 2 3M Co Scotchfil brand electrical insulation putty available in a 60 inch roll as McQuay part number 350A263H81 3 3M Co Scotchkote brand electrical coating available in a 15 oz can with brush as McQuay Part Number 350A263H16 4 Vinyl plastic electrical tape Application procedure 1 Disconnect and lock out the power source to th
41. Incorrect reference source has been programmed 1 Check Speed Ref Source 213 for the source of the speed reference 2 Reprogram Speed Ref A Sel 90 for correct source Speed reference from analog input Incorrect reference source is being selected via remote device or digital inputs Improper reference common signal 1 Check Drive Status 1 209 bits 12 15 for unexpected source selections 2 Check Dig In Status 216 to see if inputs are selecting an alternate source 3 Reprogram digital inputs to correct Speed Sel x option 1 Verify that common is properly wiring connected to AnlgIn terminal Table 42 Motor Will Not Accelerate to Commanded Speed Indication Acceleration time is excessive Cause s Incorrect value in Accel Time x 140 141 Corrective Action Reprogram Accel Time x 140 141 Drive is forced into current limit slowing or stopping acceleration Excess load or short acceleration time Check Drive Status 2 210 bit 10 to see if the drive is in current limit Remove excess load or reprogram Accel Time x 140 141 Speed command source or value is not as expected Improper speed command Check for the proper speed command using steps 1 through 7 in table 12 11 Programming is preventing the drive output from exceeding limiting values Incorrect programming Check Maximum Speed 82 and Maximum Freq 55
42. LCD OIM OPTION if COOLANT OUTPUT 3 4 NPT DRIVE TUBE C p ACC x T T 11 500 3 500 35 500 6 8 12 E 5 _ m i 125 23 e 5 COOLANT INPUT Y i F 6 000 1 1 vt 6 000 30 250 BE 17 750 l 4 150 2 380 4 625 30 250 17 750 625 X 1 25 FULL RAD SLOT 6 PLACES le i 14 000 s z 0 o f E 9 767 E 1 813 NOTES 1 Aseparate closed loop cooling module is also required 2 The mounting rails shown are shipped loose for field mounting Unit Shipping Weights mos vaan vezes Weight Ib kg 1600 726 1600 726 IOMM 1159 35 36 Figure 21 VF 2080 2110 Free Standing 75 11 3 59 56 X 1 50 SLOT 12 PLACES NOTES 1 Aseparate closed loop cooling module is also required 2 The mounting rails shown are shipped loose for field mounting Unit Shipping Weights moder vem ao Weight Ib kg 2000 908 IOMM 1159 Controls Definition of Terms Acc2 Acceleration time 2 Active LEWT Setpoint The current Leaving Evaporator Water Temperature Setpoint Analog in loss Analog input loss Anig Cal Chksum Analog input calculation check sum math function Autotune Set point adjustments made automatically not used by McQuay International AutoT MagRot Autotune rotate not used by McQuay International Auto
43. M Bolt M8X1 25 Bolt M8X1 25 VFD 027 1 4 500 MCM Bolt M8X1 25 Bolt M8X1 25 VFD 037 2 4 500 MCM Bolt M8X1 25 1 1 VFD 033 2 4 500 MCM 2 2 VFD 043 2 4 500 MCM Bolt M8X1 25 Water Cooled VED 060 2 3 0 350 MCM VED 072 VED 090 2 2 600 MCM 4 4 500 MCM VFD 120 4 4 500 MCM NOTE X is the number of terminals per phase Table 11 Air Cooled LiquiFlo Incoming Terminal Size Range Disconnects amp Circuit Breakers VFD Size Loan ami Incoming Molded Case Switch 4 350 MCM Incoming High Int CB 4 350 MCM Incoming Ultra High Int CB 4 350 MCM 1 4 350 MCM 1 1 4 350 MCM 1 4 350 MCM 2 3 0 250 MCM 1 1 2 3 0 250 MCM 2 3 0 250 MCM 2 3 0 250 MCM 1 1 2 3 0 250 MCM 2 3 0 250 MCM 2 3 0 250 MCM 2 500 MCM 2 3 0 250 MCM 2 500 MCM 2 3 0 250 MCM 2 500 MCM 2 2 500 MCM 2 2 500 MCM 2 2 500 MCM 2 3 0 350 MCM 3 3 0 400 MCM 3 3 0 400 MCM 2 2 2 500 MCM 3 3 0 400 MCM 2 2 2 500 MCM 3 3 0 400 MCM 2 2 2 500 MCM 3 3 0 400 MCM 4 4 0 500 MCM 4 4 0 500 MCM 4 4 0 500 MCM VFD 120 4 500 1000 MCM 4 500 1000 MCM 4 500 1000 MCM NOTE X is the number of terminal
44. Models VFD 2037 2110 Cooling Water Piping for Free Standing VFD STOP CHILLED VALVE BALANCING WATER T d VALVE PUMP Tl A Wd VALNE gt Po CHILLER he KI eth mono c e WATER REGULATING VALVE COMPRESSOR Factory Mounted OIL COOLER CIRCUIT SOLENOID A sky LEE A B A bw STOP J VALVE E STRAINER MAX 40 MESH l DRAIN woh STOP l N OR PLUG VALVE FACTORY SUPPLIED 3 4 NPTF FLEXIBLE HOSE IN amp OUT 1 NPTF VFD zo 1 NPTM US COOLING Field Supplied Piping Components MODULE Field Piping Connection Point FACTORY SUPPLIED 3 4 NPTF FLEXIBLE HOSE IN amp OUT NOTES 1 See page 14 for the chilled water supply quantity 2 Dual compressor chillers Models WDC and WCC have one factory combined oil cooler inlet and outlet connection Each compressor has its own dedicated VFD with a cooling module which are piped in parallel Interconnecting flexible hoses are 10 feet long and shipped with the cooling module 4 The cooling module has an on board water regulating valve on the chilled water system side Fittings shown in the dotted field piping are by the customer Basic fittings are shown local codes and or job conditions may require additional components 6 On VFD 090 and 120 the cooling module is factory mounted on the VFD frame and does not reguire field piping hoses or wiring IOMM 1159 Figure 4 LF VFD
45. S Operator Interface Touch Screen V View Menu Keypad or OITS Screen A Alarm Menu Keypad Or OITS Screen S Set Menu Keypad or OITS Screen C Compressor Menus U Unit Menus Example Setpoint location for VFD Minimum speed UC SU 10 The location would be the Unit Controller Set Unit Setpoints Menu Screen 10 OITS locations are S Setpoint screen Alarms or Motor and the number of the setpoint on the screen Additional Setpoints the following two setpoints are at Technician level and are located at UC SC 8 and not on the OITS They are for exclusive use of factory trained service technicians IOMM 1159 VFD Mode Auto auto manual this allows the VFD speed output signal to be manually controlled for testing or to be automatic for normal operation The MicroTech II controller will not allow the speed signal to go below the calculated lift control speed VFD Speed Manual Setpoint 100 when the unit is started for the first time and set up for design or to check the operation and performance of the unit it is necessary to run the unit at a constant fixed speed of 100 To accomplish this set the VFD Minimum Speed to 100 UC SU 10 or OITS S Motor 10 then set up and adjust the unit When testing is complete set the minimum speed back to the original setpoint Do not set the drive minimum speed to 100 to set up or test the unit at full speed as the controller will not know that the drive will not respo
46. S History MicroTech There is no feedback signal reguired from the variable freguency drive to the MicroTech to indicate the speed of the motor The actual percent motor speed is within 1 of the analog output signal from the MicroTech controller Digital Input DI 10 is wired to a switch on the compressor that indicates when the vanes are 100 open VO switch If the switch is open the status of the vanes is Not Open If the switch is closed the status of the vanes is Open VFD Chiller Control States There are seven VFD chiller control states viewable as shown below They are based on the unit status See Table 14 on page 43 for relationships MicroTech Menu 1 Screen 2 States VFD Off VFD Start VFD Running Adjust Speed amp Open Vanes VFD Running Hold Minimum Speed amp Adjust Vanes VFD Routine Shutdown VFD Locked Speed VFD Override Capacity Control VFD Off The VFD is turned off the speed output is 0 and the vanes are closed VFD Start The VFD is turned on the speed output is minimum speed and the vanes are modulated to maintain the leaving evaporator setpoint VFD running hold minimum speed and adjust vanes mode VFD Running Adjust Speed amp Open Vanes The VFD remains on the speed output is modulated to maintain the leaving evaporator setpoint and the vanes are pulsed to the open position This mode drives the vanes open and uses the speed to control capacity based on the ev
47. T Rs Stat Autotune static not used by McQuay International CAN Bus Fit Controlled area network bus fit Command Speed The speed command issued by the MicroTech controller to the VFD DB Dynamic breaking not used on McQuay units Dec2 Deceleration 2 not used by McQuay International Decel Inhibit Deceleration inhibited Demand Limit The maximum amp draw as established by the Demand Limit setpoint Dig in Conflict Digital input conflict contradictory instructions Drive OL Drive overload Exit a menu cancel a change to a parameter or toggle between program and process user display screens Flux Amps Amount of current out of phase with the fundamental voltage component Full Load The vane open switch closes and the speed output 100 Or Load pulses exceed the full load setpoint timer default 300 cumulative seconds and the speed output 100 Or RLA is above or equal to Max Amp Limit or Demand Limit Or The evaporator pressure is below the low evap pressure inhibit setpoint HIM Flux vector control Human interface module IGBT Insulated Gate Bi polar Transistors IntDBResOvrHeat Dynamic breaking resistor temp exceeded setpoint not used on McQuay units Lift Temperature Saturated condenser refrigerant temperature minus saturated evaporator temperature Lift Temperature Control Speed The minimum speed to maintain lift an
48. Through Time R042 Line Voltage H 021 U 018 Check DC bus voltage If incorrect replace diode set Check network cabling from network master to network option board Check that network master is operating properly Reset fault Perform Identification Request Restart drive Low DC bus voltage Input rectifier diodes defective Network comm loss Identification request not yet performed V Hz only Communications with the AutoMax network have been lost Drive started but Identification Result Zero Overcurrent steady state Trips between 185 and 200 load based on inverter type current check power module rating Output phase to phase short Bus voltage line to line Ground fault Momentary overload Bad motor Torgue boost V Hz too high V Hz Motor unknown to regulator V Hz Parameter settings vector Encoder wired incorrectly wrong PPR Check isolation between each output line Check transistor modules for correct output If incorrect possible board defect replace Possible Hall effect current sensor defective replace Check isolation between ground and output terminals Possible leakage current sensor defect replace sensor Check for motor overload reduce load on motor Check motor for correct operation Check parameters H 001 H 002 and or H 003 Enable Identification Request H 020 Check that regulator was updated with actual motor charact
49. Under Temperature Fault E4 Fluid Low Flow Fault To acknowledge the alarms hold the amp key for 3 seconds The alarm error code will be displayed and the reset led will light while the button is depressed After the key is released the process temperature will be displayed To view the alarm summary hold both the 1 Y keys for 3 seconds To exit the alarm summary screen press the q key or the screen will automatically time out after 10 seconds Figure 7 FX05 Display Panel ALARM RESET PUMP ON 6 0 O O A a W Fx05 Operation The FX controller controls to a fixed loop water setpoint Wiring General Unit Mounted Unit mounted VFDs have factory wired control wiring plus power wiring from the VFD to the compressor motor terminals The VFDs only reguire a power supply Cable entrance is shown on the dimension drawings beginning on page 29 for LF and page 35 for LF 2 0 models An exception is on models LF models 090 and 120 and all LF 2 0 models that reguire some interconnection control wiring from the VFD to the remote cooling module as described in the section beginning on page 14 Freestanding Freestanding units reguire both field control and power wiring from the VFD to the chiller and some interconnection control wiring on models 090 and 120 Wiring Diagram The control and power wiring diagram is located on page 27 IOMM 1159 17 18 Power Wiring Wiring fuse and wire size must be in
50. al and Demand Limit Enable 1 OFF ON at 10096 RLA for 20 mA signal lt lt lt lt lt z 5 o IOMM 1159 Setpoint 11 on Panel 1 setpoint 14 on Panel 2 sets the speed at O degrees F Lift point A in Figure 25 Setpoint 12 on Panel 1 setpoint 15 on Panel 2 sets the lift in degrees F at the 100 speed point point B in Figure 26 Figure 28 Operating Envelope Setpoints 11 and 12 Settings Typical Variable Frequency Drive Operating Envelope 120 110 Percent Speed O O 50 40 4 30 20 10 0 Saturated Temperature Difference F Condenser Saturation Temperature Minus Evaporator Saturation Temperature Figure 29 View I O Screen COMPR I O The MicroTech II controller View I O Screen shown to the Digital Inputs right displays the compressor motor speed as controlled by Manual Switch the VFD at the bottom of the screen This is information Morh Migh Press Motor High Temp Vanes Closed Starter Transitior Starter Fault Evap Water Flow Cond Water Flow Vanes Open only and no settings are made on this screen Digital Outputs Motor Control Relay Hot Gas Bypass Liquid Injection Oil Pump Oil Sump Heater Oil Cooler Unload Vanes Load Vanes Starter Latch Analog Outputs VFD Speed 100 IOMM 1159 51 Table 16 MicroTech II Settings and Ranges Single Compressor MicroTech II VFD Default Setpoint Keypad OITS Location Locations Mot
51. als shall be made with copper wire and copper lugs only Main power wiring between the starter and motor terminals is factory installed when chillers are supplied with unit mounted starters Power Factor Correction Do not use power factor correction capacitors with VFDs By their nature they themselves provide the following correction A C 380 480V VDF 011 043 0 98 A C 575V VDF 029 106 0 98 W C 380 480V VDF 060 120 0 98 W C 380 480V VF2037 VF2110 0 99 IOMM 1159 VFD Dimensions Air Cooled Figure 14 VFD 011RLA 022RLA Air Cooled Free Standing Unit Weights Model vFDOM VFD014 VFD016 VFD022 592 269 VFD Weight Ib kg 568 258 573 260 583 265 54 25 54 25 VFD w Reactor Weight Ib kg 43 20 50 23 IOMM 1159 Figure 15 VFD 027RLA 043RLA Air Cooled Free Standing Unit Weights Model VFD027RLA VFDO33RLA VFDO38RLA VFD 043RLA VFD Weight Ib kg 769 834 VFD w Reactor Weight Ib kg NA NA Reactor Weight Ib kg 118 118 30 IOMM 1159 Figure 16 VFD 011RMA 043RMA Air Cooled Unit Mounted Power Wiring 6 00 Entry Panel 152 40 Note Remove before drilling to pair metal particles trom alling into drive components Removable O O Lifting Eyes O o o o E o
52. aporator leaving water setpoint IOMM 1159 39 40 VFD Running Hold Minimum Speed amp Adjust Vanes The VFD remains on the speed output is held at Minimum Speed and the vanes are modulated to maintain the evaporator leaving water setpoint This mode occurs when the load tons can be satisfied with the vanes not fully open while at minimum speed Decreasing speed can no longer reduce capacity so the vanes maintain temperature control When the load increases the vanes will pulse open until the vane open switch shows that the vanes are full open At this point the MicroTech controller changes the mode to VFD Running Adjust Speed and Open Vanes VFD Routine Shutdown The VFD remains on the speed output remains the same dependent on the prior state and the vanes are driven closed VFD Locked Speed The MicroTech has a VFD LOCKED Speed Setpoint that can be selected either ON or OFF from the MicroTech controller keypad When the VFD Locked Speed mode is set to ON the VFD speed will be locked at the locked speed setpoint keypad adjustable The purpose of this mode is to allow proper setup calibration testing etc of the chiller at a constant speed with constant conditions NOTE Do not set the drive minimum speed above the factory setpoint to limit reduced speed A control incompatibility will result between the MicroTech controller and the drive Override Capacity Control Any capacity override see Capacity Ov
53. arm should clear when all motor nameplate data is properly entered The sum of Maximum Speed 82 and Overspeed Limit 83 exceeds Maximum MaxFreq Conflict Freq 55 Raise Maximum Freq 55 or lower Maximum Speed 82 and or Overspeed Limit 83 so that the sum is less than or equal to Maximum Freq 55 Result of autotune procedure 61 Continued next page IOMM 1159 76 Alarm Description Fan pump mode is selected in Torq Perf Mode 53 and the ratio of Motor NP Hertz 43 to Maximum Freq 55 is greater than 26 Power Loss Drive has sensed a power line loss NP Hz Conflict Prechrg Actv Drive is in the initial DC bus precharge state Speed Ref Cflct Speed Ref x Sel or PI Reference Sel is set to Reserved Under Voltage The bus voltage has dropped below a predetermined value Custom V Hz mode has been selected in Torq Perf Mode 53 and the V Hz slope VHz Neg Slope is negative About Faults Faults indicate conditions within the drive that require immediate attention The drive responds to a fault by initiating a coast to stop sequence and turning off power to the motor A flashing red LED indicates a fault has occurred and a fault signal will appear in the chiller touchscreen A steady red LED indicates that it is non resettable If the drive is running when this type of fault occurs and Auto Rstrt Tries 174 is set to a value greater than 0 a user configurable timer Auto Rstrt Delay 1
54. as shown below ee P MAN AUTO MAN Status Speed Reference Control Source P 000 Source Local keypad display P 000 LOCL Terminal Strip Terminal Strip Remote AUTO Selected Inputs P 000 rE Option Port P 000 OP Network Serial Port P 000 SerL Terminal Strip Terminal Strip Note Manual speed reference is not allowed on McQuay Centrifugal Chillers Use the A and V keys to e Step through the drive parameter menus and error log when the keypad display is in program mode e Increase or decrease a numeric value such as the reference or a parameter value Hold down these keys to increase the scroll speed Use the ENTER key to ENTER Display a parameter or a selection value in program mode e Save a value e Move through each monitor display item when in monitor mode IOMM 1159 89 IOMM 1159 Use the FORWARD REVERSE key to select the direction of motor rotation when the control source is local REMOTE LED is off This key is ignored if the control source is not local REMOTE LED is on See the FORWARD and REVERSE LED descriptions for more information Note Local control source is not allowed on McQuay International Chillers PROGRAM Use the PROGRAM key to move between program and monitor modes The PROGRAM LED turns on when the keypad display is in program mode and turns off when the keypad display is in monitor mode JOG Use the RUN JOG key to toggle
55. c overload Self tuning status Vector only Power Module overloaded Too high DC Braking Current H 007 or Torque Boost H 003 Check load to Power Module Check Power Module sizing versus application Check DC Braking Current value H 007 Check Torque Boost H 003 See parameter U 009 Communication loss between regulator PC OIM Serial Port communication cable PC or OIM communication port setup Check connection cable and communication port setup Spurious host PC comm interrupt Regulator board failure Replace Regulator board Asymmetrical bus charge Bad Power Module Contact McQuay International Note If extensive troubleshooting or corrective actions are necessary only properly trained and qualified technicians should be used IOMM 1159 Accessing Reading and Clearing the Faults in the Error Log The following procedure shows how to access and clear the error log Note that you cannot clear a single entry from the error log The entire log including all of the fault codes and the day and time stamp of each fault will be cleared simultaneously using this procedure Step 1 Press the PROGRAM key The First Menu General parameters are M EM displayed The PROGRAM LED will turn on zr ge O wm I ronwARD JOG L TORQUE C Reverse LL Pasewors JA PROGRAM RELIANCE ELECTRIC Step 2 Press the tkey until Err is displayed La Ly 636 NN sreco CO nuNN
56. d avoid surge The controller continuously calculates the minimum operating speed in all modes based on the lift temperature Low evap pressure inhibit setpoint The low evaporator pressure that inhibits any further compressor loading Manual Load Setpoint MicroTech controller manual operation of the guide vanes for testing Maximum Pulldown Rate Maximum pulldown rate of chilled water in degrees per minute MCB Main control board MCR Motor control relay Minimum Amp Setpoint MicroTech controller minimum unloading setpoint Minimum Rate Setpoint Pulldown rate for MicroTech 200 controller Minimum Speed The minimum speed allowed usually set at 70 Mod Module Net Network Network Setpoint Chilled water setpoint from an external source NP Hz OIM Operator interface module PCB Printed circuit board Continued next page 37 38 Precharge Precharge capacitors PWM Pulse width modulated Rapid Shutdown If there is a fault the MicroTech switches the state to VFD OFF This includes changing the Unit Control Panel switch to OFF RLA Rated Load Amps the maximum motor amps RMI Remote meter interface located in the VFD panel Softloading Extended ramp up in capacity set in the MicroTech controller Speed Speed signal to the compressor motor from the variable frequency drive VFD p based on analog output 0 10 VDC from th
57. data 2 Check motor connections 3 Verify that Accel Time lt Base Speed 40 x 33 sec Note 33 sec time limit to bring motor to 40 Hz AutoT MagRot AutoT Saturat UserSet Timer Param Chksum PwrBrd Chksum Table continued next page Autotune magnetizing current rotate test failed Autotune saturation curve test failed User Set load or save not completed in less than 5 sec The checksum read from the board does not match the checksum calculated The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data 1 Check motor nameplate data 2 Check motor connections 3 Verify that Accel Time lt Base Speed 40 x 33 sec see above 1 Check motor nameplate data 2 Check motor connections Replace main control 1 Restore defaults 2 Cycle power 3 Reload User Set if used 1 Cycle power 2 Replace drive IOMM 1159 65 106 MCB PB Config New IO Option Fatal App AutoT Enable I O Change I O Comm Loss Digln CnflctA DigIn CnflctB Digln CnflctC Description Drive rating information stored on the power board is incompatible with the main control board New option board added to control Fatal Application error Autotune enabled but not started Option board replaced l O Board lost communications with the Main Control Board Action if appropriate 1 Reset fault or cycle power 2 Replace con
58. e Group 1 Name FGP Parameter File 3 Name Group2Name Parameter Name Group 3Name Parameter Name Parameter Name Y Set Device HIM Reset To Defaults Save To User Set Delete HIM Set Load Frm Usr Set Active Name Set ee Sabie Lo Introduction 3 Complete Steps __ I 1 Input Voltage OO lily avaiable if power 2 Motor Dat Ramp cycled during startup 3 Motor Tests 4 Speed Limits Make a selection i i 5 Speed Control Abort Device Identit O change en 6 Str Stop O Backup User Dspy Lines 7 Done Exit Resume OO User Dspy Time Start Up Menu User Dspy Video Reset User Dspy a Press OD ED to move between menu items Press to select a menu item Press e to move 1 level back in the menu structure Press ED to select how to view parameters IOMM 1159 60 Using the LEDs Drive LEDs Figure 38 Front Panel LED Indications ra Description PWR Illuminates when power is Power Green applied to the drive PORT 1 Green Status of DPI port internal communications if present i Status of communications MOD Yelow module when installed Status of network if 3 NEAR ned connected S Status of secondary network l n NET B 1 Red if connected 1 H This section provides information to guide you in lo 1 X troubleshooting the PF 700H control family Included
59. e MicroTech controller Stage Delta Multi compressor or dual compressor unit on off cycling temperature delta T SVC Sensorless vector control Parameters Throughout this manual you will see references to parameter names and numbers that identify them for the drive This manual uses the same format that will be shown on the keypad display to refer to parameters P nnn H nnn R nnn Where nnn is a number P designates general parameters H designates Volts Hertz parameters R designates optional RMI parameters A CAUTION The original parameters values set by the McQuay International startup technician must never be changed by anyone not specifically trained and experienced with these VFDs Damage to the chiller or drive could occur IOMM 1159 MicroTech 200 VFD Control Figure 22 MicroTech 200 Control Panel The MicroTech 200 unit controller has control wiring to M Alarm 1 UNI STATUS 8 30 Ser 21 98 E mm Load icum A EE the variable frequency drive Ill Unioaded EEUU tnei instead of to a motor starter CATEGORY MENU ITEM ACTION The MicroTech controller IA l Son AG Pre me provides the speed setpoint le CES signal to a hardwired input on WE ex EB the VFD The output on the na MicroTech AOX auxiliary output board is configured using jumpers to provide a 0 10 VDC signal to a hard wired analog input on the VFD Reflrg M Motor oll Alarm OUICK ACCESS Eg Reports Temps PP
60. e U to Grnd Phase V to Grnd Phase W to Grnd Phase UV Short Phase VW Short Phase UW Short Port 1 5 DPI Loss Port 1 5 Net Loss Power Loss Precharge closed Precharge open Pwr Brd Chksum1 Description A phase to ground fault has been detected between the drive and motor in this phase Excessive current has been detected between these two output terminals DPI port stopped communicating An attached peripheral with control capabilities via Logic Source Sel 89 or OIM control was removed The fault code indicates the offending port number 81 port 1 etc The network card connected to DPI port stopped communicating The fault code indicates the offending port number 71 port 1 etc DC bus voltage remained below 85 of nominal for longer than Power Loss Time 185 Enable disable with Fault Config 1 238 Precharge was closed when it should be open Precharge was open when it should be closed The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data Action 1 Check the wiring between the drive and motor 2 Check motor for grounded phase 3 Replace drive 1 Check the motor and drive output terminal wiring for a shorted condition 2 Replace drive 1 If module was not intentionally disconnected check wiring to the port Replace wiring port expander modules Main Control board or complete drive as required 2 Check OIM co
61. e compressor motor 2 Using the safety solvent clean the motor terminals motor barrel adjacent to the terminals lead lugs and electrical cables within the terminal 40X to remove all dirt grime moisture and oil 3 Wrap the terminal with Scotchfil putty filling in all irregularities The final result should be smooth and cylindrical 4 Doing one terminal at a time brush the Scotchkote coating on the motor barrel to a distance of up to 2 around the terminal and on the wrapped terminal the rubber insulation next to the terminal and the lug and cable for approximately 10 Wrap additional Scotchfil insulation over the Scotchkote coating Tape the entire wrapped length with electrical tape to form a protective jacket Finally brush on one more coat of Scotchkote coating to provide an extra moisture barrier General Wiring Practice 1 Never connect input AC power to the motor output terminals T1 U T2 V or T3 W 2 Power wiring to the motor must have the maximum possible separation from all other wiring Do not run control wiring in the same conduit this separation reduces the possibility of coupling electrical noise between circuits Minimum spacing between metallic conduits containing different wiring groups should be three inches 76 mm 3 Minimum spacing between different wiring groups should be six inches 152 mm 4 Wire runs outside of an enclosure should be run in metallic conduit or have shielding armor
62. e evaporator refrigerant pressure is less than 31 0 psi default hold speed and close vanes Low evaporator pressure shutdown alarm setpoint is 26 0 psi default Note The above pressures must be set at unit design conditions High Discharge Temperature If the discharge temperature is higher than 170 F pulse the load solenoid if the vanes are not fully open If the vanes are full open increase command speed at the rate of 1 every five seconds IOMM 1159 MicroTech II VFD Control General Description Figure 24 MicroTech II Operator Interface Panel 1 The following describes the software for centrifugal chillers with variable speed drive and the MicroTech II controller Complete information on the MicroTech II controller operation is contained in the Operating Manual OM CentrifMicro II Variable Freguency Drive VFD Control Digital output NOI terminal J12 on the compressor controller is wired to the CR relay Compressor Relay The CR relay energizes the MCR Motor Control Relay which enables the variable freguency drive instead of a standard motor Analog output Y1 terminal J4 on the compressor controller provides the speed setpoint signal to the VFD The output is a 0 10 Y 4 VDC analog output signal hard wired to VIEW 55 the VFD Tun There is no feedback signal required from the variable frequency drive to the MicroTech II controller to indicate the speed of the motor The actual percent
63. e local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment Z WARNING The drive contains printed circuit boards that are static sensitive Anyone who touches the drive components should wear an anti static wristoand Erratic machine operation and damage to or destruction of equipment can result if this procedure is not followed Failure to observe this precaution can result in bodily injury Introduction This manual covers Air Cooled 380 480V Air Cooled 575V LiquiFlo LF and LiquiFlo 2 0 LF 2 0 VFDs on centrifugal chillers with the obsolete MicroTech 200 for retrofit or the current MicroTech II controllers Many operations are the same for the four VFD families and are treated in common Where differences occur information will be designated as being for a specific VFD or controller model The four families of VFDs and their associated VFD models are shown in Table 1 IOMM 1159 VFD Sizes Mounting Cooling Type Table 1 Model Sizes by Family Air Cooled Standard Air Cooled Standard Water Cooled Standard Water Cooled Critical Harmonics 380V 480V Harmonics 575V Harmonics 380V 480V Harmonics 380V 480V Rated Rated E Rated Amps Model Family Amps Model Family Amps VFDO11 VFD029 PF700H VF2037 VF 014 VFD035 PF700H VF2055 VFD016 VFD038 PF700H VF2080 VFD022 VFD042 PF700H VF2110 VFD027 VFD045 PF700H VFD033 VFD0
64. e option Load compatible version files into drive 1 Cycle power to the drive 2 If problem persists replace drive IOMM 1159 81 Fault No Rectifier Base Temp Type Excessive rectifier temperature measured Description Action Check for proper temperature and flow rate of coolant Rectifier Dsat U V W High current was detected in an IGBT 1 Check for loose connection in IGBT wire harness 2 Check IGBTs Rectifier Ground Fault Rectifier IGBT Temp Excessive ground current measured Excessive calculated IGBT temperature Check for grounded input wiring Check for proper temperature and flow rate of coolant Rectifier IOC U V W Rectifier overcurrent 1 Verify proper motor data is entered 2 Reduce current limit Rectifier Checksum The checksum read from the board does not match the checksum calculated 1 Restore defaults 2 Reload user set if used Reactor Temp Rectifier IT Overload Rectifier 12T Overload Replaced MCB PB Ride Thru Abort Shear Pin SW OverCurrent UnderVoltage UserSetl Chksum UserSet2 Chksum UserSet3 Chksum Temperature switch in reactor opened Short term current rating of rectifier exceeded Long term current rating of rectifier exceeded Main Control board was replaced and parameters were not programmed Input power loss timed out Programmed Current Lmt Val 148 has been exceeded Enab
65. ec Default Setpoints Ranges MicroTech Keypad Menu 1 to 63 Sec Menu 11 Screen 2 Deadband 0 5 00 2 to 91 Menu 11 Screen 2 Mod Limit 2 5 F 1 0 to 10 F Menu 11 Screen 2 Maximum Speed Steps 2 1 to 5 Menu 11 Screen 2 Motor Current Set From Compressor Nameplate RLA NA Menu 26 Screen 3 Motor Current Threshold 5 1 to 20 Menu 22 Screen 3 Minimum Amp Setpoint 10 5 to 100 Menu 13 Screen 1 Maximum Amp Setpoint 100 0 to 100 Menu 13 Screen 1 Locked VFD Speed On for Start up set up On Off Menu 11 Screen 2 Locked VFD Speed Off for VFD operation On Off Menu 11 Screen 2 Locked Speed 100 for Start up Set up NA Menu 11 Screen 2 NOTE Setpoints shown above apply only to Menu 11 Screen 1 through Menu 26 Screen 3 Table 14 MicroTech Unit Status vs VFD Status Unit Status MicroTech Menu 1 Screen 1 VFD Status MicroTech Menu 1 Screen 2 All Systems Off VFD Off Off Alarm VFD Off Off Ambient Lockout VFD Off Off Front Panel Switch VFD Off Off Manual VFD Off Off Remote Contacts VFD Off Off Remote Communications VFD Off Off Time Schedule VFD Off Start Requested VFD Off Waiting Low Sump Temperature VFD Off Evaporator Pump Off VFD Off Evaporator Pump On Recirculate used for chillers Evaporator Pump On Cycle Timers used for chill
66. ed No brake resistor detected An analog input is configured to fault on signal loss A signal loss has occurred Configure with Anlg In 1 2 Loss Microprocessor watchdog timeout Fan is not energized at start command Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of Flt RstRun Tries Enable Disable with Fault Config 1 Sent message not acknowledged Ambient temperature is too low New power unit or option board installed of different type New option board added Error reading Elapsed MWh and Elapsed Run Time from EEPROM The drive was commanded to write default values to EEPROM Incorrect motor nameplate data This event called from arithmetical functions if divider is zero Table continued on next page 1 Program Bus Reg Mode x to not use brake 2 Install brake resistor 1 Check parameters 2 Check for broken loose connections at inputs 1 Cycle Power 2 Replace control Correct the cause of the fault and manually clear 1 Cycle Power 2 Replace control Raise ambient temperature Clear fault and reset drive to factory defaults Clear fault 1 Clear the fault or cycle power to the drive 2 Program the drive parameters as needed Check motor nameplate data 1 Cycle Power 2 Replace control IOMM 1159 64 Shear Pin I O Removed Power Unit Periph Loss Port DPI Loss Hardware Enbl
67. ee standing VFD Line Harmonics VFDs have many benefits but care must be taken when applying VFDs due to the effect of line harmonics on the building electric system All VFDs cause distortion of the AC line because they are nonlinear loads that is they don t draw sinusoidal current from the line They draw their current from only the peaks of the AC line thereby flattening the top of the voltage waveform Other nonlinear loads are electronic ballasts and uninterruptible power supplies Reflected harmonic levels are dependent on the source impedance and the KVA of the of the power system to which the drive is connected Generally if the connected power source has a capacity greater than twice the drive s rated amps see Table 1 for rated amps the installation will conform to IEEE Standard 519 with no additional attenuation It is important that the application be been checked for harmonic levels The IEEE 519 1991 Standard The Institute of Electrical and Electronics Engineers IEEE has developed a standard that defines acceptable limits of system current and voltage distortion A simple form is available from McQuay International that allows McQuay International to estimate compliance with IEEE 519 1991 Line harmonics and their associated distortion may be critical to AC drive users for three reasons 1 Current harmonics can cause additional heating to transformers conductors 2 Voltage harmonics upset the smooth voltage sinusoidal
68. entries again The display shows the error log entry viewed prior to or associated with the time stamp Step 8 Repeat steps 4 through 7 for each additional error log entry to view the time and date for each error log entry Step 9 When you have viewed all the entries you should clear the error log Press the t key while you are viewing any entry in the log until the display shows CLr Press ENTER to clear the error log All entries will be cleared 11333 Cir RUNNING C vots C Remote CD aurs C oG TAM C3 auto Lx BN fonwano TJ TORQUE C REVERSE O Password ME PROGRAM En RELIANCE NESET ELECTRIC Step 10 Err will be displayed again to indicate that the log is empty 98 Err JAN Co voirs C REMOTE CI aes C soc RUN Er xe E mom JE C Tongue C reverse COJ Password MENS PROGRAM RELIANCE sr START ELECTRIC Step 11 Fatal Faults Press the PROGRAM key to access monitor mode Fatal fault codes are distinguished by the letter F preceding the code They normally indicate a malfunction of the microprocessor on the regulator board In some cases fatal fault codes can be reset and the drive can be re started Table 50 lists the fatal fault codes that can be reset If any other fault code appears on the display the regulator board will have to be replaced If the fault code FUE appears in error log entry O it indicates a fatal fault occurred as power was lost Contact McQuay Internationa
69. er MicroTech controllers NOTE VFDs are programmed differently in the factory for 50 and 60 hertz applications It is prudent to verify this by checking the settings sticker in the unit and the actual unit settings using the Reliance manual shipped with the VFD unit as a reference Environmental Conditions Operating Temperature inside NEMA 1 enclosure 32 to 131 F 0 C to 55 C Ambient Temperature outside NEMA 1 enclosure 32 to 104 F 0 C to 40 C Storage Temperature Ambient 32 to 131 F 0 C to 55 C Humidity 5 to 95 non condensing AC line distribution system capacity not to exceed 85 000 amps symmetrical available fault current Harmonic Distortion Harmonic distortion the effect that any variable frequency drive has on the electrical system supplying it power is a consideration on some applications and is discussed in detail in Catalog Starter which can be obtained from the local McQuay International sales office or on www DaikinApplied com General Description The VFD will not generate damaging voltage pulses at the motor terminals when applied within 500 feet of each other The VFD drive complies with NEMA MGI section 30 40 4 2 which specifies these limits at a maximum peak voltage of 600 volts and a minimum rise time of 0 1 microseconds All VFDs require cooling Models VFD 011 to 043 380 480V and VFD029 106 575V are air cooled All others are water cooled Factory mounted water cooled VFDs have VFD coo
70. er of the drive in kilowatts is displayed Note that this is intended for display purposes as a general indication of kilowatt output and should not be used for control or exact metering purposes Motor output torque is displayed in percent Valid only for vector regulation ALL LEDs IOMM 1159 Selected speed reference or torque reference in is displayed 91 IOMM 1159 Troubleshooting NDANGER DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or death The drive can display two kinds of error codes alarms and faults to signal a problem detected during self tuning or drive operation Fault and alarm codes are shown in Table 48 and Table 49 A special type of fault code which occurs rarely is the fatal fault code Alarm Codes An alarm condition is signified by a two or three letter code flashing on the display The drive will continue to operate during the alarm condition The cause of the alarm should be investigated to check that it does not lead to a fault condition The alarm code remains on the display as long as the alarm condition exists and clears when the condition causin
71. eristics via Identification Request H 020 Check Encoder PPR U 001 Motor Poles U 002 Base Frequency U 003 Motor Nameplate Amps U 004 Magnetizing Current U 006 Speed Regulator Prop Gain U 012 Check encoder wiring Perform vector self tuning Overcurrent at acceleration Overcurrent condition occurred while accelerating Acceleration time too short See OC fault corrective actions Increase acceleration time POOI P017 P021 Overcurrent at DC braking DC voltage too high Check parameters H 006 H 007 Overcurrent at deceleration Continued on next page Overcurrent condition occurred while decelerating Deceleration time too short See OC fault corrective actions Increase deceleration time P002 P018 P022 95 Alarm Description Overfrequency Fault Cause Drive has exceeded maximum allowable output frequency Regenerating energy is too high Stability or slip compensation circuit adds frequency reference If H 016 ON searching current is too high Motor is too small Correction Action Vector Check parameters Encoder PPR U 001 Motor Poles U 002 Base Frequency U 003 V Hz Check DC bus voltage increase decelerating time Check values Max Speed P004 Overfreq H 022 Check slip compensation H 004 If H 016 ON check motor size versus Power Module size recheck setting of P005 too high Drive overtemperature Motor ove
72. errides on page 45 that forces the VFD out of normal speed control To return to normal speed control the capacity override condition is corrected First level capacity overrides hold speed and vane position while waiting for the condition to correct If the override condition becomes critical second level capacity override speed and vane position will be modulated in an attempt to correct the critical condition Control Sequence MicroTech 200 VFD Off The VED is turned off the speed output is 0 and the vanes are closed If the chiller is turned on and if there is a load the chiller will go through its start sequence and when the unit status reaches Motor Control Relay MCR Started the VFD status MicroTech II controller Menu 1 Screen 2 will switch to VFD Start VFD Start The VFD is turned on the speed output is minimum speed and the vanes are modulated to maintain the chilled water setpoint Active Setpoint on keypad display At the same time the minimum speed will continually be re calculated based on the lift temperature In the start mode capacity control is Hold Minimum Speed amp Adjust Vanes to satisfy the Active Setpoint leaving chilled water temperature When the vanes have been pulsed to the full open position the Vane Open V O switch closes the VFD mode changes to VFD Running adjust speed open vanes VFD Running Adjust Speed amp Open Vanes The VFD remains on the speed output is
73. ers VFD Off VFD Off Evaporator Pump On Waiting For Load used for chillers VFD Off Condenser Pump Off VFD Off Oil Pump Off VFD Off Oil Pump On Pre Lubrication VFD Off Condenser Pump On Waiting for Flow VFD Off Evaporator Pump On Waiting for Flow VFD Off Startup Unloading VFD Off MCR Started Running OK Or Running Capacity Override Can have either VFD status shown to the right MCR Off Rapid Shutdown Shutdown Unloading MCR Off Routine Shutdown Condenser Pump Off Shutdown Evaporator Pump Off Shutdown Post Lubrication Shutdown Oil Pump Off VFD Start VFD Start Then VFD Running Hold Minimum Speed amp Adjust Vanes VFD Running Capacity Override Or VFD Running Adjust Speed amp Open Vane VFD Off VFD Routine Shutdown Or VFD Off VFD Off VFD Off VFD Off VFD Off VFD Off IOMM 1159 43 Figure 23 MicroTech 200 VFD Speed Control State Diagram VFD Off Command Speed is held at 0 Vanes closed VED Start Command Speed starts at 70 full speed and increases with Minimum Speed Vanes modulating to chilled water Capacity Overrides effect Vane modulations Vane Closed Switch is VFDCapOverrides ic Motor Relay Vanes are Command Speed and vane position held constant UnitStatus is closed AND Full Open except if override becomes critical then modualte is Rapid Locked Speed Command Speed amp Vane
74. es software The fault queue holds the eight most recent faults The last fault to occur is indicated in queue entry 1 As new faults are logged into the queue existing fault entries are shifted for example entry 1 will move to entry 2 Once the queue is full older faults are discarded from the queue as new faults occur All entries in the fault queue are retained if power is lost The Time Stamp For each entry in the fault queue the system also displays a fault code and time stamp value The time stamp value is the value of an internal drive under power timer at the time of the fault The value of this timer is copied to PowerUp Marker 242 when the drive powers up The fault queue time stamp can then be compared to the value in PowerUp Marker to determine when the fault occurred relative to the last drive power up The time stamp is cleared when the fault queue is cleared Clearing Faults A fault condition can be cleared by the following Step 1 Press the ESC Prog key or any F Key to acknowledge the fault and remove the fault pop up from the LCD OIM screen Step 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared Step 3 After corrective action has been taken clear the fault using one of the following e Setting Fault Clear 240 to Clear Faults 1 e Press Fl Cflt from the fault queue screen e Issuing a Stop Clear Faults command from the control source
75. f diagnostics During drive operation the display indicates parameter numbers parameter values fault or alarm codes and drive output values Display Range Normally a minus sign is used as one of the four characters in the display to indicate a negative value If a value including the minus sign exceeds four characters the display will drop the minus sign and display four digits In this case the SPEED LED will flash to indicate that the displayed value is a negative number Refer to the examples in the following table A decimal point to the right of the last digit in the display indicates there is further resolution examples A and E below unless a decimal point already appears as part of the number displayed example G below In either case the system uses the full resolution of the number for drive control not the displayed value 88 Table 45 Display Range Examples It will appear on the And the SPEED LED display as will Not Flash Not Flash Flash Not Flash Flash Not Flash Flash Flash This does not apply for the speed display For the speed display the FORWARD REVERSE LEDs indicate actual speed reference polarity Example If the actual number is The Keypad The drive s keypad has nine membrane keys that are used to monitor program and control the drive Use the AUTO MAN key to switch between the auto speed reference and AUTO the manual speed reference
76. factured in an ISO Certified facility 2013 Daikin Applied Illustrations and data cover the McQuay product at the time of publication and we reserve the right make changes in design and construction at anytime without notice The following are trademarks or registered trademarks of their respective companies BACnet from ASHRAE LONMARK LonTalk LONWORKS and the LONMARK logo are managed granted and used by LONMARK International under a license granted by Echelon Corporation Modbus from Schneider Electric MicroTech II Open Choices from McQuay International IOMM 1159 DANGER Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life N DANGER DC bus capacitors retain hazardous voltages after power has been disconnected After disconnecting input power to the unit wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of life A CAUTION The user is responsible for conforming to all applicabl
77. flow of coolant liquid Thermal tests are performed on the VFD to verify that the cooling occurs within the correct temperature range Air Water Cooled Nomenclature VFD XXX M A Cooling Method Variable Frequency Drive A Air cooled W Water cooled Model Number 011 through 120 Mounting 2037 through 2110 LF 2 M Factory mounted L Shipped Loose for Field Mounting LiguiFlo 2 0 Nomenclature Since all LF 2 0 models are field mounted and water cooled there are no characters after the Model Number typically VFD 2037 IOMM 1159 Figure 1 LiquiFlo Internal Components Factory Mounted Water Cooled Model Motor Terminals Disconnect Switch Motor Control Relays MCR Control Transformer w Fuses Optional Meter Transformers 2 Terminal Board Fuses Drive Unit Keyboard Display Cooling Water Lines IOMM 1159 Installation Mounting Arrangements Depending on size and type VFDs may be factory mounted with power and control wiring factory installed or free standing requiring field mounting remote from the unit and field wiring of power and control wiring Because of dimension restrictions for shipping some factory mounted VFDs for some large chillers are shipped separate from the unit Mounting supports are on the unit and preassembled cable kits are provided Mounting and wiring on site are the customer s responsibility and can be subcontracted to McQuay International service if desired Fac
78. g Rev Fwd Rev Digital input functions are in conflict Combinations marked with a will x cause an alarm Stop Run Run Jog Jog Fwd Start CF Fwd Rev Jog Fwd Rev Rev Start x x x x Stop CF j Run Dig In ConflictB Run Fwd Run Rev Jog Jog Fwd Jog Rev Fwd Rev More than one physical input has been configured to the same input function Multiple configurations are not allowed for the following input functions Bus Regulation Mode B Dig In ConflictC Speed Select 1 Jog Forward Acc2 Dec2 Speed Select 2 Jog Reverse Accel 2 Speed Select 3 OIM Control Decel 2 Run Forward Stop Mode B Run The calculated IGBT temperature requires a reduction in PWM carrier frequency Drive OL Level 1 If Drive OL Mode 150 is disabled and the load is not reduced an overload fault will eventually occur The calculated IGBT temperature requires a reduction in Current Limit If Drive OL Drive OL Level 2 Mode 150 is disabled and the load is not reduced an overload fault will eventually occur Forward Reverse Run Reverse Flux Amps Ref Rang IntDBRes OvrHeat The drive has temporarily disabled the dynamic braking regulator because the resistor temperature has exceeded a predetermined value The drive autotuning default is Calculate and the value calculated for IR Drop IR Volts Range Volts is not in the range of acceptable values This al
79. g it is corrected Fault Codes A fault condition is also signified by a two or three letter code flashing on the display If a fault occurs the drive coasts to stop and the RUNNING LED turns off The first fault detected is maintained flashing on the display regardless of whether other faults occur after it The fault code remains on the display until it is cleared by the operator using the STOP RESET key or using the fault reset input from the selected control source Error Log The drive automatically stores all fault codes for faults that have occurred in the system error log The error log is accessible through the keypad or the OIM There is no visual indication that there are faults in the log You must access the error log to view the faults The error log holds the 10 most recent faults that have occurred The last fault to occur is the first one to appear on the display when you access the error log The faults in the log are numbered sequentially The most recent fault is identified with the highest number up to 9 Once the log is full older faults are discarded from the log as new faults occur For each entry in the error log the system also displays the day and time that the fault occurred The day data is based on a relative 247 day counter rolls over after 247 55 Scrolling through the error screens will give the day for example 117 which would be 117 days from the 0 day The time is based on a 24 hour clock The firs
80. he desired display item Pressing the ENTER key advances you through each of the displays Note All of the LEDs turn on to indicate the selected reference display Figure 47 Example of a Monitor Mode Display Displays value SPEED VOLTS etc based on selected monitor mode LED MAIN To enter monitor E poe em mode press the One of 6 LEDs Jane 00 BUN j n O tz C auto until the is on CD kw BB ronwano JoG LL Torque C REVERSE PROGRAM LED C Password 7 PROGRAM turns off STOP Displaying the Selected Reference In monitor mode you can display the speed reference speed and frequency or the torque reference the drive is using while it is running RUNNING LED is on JOG LED is off Follow these steps to display the selected reference Step 1 If you are not already in monitor mode access it by pressing the PROGRAM key until the PROGRAM LED turns off Step 2 Press the ENTER key repeatedly to advance through each of the monitor mode LEDs All of the monitor mode LEDs will then turn on at once and the reference will be displayed Note that the displayed speed reference value is scaled based on P 028 The torque reference value is displayed in percent If the selected reference is negative and its value is greater than 999 the SPEED LED will flash The Display The display portion of the keypad display is a four character seven segment LED At drive power up SELF is displayed as the drive performs power up sel
81. iNG Reverse Co voirs CJ remote CoJames C oe RUN EE a O kw EN FORWARD J TORQUE C REVERSE C Password MMA PROGRAM ENTER RELIANCE RESET ELECTRIC Step 3 Press the ENTER key NN sreco C RUNNING Co vots C Remote CIJ aurs C Joc RUN Br Eu Coke EH Forward JoG J TORQUE 7 REVERSE CO Passwors MEN PROGRAM STOP ELECTRIC If no faults have occurred Err will be displayed again If only one fault has occurred the fault code will be displayed as the first entry in the log If more than one fault has occurred the first entry is the latest fault that occurred IOMM 1159 97 IOMM 1159 Step 4 Press the o and the t key The display steps through the error log entries which are numbered 0 through 9 maximum Step 5 Press the ENTER key 11 704 me The display shows the day stamp which can range Reverse MEME sreco C RUNNING Co vots remote from 0 to 248 days C aurs C sos CI auto EN FORWARD CE J Torque C reverse CO Password MN PROGRAM ENTER STOP START RELIANCE m ELECTRIC Step 6 Press the tkey The display shows the time stamp which is based 22 17 la on a 24 hour clock Use the arrow keys to move SPEED RUNNING Rev m btt REMOTE between the day and time data CD aurs 300 Co OD auto Se mmu mn J To aut C Reverse LL Password BEN PROGRAM RESET RELIANCE ELECTRIC Step 7 Press the PROGRAM key which displays the error log
82. kA SCCR 3 Units with 100kAIC Circuit breaker 100kA SCCR General WSC and WDC single and dual compressor and WCC dual compressor chillers can be equipped with Variable Frequency Drives VFD A VFD starts the compressor motor and then modulates the compressor speed in response to load evaporator pressure and condenser pressure as sensed by the chiller microprocessor Despite the small power penalty attributed to the VFD internal losses a chiller can achieve outstanding overall efficiency by using a VFD VFDs are effective when there is a reduced load combined with a low compressor lift lower condenser water temperatures dominating the operating hours The traditional method of controlling centrifugal compressor capacity is by inlet guide vanes Slowing down the compressor thereby reducing the impeller tip speed can also reduce capacity However sufficient impeller tip speed must always be maintained to meet the chiller s discharge pressure requirements The speed control method is more efficient than guide vanes by themselves In actual practice a combination of the two techniques is used The microprocessor slows the compressor to a programmed minimum percent of full load speed as much as possible considering the need for sufficient tip speed to make the required compressor lift Then the guide vanes take over for further capacity reduction This methodology provides the optimum efficiency under any operating condition Inlet g
83. l or observe the drive for subsequent fatal errors before turning off power Fatal fault codes are lost after power loss Table 50 Fatal Fault Codes That Can Be Reset Code Fault Description Fault Cause Corrective Action F3 Encoder power up diagnostic errors Encoder voltage is less than 10V Turn off power to the drive Disconnect the encoder wiring from the terminal strip Turn power to the drive back on If the F3 error does not occur again the problem is in the wiring between the drive and the encoder If the F3 error does occur again the problem is in the regulator board which should be replaced F 60 Option port identification errors The option board could not be identified by the regulator Check the ribbon cable between the regulator board and the option board Check the option board s jumper settings Refer to the appropriate option board instruction manual for more information about the option board F 61 Option board power up diagnostic failure Option board has failed one or more power up diagnostics Check the ribbon cable between the regulator board and the network option board Replace the option board if necessary Refer to the appropriate option board instruction manual for more information about the option board F 62 F 26 Option board runtime errors During operation the option board watchdog failed or handshaking with the d
84. le OIM or on various LEDs Using the Interface The LCD Operator Interface Module is a keypad display that enables programming monitoring and controlling the drive Figure 39 Operator Interface Module Refer to _ Figure 39 for display A CAUTION Stop and start keys are never used to start or stop the drive compressor These functions are controlled by the chiller MicroTech II only Refer to Table 30 for key descriptions Powering Up and Adjusting the LCD OIM The first time the LCD OIM is powered up you will be prompted to select a language for the display text If the Start Up routine has not been completed the Start Up menu is displayed immediately following the language selection screen Selecting the Fast Power Up Feature o The fast power up feature bypasses the initialization screen at power up and the Main Menu is displayed immediately To select this feature select Fast PwrUp Mode from the Display menu Adjusting the Screen Contrast e To adjust the screen contrast select Contrast from the Display menu Resetting the Display o Do not reset the display to factory settings as these may be the display manufacturer s settings and not the McOuay factory settings IOMM 1159 71 Figure 40 Display Description Pl Stopped E Operational Status Line P0 LiguiFlo 2 0 lt Device Selected Error Text Menu Programming Screen or Process User Display Function Key Line Fu
85. le memory write failure Failure to write on non volatile memory Connect CS3000 software to upload parameters or record by hand Then replace regulator board Parameter values will be lost when power is cycled Encoder loss Drive is not detecting feedback from the encoder Check the connection between the encoder and the drive Check the encoder motor coupling Function loss Function loss input on control terminal is opened Check external interlocks at terminals 16 20 High time identification aborted Identification process for B Hz has been aborted See H 019 for identification result High line voltage Input voltage more than 1596 above nominal Check actual line voltage against U 018 or H 021 High Dc bus voltage Continued on next page DC bus voltage too high capacitor protection Deceleration time too short Check input line voltage if necessary add transformer Increase deceleration time P 002 P 018 P 023 versus Maximum Speed Hz P 004 Install DB option with resistors 94 Alarm Description Input phase loss Fault Cause Voltage ripple on DC bus due to missing input phase or an imbalance between phases DC bus voltage too low Line dip too long P 042 Correction Action Verify that proper voltage is being applied to the drive Check all phases Check input voltage line fuses If necessary add transformer Check value of Ride
86. learing Alarms Alarms clear automatically when the condition that caused the alarm is no longer present IOMM 1159 61 HIM Indication The LCD HIM also provides visual notification of a fault or alarm condition on the top line Drive is indicating a fault The LCD HIM immediately reports the fault condition by displaying the following Faulted appears in the status line Fault number Fault name Time that has passed since fault occurred Press Esc to regain HIM control F gt Faulted Auto H Fault F OverVoltage Time Since Fault 0000 23 52 Drive is indicating an alarm The LCD HIM immediately reports the alarm F gt Power Loss Auto condition by displaying the following Hz e Alarm name Type 2 alarms only Main Menu e Alarm bell graphic Diagnostics Parameter Device Select Manually Clearing Faults 1 Press Esc to acknowledge the fault The fault information will be removed so that you can use the HIM 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared 3 After corrective action has been taken clear the fault by one of these methods Press Stop Cycle drive power Set parameter 240 Fault Clear to 1 e Clear Faults on the HIM Diagnostic menu Table 20 Fault Alarm Types Description and Actions NOTE See Table 18 and Table 19 for definition of fault
87. led disable with Fault Config 1 238 The drive output current has exceeded the software current DC bus voltage fell below the minimum value of 407V DC at 400 480V input or 204V DC at 200 240V input Enable disable with Fault Config 1 233 The checksum read from the user set does not match the checksum calculated Check for proper temperature and fan operation Low input voltage can result in increased current load Provide proper input voltage to the drive Low input voltage can result in increased current load Provide proper input voltage to the drive 1 Restore defaults 2 Reprogram parameters 1 Verify input power and connections 2 Check Line Sync board 3 Check AC Line I O board Check load reguirements and Current Lmt Val 148 setting Check for excess load improper DC boost setting DC brake volts set too high Monitor the incoming AC line for low voltage or power interruption Re save user set IOMM 1159 82 Troubleshooting Common Symptoms and Corrective Actions Table 38 No Start from Terminal Block Logic Indication s Flashing red Ready LED Cause s Drive is faulted Corrective Action Clear fault e Press OIM stop key if that OIM is control source Cycle power Set Fault Clear 240 to 1 Toggle terminal block stop or terminal block reset digital input if terminal block is the control source Incorrect operation from the terminal block
88. led from the keypad Not Allowed Flashing On Off On The network connection is lost Not Allowed The drive is receiving its speed reference from the terminal strip input or network option Off Flashing The drive is receiving its speed reference from the local keypad or serial port OIM or CS3000 i e using a manual reference Not Allowed The requested motor direction is forward the actual motor direction is reverse REVERSE LED is on On The motor is running in the forward direction Off Flashing On Off The motor direction is not forward Not Allowed The keypad display is in program mode The keypad display is in monitor mode Parameters cannot be modified from the keypad without entering the correct password into P 051 Programming Disable Note that disabling program changes by means of P 051 does not prevent parameter changes being made from the serial port or the network Parameters can be modified from the keypad Table 47 describes the values that will be displayed when the corresponding monitor mode LED is on Table 47 Monitor Mode LEDs Monitor Mode LED Corresponding Display When LED Is On Actual Values SPEED Motor speed is displayed VOLTS AMPS Drive output volts are displayed This value is not DC bus volts Drive output amps are displayed Hz TORQUE Drive output frequency in hertz is displayed Output pow
89. ler pulses the vanes open for a cumulative 300 seconds default and the LEWT is greater than the active setpoint the mode switches to VFD Running Adjust Speed Open Vanes Otherwise the controller stays in this mode with the speed at Minimum Speed and the vanes being controlled to satisfy the Active LEWT Setpoint VFD Running Adjust Speed Open Vanes The VFD remains on the speed output is modulated to maintain the Active LEWT Setpoint and the vanes are driven to the open position As the load decreases if the speed equals the lift temperature control speed and the LEWT is less than the active LEWT setpoint the mode switches to VFD Running Hold Minimum Speed Adjust Vanes Otherwise the controller stays in this mode Compressor Shutdown The VFD remains on the speed output remains constant and the vanes are driven closed shutdown unload state This state is used during a routine shutdown of the chiller If there is a rapid shutdown caused by a fault alarm the MCR will be immediately de energized the speed signal will go to zero and the compressor state will go directly to Postlube WDC Dual Compressor VFD Operation The MicroTech II controller has the capability to control a dual compressor VFD chiller or multiple stand alone VFD chillers with interconnecting network communications including all compressor staging and load balance functions See OMCentrifMicro II for set up of multiple compressor staging Gene
90. ling water combined in the factory with the compressor oil cooling system IOMM 1159 Freestanding water cooled VFDs require field installed chilled water supply and return piping for the VFD Models VFD 090 and 120 and all LF 2 0 models have an intermediate cooling module field piped between the cooling source and the VFD Water cooled VFD s have a liguid cooled heatsink assembly enabling liguid cooling of the drive though a single inlet and outlet connection point There is a temperature regulating valve located in the drive It must be set to maintain 95 F 35 C leaving coolant temperature This is necessary to prevent condensation from forming in the heatsink Minimum entering coolent temperature is 40 F 4 4 C Codes Standards o VFDs are UL 508 listed e VFDs are designed to comply with the applicable requirements of the latest standards of ANSI NEMA National Electric Code NEC NEPU 70 IEEE 519 1992 FCC Part 15 Subpart J CE 96 Quality Assurance e Every VFD is functionally tested under motor load During this test the VFD is monitored for correct phase current phase voltages and motor speed Correct current limit operation is verified by simulating a motor overload e Scrolling through all parameters verifies proper factory presets The computer port also verifies that the proper factory settings are loaded into the drive e Every VFD s heatsink is tested to verify proper embedding of the tubing for
91. modulated to maintain the Active Setpoint and the vanes are driven to the open position As the load decreases if the Speed eguals the lift temperature control speed and the Leaving Evaporator Water Temperature LEWT is less than the active setpoint minus one half the control band the mode switches to VFD Running Hold Minimum Speed amp Adjust Vanes Otherwise the controller stays in this mode If any capacity override exists the VFD mode changes to the Override Capacity Control mode see Capacity Overrides on page 45 IOMM 1159 VFD Running Hold Minimum Speed amp Adjust Vanes The VFD remains on the command speed is held at Minimum Speed and the vanes are modulated to maintain the Active Setpoint As the load increases if the vane open switch closes and the LEWT is greater than the active setpoint plus the control band the mode switches to VFD Running Adjust Speed amp Open Vanes Otherwise the controller stays in this mode with the speed at Minimum Speed and the vanes being controlled to satisfy the Active Setpoint If any capacity override exists the VFD mode changes to the Override Capacity Control mode VFD Routine Shutdown The VFD remains on the speed output remains constant and the vanes are driven closed This state is used during a routine shutdown of the chiller If there is a rapid shutdown cause by a fault alarm the state switches to VFD Off Rapid Shutdown If there is a fault alarm
92. mon dd yy Master Command Auto Compress Req One Slave Command Stop Status Lead amp Lag Off Lead Unit Slave LagShtdwnDT XX F 4 Menu 11 Screen 1 Control Mode MinVFDSpeedSpt XXX Max Speed Spt XXX y 11 Control Mode hh mm mon dd yy Mode Manual Off etc Menu 11 Screen 2 Control Mode Setpoints This entire screen only 11 Control Mode hh mm mon dd yy appears when a VFD is used Sample Time XXSec Max Spd Step XX t Mod Limit X X F Lock VFD Speed Off On Deadband X X F Lock Speed XXX Menu 13 Screen 1 Motor Amp Setpoints 13 Motor Amp Spts hh mm mon dd yy Amp Reset No Reset Active Spt XXX 4 Reset Signal XX Xma Min Amp Spt XXX Network Spt XXXA Max Amp Spt XXX Menu 13 Screen 2 Motor Amp Setpoints 13 Motor Amp Spts hh mm mon dd yy Soft Load Off Dual Speed Spt XXX Begin Amp Lim XX LagPDRateSpt X X M Ramp Time XXMin y Menu 23 Screen 1 Dual Network Setpoints 23 Dual Net Spts hh mm mon dd yy Slave Address 01 01 Start up Unload LL Mode Auto LagStrtup DT X X F LL SwOver N A 00 00 LagShtdnOffst X X y IOMM 1159 Menu 26 Screen 3 Unit Setup 26 Unit Setup hh mm Mon dd yy Full Load Amp XX Hi MtrCur Enable 4 Vane Open Switch Yes No Str Tran Enable Low Mtr Cur Enable Starter Fit Enable y Table 13 MicroTech 200 VFD Setpoints Sample Time 10 S
93. motor speed is within 1 of the analog output signal from the MicroTech II controller Digital Input ID9 terminal J7 on the compressor controller is wired to the Vane Open switch VO switch that indicates when the vanes are 100 open If the switch is open the status of the vanes is Not Open If the switch is closed the status of the vanes is Open Or If the compressor controller pulses a load output for the vanes to load for a cumulative time of 300 seconds user adjustable the MicroTech II controller will assume the compressor is fully loaded the same as if the V O switch closed one unload pulse will reset the timer Sequence of Operation Compressor Off The VFD is turned off the speed output is 0 and the vanes are closed If the chiller is turned on and if there is a load the chiller will go through its start sequence The MCR will be energized the speed signal will be set to minimum speed and the VFD will start the compressor When the compressor starts it will be in the VFD Running hold speed adjust vanes mode E nm Figure 25 MicroTech II Operator Interface Panel 2 WATER TEMPERATURES PERCENT OUT UNIT ALA IOMM 1159 47 48 VFD Running Hold Minimum Speed Adjust Vanes The VFD remains on the command speed is held at Minimum Speed and the vanes are modulated to maintain the Active LEWT Setpoint As the load increases if the vane open switch closes or the MicroTech II control
94. n severe bodily injury or death VFD drive fault codes are shown in Table 49 To clear a single fault that has occurred so that the drive can be started again correct any problems indicated by the fault code and press the STOP RESET key on the keypad or assert the fault reset from the selected control source P000 Because multiple faults can occur and only the first will be displayed you must access the error log repeatedly in order to view all of the faults that have occurred and correct them Table 49 List of Fault Codes Alarm Description Analog input signal loss Fault Cause P 011 24 or 5 and 4 to 20 mA analog input is below 1 mA Correction Action Verify that P 011 is set correctly Check that the analog input source supply 2 1 mA DC bus charging bypass contactor Charging bypass contactor did not close or contact closure was not sensed by the system Check operation of the bypass contactor Verify the contactor is closing when the proper bus voltage is applied Replace contactor Default parameter restore check sum error During drive operation Regulator board failure After Regulator board replacement Contact McQuay International or replace regulator board Contact McQuay International Earth current failure ground fault Unintentional grounding Check isolation between ground and output terminals Possible leakage current sensor defects replace sensor Non volati
95. nction Key F1 F2 F3 F4 definitions Port peripheral identification Identifies port or peripheral on DPI about which the OIM is displaying information See section B 5 PI loop status PI PI control is active Operating status for example Running Stopped etc Alarm annunciation 3 Alarm has occurred Auto Hand mode status 9 0 0 8 6 E 0 Write protect password status a unlocked password disabled li locked password enabled See section 8 4 Table 30 Key Descriptions Scroll through options or user function keys move cursor to the left Scroll through options or user functions keys move cursor to the right Scroll through options increase a value or toggle a bit ESC PROG E HAND Scroll through options decrease a value or toggle a bit Exit a menu cancel a change to a parameter or toggle between program and process user display screens Enter a menu select an option or save changes to parameter value Enable Hand manual reference control AUTO Release Hand manual reference control Stop the drive Clear a fault if the OIM is the control source Start the drive if the OIM is the control source F1 though F4 Predefined or user configured functions The definition of each key is shown directly above the key on the display See item Dn figure B 3 From the main menu use the lt or gt keys to scroll through the sub menus The
96. nd to it s speed signal The controller will try to control the LEWT setpoint with speed and a control conflict will result Figure 30 MicroTech II VFD Speed Control State Diagram OFF Manual Switch AUTO Remote Switch Shutdown Manual Switch Compressor OFF Compressor Motor Relays CR amp LR are off and VFD Speed 0 Vanes closed ICOMPRESSOR STATE BOX OFF Unit State or OFF Manual Switch OFF Evap Flow Recirculate 30 sec OFF Low Oil Sump Temp OFF Staging Next ON OFF Awaiting Load PRELUBE Vanes Open PRELUBE Timer 30 30 sec PRELUBE 6 sec Startup Transition N ye Loads Vanes to LEWT control and N V reduces speed at a fixed rate to Min N Speed Line k Motor Relay is closed amp VFD Speed Min Vanes Open X Switch Closed or Iu Loading The starting and running continuously Full compressor are bumped VFDSpeed Vanes Load timer to 100 speed expired 5min and MinSpeed Vala Closed reached Min Switch is Speed Line Startup Unloading Closed 1 OR Speed is locked the vanes are unloaded UnitStatus to the Unload timer is Rapid l vol Shutdown l l l Full load flag set and over yA I Full load flag set and Stage Delta T Va over Stage Delta T Likely Capcity override bd d More that and More that one limited and More than one Li j Compressor set
97. ng A fault has occurred Steady A non resettable fault has occurred Red About Alarms Alarms indicate conditions that may affect drive operation or application performance There are two alarm types as described in Table 34 Alarms do not shut down a unit but often lead to a fault that will Table 34 Types of Alarms Alarm Description These alarms alert the operator of conditions that if left untreated may User lead to a fault condition The drive continues to operate during the Configurable alarm condition The alarms are enabled or disabled using Alarm Config 1 259 The status of these alarms is shown in Drive Alarm 1 211 These alarms alert the operator of conditions caused by improper Non programming and prevent the drive from starting until the problem is Configurable resolved These alarms are always enabled The status of these alarms is shown in Drive Alarm 2 212 The drive indicates alarm conditions in the following ways e Yellow LED visible from the front of the drive e Ready LED on the drive cover see Table 32 e Alarm name and bell graphic on the LCD OIM The alarm is displayed as long as the condition exists The drive automatically clears the alarm when the condition causing it is removed e Alarm status parameters Two 16 bit parameters Drive Alarm 1 211 and Drive Alarm 2 212 indicate the status of type 1 and type 2 alarms respectively e Noexternal signal is available for alarms
98. nnection 1 Check communication board for proper connection to external network 2 Check external wiring to module on port 3 Verify external network fault Monitor the incoming AC line for low voltage or line power interruption 1 Check AUX contacts on precharge 2 Check input bit 0 in rectifier parameter 216 to view status of input 3 Check wiring 1 Check AUX contacts on precharge 2 Check input bit 0 in rectifier parameter 216 to view status of input 3 Check wiring Clear the fault or cycle power to the drive Pwr Brd Chksum2 The checksum read from the board does not match the checksum calculated 1 Cycle power to the drive 2 If problem persists replace drive Retfr 1 O Board Rctfr Not OK Rctfr Over Volt Rctfr Pwr Board Continued next page Loss of communication to I O board Board failure A fault was detected in the rectifier other than one specifically decoded The bus voltage is too high Drive rating information stored on the power board is incompatible with the Main Control board The checksum read from the board does not match the checksum calculated Cycle power 1 Cycle power 2 2 ffault repeats replace I O board Look at rectifier parameter 243 to see fault code Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brak
99. o 72 00 1828 80 A C o D i o o 9 E o A AAA A O Ser o s 360 a 180 m 91435 457 20 NOTE Consult the chiller unit dimension drawing for location of the VFD on the chiller IOMM 1159 31 Figure 17 VFD O60LW 072LW Water Cooled Free Standing 6 0 12 0 L 120 1 150 J 1524 304 8 304 8 381 3 0 76 2 3 0 76 2 5 e jo i Note Remove before drilling i ER WIRING FOWER WIRING to prevent metal particles from 12 0 HESS pl CCESS Lk 120 falling into drive components 804 8 a 9 0 1 19 1 60 0 228 6 485 1 1524 OUTLET VALVE 3 4 19 1 NPT INLET VALVE 3 4 19 1 NPT 72 0 1828 8 18 6 473 2 NOTES Power entry for unit mounted VFD is on top left hand Unit Weights Weight Ib kg 1272 577 1272 577 IOMM 1159 32 Figure 18 VFD 060 MW 072 MW Water Cooled Unit Mounted 4 00 1 16 00 e et 4 00 o o o o 38 00 Q ALA cn Es a ea Ga Ga o Ba BA EA ED ES a A A 2 SA HAH ON SS1 SS2 Esc Y Y A Y Ac ic lc y gt Ar Bs aAa AA Sa Ga A A RARA A n RA Ra 72
100. oad data from a HIM set to active drive memory or delete a HIM set Device lt HIM Save data to a User set load data from a User set to active Device User Sets drive memory or name a User set Reset To Defaults Restore the drive to its factory default settings Preferences Menu The HIM and drive have features that you can customize Option Description Drive Identity Add text to identify the drive Change Password Enable disable or modify the password Select the display parameter scale and text for the User Display User Dspy Lines The User Display is two lines of user defined data that appears when the HIM is not being used for programming User Dspy Time Set the wait time for the User Display or enable disable it Select Reverse or Normal video for the Frequency and User Display lines User Dspy Video Return all the options for the User Display to factory default values Reset User Dspy IOMM 1159 70 Operation LF 2 0 A WARNING Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this eguipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life The status of the drive can be viewed on the Operator Interface Modu
101. ocedure start drive and allow procedure to begin Display will change to I Ac when drive is started Change H 020 to OFF to cancel identification and clear I En if desired Low AC input line AC input line is low For SVC indicates DC bus is being regulated No corrective action is required Adjust line voltage parameter H 021 or U 018 to match actual Ac line voltage Vector self tuning Vector self tuning is active enabled and in progress Allow vector self tuning procedure to finish Press keypad STOP RESET to cancel vector self tuning procedure if desired Vector self tuning U 008 On vector self enabled tuning has been enabled but not started Proceed with vector self tuning start drive and allow self tuning procedure to begin Display will change to S Ac when drive is started Change U 008 to OFF to cancel self tuning and clear S En if desired Note Only properly trained and qualified service personnel should change the program or operating parameters IOMM 1159 93 Identifying Fault Codes and Recovering N DANGER DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result i
102. ocnoncncnonanonanoncnnnnnnns 37 MicroTech 200 VFD Control 39 VED Chiller Control States 39 Control Sequence MicroTech 200 40 WDC WCC Dual Compressor VFD Operation41 MicroTech 200 Controller VFD Menu Screens41 MicroTech II VFD Control 47 General Description sss 47 Sequence of Operation 47 Interface Panel Screens MT II 49 Operation VFD011 043 PF755 54 Using the Interface ooooonconinnnccnnocnnoncnanconocnoso 54 Faults and Alarms esee 56 Troubleshooting eeeee 57 Operation 575V VFD029 106 58 Using the Interface esee 58 Using the LEDS enres A Eva er ae 61 Faults and Alarms eee 61 Troubleshooting eee 68 Operation LF 2 0 71 Using the Interface esses 71 Using the LEDs eee 73 About Alarms esee 75 About Faults see TI Troubleshooting eee 83 Operation LF 87 Using the Interface esses 87 Using the LEDs nte 90 Troubleshooting eee 92 CERTIFICATIONS UL508C CAN CSA C22 2 EMC Directive 2004 108E C EPRI SEMI F47 IEC 61000 4 34 TUV Rheinland Manu
103. oft Load Ramp 5 min 1 to 60 min Time period to go from initial load point RLA set in SP 5 to 100 RLA Initial Soft Load Amp Limit 005 20 to 100 Initial amps as of RLA Used with SP 4 and SP 6 Soft Load Enable OFF OFF ON Soft load on using SP 5 and SP 6 or off Maximum Amps 100 40 to 100 RLA above which loading is inhibited Load Limit Unloading is forced at 5 above this value 40 Minimum Amps 20 to 80 RLA below which unloading is inhibited Demand Limit Enable NOTE Shaded settings are VFD related OFF OFF ON O AA jz lt Ss AA ON sets RLA at 0 for 4 mA external signal and at 100 RLA for 20 mA signal IOMM 1159 49 Figure 27 MOTOR VFD Setpoint Screen Panel 2 Unit Status Chiller A SETPOINTS Compressor Status 1 RUN Hold i O F PSI 2 OFF Awaiting Load Lift 100 VFD Speed Demand Limit Enable VFD Speed Zero Lift ON Limits RLA to a value set by the Demand Limit VFD Minimum Speed analog input where Compressor VFD 4mA 0 RLA Oil No Start Differential 20mA 100 RLA OFF The Demand Limit Nominal Capacity input is ignored Maximum LWT Rate Minimum LWT Rate Soft Load Ramp Time Initial Soft Load Limit Soft Load Enable Nameplate RLA Maximum Amps CANCEL Minimum Amps DOWN Demand Limit Enable ENTER HISTORY E SET Table 15 MOTOR Setpoint Settings VFD related settings are 12 through 15
104. oled units reject heat into the surround space as shown below 115 144 171 228 278 332 374 429 Watts Heat Loss 1408 2076 2076 2876 3195 4015 4287 4833 Grounding the Drive Use the following steps to ground the drive Step 1 Open the door of the enclosure Step 2 Run a suitable equipment grounding conductor unbroken from the drive enclosure ground lug to earth ground See figure 2 2 Tighten these grounding connections to the proper torque Step 3 Close the door of the enclosure Safety Precautions Electrical codes require that all equipment VFD motor operator station etc be properly grounded An incoming disconnect must be locked open before wiring or servicing the starter motor or other related equipment The equipment must only be serviced by qualified personnel fully trained and familiar with the equipment The opening of the branch circuit protective device may be an indication that a fault current has been interrupted To reduce the risk of electrical shock current carrying parts and other components of the starter should be inspected and replaced if damaged Equipment is at line voltage when AC power is connected Pressing the Stop push button does not remove AC mains potential All phases must be disconnected before it is safe to work on machinery or touch motor terminals and control equipment parts Cooling Requirements for VFDs Air cooled VFDs all air cooled have self contained cooling
105. or Current Comp Nameplate RLA N A UC SC 4 N A Set Alarms Motor Current Threshold 1 5 1 to 20 UC SA 4 Minimum Amp Setpoint 2 10 5 to 100 UC SC 1 Set Motor 2 Maximum Amp Setpoint 100 0 to 100 UC SC 1 Set Motor 3 VFD Yes yes no UC SU 10 Set Motor 9 Minimum Speed 70 70t0100 UC SU 0 el du Setpoint 11 on Panel 1 setpoint 14 on Panel 2 R L 50 OFF lift Y axis sets the speed UC SU 10 Se a at 0 degrees F Lift point A in Figure 25 Setpoint 12 on Panel 1 setpoint 15 on Panel 2 40 F 100 speed X sets the lift in fant Set Motor axis degrees F at the UC SU 10 12 100 speed point point B in Figure 26 12 NOTES 1 Motor Current Threshold current at which a low current fault occurs 2 Minimum Amp Setpoint Minimum unloading amp setpoint 3 The OITS is the preferred place to adjust setpoints The unit controller is the second choice and the compressor controller should never be used Table 17 MicroTech II Settings and Ranges Multiple Compressor Includes Duals Max Comp On 2 for Dual 1 to 16 Modes 9 Stage Delta 1 F 0 5 to 5 0 F Water 6 Nominal Capacity Unit Design Tons N A Motor 14 Unload Timer 1 Min LWT Rate 0 1 F 0 0 to 5 0 UC SU 7 Motor 7 NOTE 1 This must be set longer than the mech vane speed to unload the compressor Code UC Unit Controller CC Compressor Controller OIT
106. or phase 1 Check user supplied fuses 2 Check AC input line voltage 1 Check motor wiring 2 Check motor for open phase Fan pump mode is selected in Motor Cntl Sel and the ratio of Motor NP Hertz to Maximum Freq is greater than 26 The sum of Maximum Speed and Overspeed Limit exceeds Maximum Freq Raise Maximum Freq or lower Maximum Speed and or Overspeed Limit so that the sum is less than or equal to Maximum Freq IOMM 1159 63 Decel Inhibit OverSpd Limit VHz Neg Slope SpdRef Cnflct BrakResMissing Anlg In Loss MicroWatchdog Fan Cooling AutoReset Lim CAN Bus Fit HeatsinkUndTp Device Change Device Add NvsReadChksum ParamsDefault MotorCalcData Zero Divide Description Drive cannot follow commanded decel due to bus limiting Functions such as Slip Compensation or Bus Regulation have attempted to add an output frequency adjustment greater than that programmed in Overspeed Limit Action if appropriate 1 Verify that input voltage is within specified limits 2 Verify that system ground impedance follows proper grounding techniques 3 Disable bus regulation and or add dynamic brake resistor and or extend deceleration time Remove excessive load or overhauling conditions or increase Overspeed Limit Motor Cntl Sel Custom V Hz amp the V Hz slope is negative Speed Ref x Sel or PI Reference Sel is set to Reserv
107. orne contaminants Do not install the drive above 1000 meters 3300 feet without derating output power For every 91 4 meters 300 feet above 1000 meters 3300 feet derate the output current 1 Verify that the drive location meets the environmental conditions specified on page 6 Floor mounted units should be attached to the floor with the C channel rails provided Clearance The VFDs must be mounted on a level concrete or steel base and must be located to provide adequate service Local codes or the National Electric Code NEC can require more clearance in and around electrical components and must be checked Mounting Make sure that the floor or structural support is adequate to support the weight of the unit shown on the dimension drawing IOMM 1159 Standard NEMA 1 and NEMA 12 VFDs must be installed indoors in an area that is not exposed to direct water spray Do not install in areas where the ambient temperature falls below 32 F 0 C or exceeds 104 F 40 C enclosed or 122 F 50 C open unless this was noted at the time of order placement and special precautions were taken to protect against these abnormal temperatures Heatsink temperatures can run as high as 158 F 70 C during normal operation Do not mount the starter in contact with any material that cannot accept this heat The VFD must be mounted with the heat sink fins oriented vertically in an area that will not experience excessive shock or vibration Air co
108. position Shutdown is ON ommand Speed always gt MinimumSpeed Override Corrects Override corrects Command Speed equals Unit Status Command Speed gt Minimum Speed Pn Minimum Speed Any Shutdown Override Any Override exists exists L FD Running Adj Speed H pes VFD Running Hold Min Open Vanes AND Speed Adj Vanes Speed Modulating to chilled water LEWT gt Command Speed equals Minimum Speed except when driven faster by MinSpeed Spt 5CB Vanes modulating to LEWT Vanes continuously pulsed Open Command Speed gt Locked MinSpeed N AND LEWT lt Spt 50B Unit Status Speed is is any OFF Shutdown Unit Status is any Shutdown VFD locked speed Command Speed equals Locked speed set point except when driven faster by Minimum Speed VFD Routine Shutdown N Command Speed held 0 3 Unit Status Em vanes continuosly pulsed closed Vanes modulating to LEWT isany Shutdown LEWT leaving evap water temperature SEO s CB Control Band 44 IOMM 1159 Capacity Overrides Override Types Listed by Priority The following explains certain control functions and setpoints of interest NOTE Stp Setpoint 1 Max Amp Limit If the motor current is greater than 100 RLA Hold Command Speed pulse vanes closed for two seconds once every two minutes If the motor cur
109. r nameplate data Verify connection between AC Line Sync and AC Line I O boards Low DC Bus The bus voltage is too low Verify proper input voltage Motor Imbalance Phase current displayed in Imbalance Display 221 percentage set in Imbalance Limit 49 for time set in Imbalance Time 50 Clear fault Motor Overload OverSpeed Limit Internal electronic overload trip Enable disable with Fault Config 1 238 Functions such as slip compensation or bus regulation have attempted to add an output frequency adjustment greater than that programmed in Overspeed Limit 83 An excessive motor load exists Reduce load so drive output current does not exceed the current set by Motor NP FLA Remove excessive load or overhauling conditions or increase Overspeed Limit 83 OverVoltage DC bus voltage exceeded maximum value Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the Ulecal time or install dynamic brake option Parameter Chksum Params Defaulted Continued next page The checksum read from the board does not match the checksum calculated The drive was commanded to write default values to EEPROM 1 Restore defaults 2 Reload user set if used 1 Clear the fault or cycle power to the drive 2 Program the drive parameters as needed IOMM 1159 80 Fault Phas
110. r to the VFD than the source from the PCC Z DANGER Even if the upstream disconnect protection device is open a drive or inverter down stream of the line load reactor may feed back high voltage to the reactor The inverter or drive safety instructions must be followed INJURY OR DEATH MAY RESULT IF SAFETY PRECAUTIONS ARE NOT OBSERVED A A DANGER High voltage is used in the operation of line load reactors Use Extreme caution to avoid contact with high voltage when operating installing or repairing equipment containing line load reactors INJURY OR DEATH MAY RESULT IF SAFETY PRECAUTIONS ARE NOT OBSERVED A CAUTION An upstream disconnect protection device must be used as required by the National Electrical Code A CAUTION The frame of line load reactors must be grounded at least at one of the reactor s mounting holes This section is intended for use by personnel experienced in the operation and maintenance of electronic drives inverters and similar types of power electronic equipment Because of the high voltages required by the equipment connected to line reactors and the potential dangers presented by rotating machinery it is essential that all personnel involved in the operation and maintenance of line load reactors know and practice the necessary safety precautions for this type of equipment Personnel should read and understand the instructions contained in this section before installing operating or
111. ral Dual Compressor VFD Operation The first compressor starts and runs as a single VFD compressor controlling speed and vane position based on LEWT Leaving Evaporator Water Temperature When the capacity of the first compressor reaches Full Load and LEWT is greater than stage delta and the slope pull down rate is less than the user adjustable minimum rate setpoint the next compressor will be enabled Dual Compressor Unit Stage Down When Compressor Capacity exceeds calculated system load internal algorithm the next off compressor will be disabled When the next off compressor is disabled the controller will unload the compressor by closing the vanes shutdown unload to unload the compressor The load balance function will make the other compressor follow When the shutdown unload timer expires or the vane close switch closes which ever occurs first the MCR will de energized and the controller will transition to the post lube sequence At the end of the post lube timer the oil pump will be turned off and the controller will transition to the off sequence IOMM 1159 Interface Panel Screens MT Il NOTE This section contains the MicroTech II controller and Operator Interface Panel display screens Figure 25 is the setpoint screen on the initial production panel Panel 1 Figure 26 shows the screen used on the second issue panel Panel 2 that went into production mid 2005 Figure 26 MOTOR VFD Setpoint Sc
112. rce Clean and non corrosive chilled water must be used as the coolant Figure 5 Cooling Module Dimensions All Sizes REMOTE CONTROL CABLE ENTRANCE DRIVE OUTLET FROM CHILLER DRIVE INLET CHILLER VFD Model VF 2037 300 Ibs 136 kg LDW LEVEL WARNING FLOAT SWITCH BREATHER MANUAL FILL 20 000 WARNING DISCONNECT POWER EFORE SERVICING 22 000 FILL TUBE SUPPLY INLET TO CHILLER SUPPLY OUTLET FROM CHILLER BRAZE PLATE i 1 1 Li I L U 1 4 amp mr os VF 2055 300 Ibs 136 kg VF 2080 310 Ibs 136 kg VF 2110 310 Ibs 136 kg 250 Ibs 114 kg 250 lbs 114 kg 260 Ibs 114 kg 260 Ibs 114 kg Operating weight 270 lbs 123 kg 270 lbs 123 kg 290 Ibs 123 kg 290 Ibs 123 kg IOMM 1159 15 16 Figure 6 Field Wiring between VFD and Cooling Module TB2 Terminal Board Terminal Board in in VFD Enclosure Cooling Module TB2 is the terminal board located in the VFD The cooling module has a similarly number terminal board Field wire number to number Maximum Static Pressure 300 psi nominal limited by ball valve and piping pressure ratings Requirements for proper operation of the drive cooling module cooling loop Cooling Loop Liquid 25 inhibited corrosion protected propylene glycol DOWFROST or equivalent concentration by volume with distilled water Non inhibited or silicate containing glycols
113. rcuit the reactors must be removed from the motor circuit in the bypass mode Damage to the motor and other eguipment will result if this warning is not observed Figure 12 Line Reactor Wiring Grounding A stud is provided in the reactor enclosure for grounding the enclosure The enclosure must be grounded A WARNING The frame of line load reactors must be grounded at the designated grounding terminal or one of the reactor mounting holes if no designated grounding terminal is provided The enclosure of reactors supplied in enclosures must be grounded INJURY OR DEATH MAY RESULT IF SAFETY PRECAUTIONS ARE NOT OBSERVED IOMM 1159 VFD Chiller Interconnection Wiring Diagram Figure 13 Control and Power Wiring Diagram MICROTECH CONTROL BOX TERMINALS asv eav UTB1 GND PE 54 il 5 e 85 REMOTE POWER L e ON OFF Q NOTE7 amp NOTE 5 NEUTRAL e eo Ke N NOTE
114. reen Panel 1 Unit Status AUTO SETPOINTS Demand Limit Enable set by the Demand Limit F PSI FEN Status Oil No Start Differential analog input where 4mA O RLA 20mA 100 RLA OFF The Demand Limit input is ignored Lift 100 VFD Speed VFD Speed Zero Lift VFD Minimum Speed Compressor VFD Maximum LWT Rate Minimum LWT Rate Soft Load Ramp Time Initial Soft Load Limit Soft Load Enable VFD related settings are 9 through 12 NIITDNEDTO CEE EEE EEE Password T Technician Level M Manager Level O Operator Level Range 0 to 9999 Tons Description No Default Nominal Capacity Design Password Comments Determines when to shut off a compressor Oil No Start Diff above Evap Temp 40 F 30 to 60 F Minimum Delta T between oil sump temperature and saturated evaporator temperature Lift Max Speed 40 F 30 to 60 F Temp lift at 100 speed cond sat evap sat temp Speed 0 Lift 50 0 to 100 Lift min speed as a of 100 lift SP 10 has priority over this setting Minimum Speed 70 60 to 100 Min VFD speed has priority over SPs 11 amp 12 VFD No No Yes VED on unit or not 0 1 to 5 0 0 5 F min F min Maximum Rate Inhibits loading if LWT change exceed the setpoint value 0 0 to 5 0 0 1 F min F min Minimum Rate Additional compressor can start if LWT change is below setpoint S
115. rent is greater than 105 RLA If Command Speed is 10 greater than Minimum Speed reduce Command Speed by 5 If Command Speed is within 10 of Minimum Speed reduce Command Speed by 2 Close the vanes by one two second pulse Wait 15 seconds to see the if motor current corrects before repeating the process Manual Loading Manual Load setpoint is adjustable from the keypad display If Manual Loading is Enabled Pulse vanes open OR closed to drive the motor current RLA to the Manual Load Setpoint Minimum Amp Limit Minimum Amp setpoint is adjustable from the keypad display Range 5 to 100 in 1 increments Default value is 10 If the motor current RLA is less than Minimum Amp Setpoint hold vane position and command speed If the motor current RLA is 5 below the Minimum Amp Setpoint open vanes and hold command speed Manual Amp Limit User defined capacity limit adjustable from the keypad display from 0 to 100 If the motor current RLA exceeds the Network setpoint hold Command Speed and vane position If the motor current RLA is 5 greater than the Network setpoint reduce command speed by 1 every five seconds If the command speed should be reduced to minimum speed close the vanes Network Capacity Limit Network provided capacity limit setpoint The setpoint is limited in the software from 0 to 100 If the motor current YRLA exceeds the Network setpoint hold Command Speed and vane position If the motor cu
116. rent path to earth ground greater than 25 of drive rating Ground fault level is 50 of the drive s heavy duty current rating The current must appear for 800ms before the drive will fault Hardware problem in the power structure Option board thermistor input is greater than limit Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option 1 Run Autotune 2 Reduce Load 1 Run Autotune 2 Verify settings of Motor Overload Factor and Motor Overload Frequency 3 Reduce load so drive output current does not exceed the current set by Motor NP FLA 1 Verify that maximum ambient temperature has not been exceeded 2 Check fan 3 Check for excess load 4 Check carrier frequency 1 Verify that maximum ambient temperature has not been exceeded 2 Check fan 3 Check for excess load 1 Cycle power 2 Replace drive Check programming Check for excess load improper DC boost setting DC brake volts set too high or other causes of excess current Check for shorted motor leads or shorted motor Check the motor and external wiring to the drive output terminals for a grounded condition 1 Cycle power 2 Replace drive Input Phase OutPhasMissng NP Hz Cnflct MaxFreqCnflct Table continued on next page One input line phase missing Zero current in one output mot
117. rive failed If intermittent check for causes of noise for proper grounding and that outputs are not exceeding rated current capacities Replace the option board if necessary Refer to the appropriate option board instruction manual for more information about the option board IOMM 1159 99 McQuay Training and Development Now that you have made an investment in modern efficient McQuay equipment its care should be a high priority For training information on all McQuay HVAC products please visit us at www DaikinApplied com and click on Training or call 540 248 9646 and ask for the Training Department Warranty All McQuay equipment is sold pursuant to its standard terms and conditions of sale including Limited Product Warranty Consult your local McQuay International representative for warranty details Refer to form 933 430285Y To find your local McQuay International representative go to www DaikinApplied com This document contains the most current product information as of this printing For the most up to date product information please go to www DaikinApplied com McQuay Internationa 2013 Daikin Applied 800 432 1342 www DaikinApplied com IOMM 1159 6 12
118. rload Cooling fan failure Excess motor current V Hz Torque boost too high therm overload level too low Excess load on motor for example at too low speeds Loss of phase connection Check ambient temperature cooling fan minimum clearances around drive Vector Check actual Motor Rated Nameplate Amps U 004 V Hz Check actual current Torque Boost H 003 Check that Power Module is sized correctly Reduce load on motor for example at low frequency Check that Power Module is sized correctly Reduce load on motor e g at low frequency Check output lines to the motor Motor output phase loss Phase lost between drive and motor Check connections and cable of all 3 phases and motor windings Replace any damaged cable Overspeed vector only Missing power module ID connector RPM above 130 Maximum Speed P 004 speed regulator response not optimized Bad or disconnected cable between Regulator and Power Module Check Encoder PPR U 001 Motor Poles U 002 Base Frequency U 003 Motor Nameplate RPM Speed U 005 Check Reg Proportional U 01 2 Integral Gain U 01 3 Check cables between Regulator board and Power Module Power module not Identified Drive parameters have been restored to power up defaults Regulator has not been configured to match Power Module Power Module must be configured by Reliance service personnel Drive power electroni
119. rrent RLA is 5 greater than the Network setpoint reduce command speed by 1 every five seconds When the command speed is reduced to minimum speed close the vanes Max Pulldown Rate Max Pull Down Rate setpoint is an adjustable setpoint range 0 1 to 5 0 F minute in 0 1 F increments default is 1 0 F minute Pulldown rate leaving evap water temp one minute ago minus leaving evap water temp now If the Pulldown rate exceeds the setpoint hold command speed and vane position IOMM 1159 45 46 7 10 Demand Limit Establishes a demand limit between 10 and 100 RLA based on a 4 20 mA signal input If the motor current RLA is greater than the demand limit hold command speed and vane position If the motor current RLA is 5 greater than the demand limit reduce command speed by 1 every five seconds If the command speed is reduced to Minimum Speed close the vanes Softloading Establishes a soft load capacity limit between 10 and 100 RLA based on time from the first start of the day If the motor current RLA is greater than the soft load capacity limit hold command speed and vane position If the motor current RLA is 5 greater than the soft load capacity limit reduce command speed by 1 every five seconds If Command Speed is reduced to Minimum Speed close the vanes Low Evap Pressure If the evaporator refrigerant pressure is less than 38 0 psi default hold speed and vane position If th
120. rst time installation product has not been running Established installation product has been running IOMM 1159 57 Operation 575V VFD029 106 These drives are in the PF 700H family The status of the drive can be viewed on the Human Interface Module HIM or on various LEDs Using the Interface Figure 35 Human Interface Module HIM OC0ve SOS De 0000 Om The interface module can be removed to provide security against tampering with the control To do so first press the ALT key release it and then press the left arrow REMOVE key This procedure allows the module to be removed without causing a fault Then press the tab on top of the module and slide the module upwards and out One function of the module is to program the various parameters that control the VFD chiller operation Programming is to be done only by service technicians who are factory trained and authorized to work on VFDs The module is used by the operator to troubleshoot the drive by viewing faults and to clear faults after corrective action has been taken as explained later in this section IOMM 1159 58 Figure 36 LCD Display Main Menu Display Description F gt PowerLoss _ Auto i Direction Drive Status Alarm Auto Man Information Hz Main Menu Diagnostics Parameter Device Select LEDs Commanded or Output Frequency Programming Monitoring Troubleshooting Illumination of a
121. s must be provided by McQuay International All line and load side power conductors must be copper 2 f VFDs are freestanding then field control wiring between the starter and the control panel is required Minimum wire size for 115 Vac is 12 GA for a maximum length of 50 feet If greater than 50 feet refer to McQuay International for recommended wire size minimum Wire size for 24 Vac is 18 GA All wiring to be installed as NEC Class 1 wiring system and must be made with copper wire and copper lugs only All 24 Vac wiring must be run in separate conduit from 115 Vac wiring 3 Main power wiring between VFD and motor terminals is factory installed when chillers are supplied with unit mounted VFDs 4 Six conductors are used between the VFD and the motor as shown in the wiring diagram Wiring of free standing VFDs must be in accordance with the NEC and connection to the compressor motor terminals must be made with copper wire and copper lugs only 5 LF 2 0 models require field wiring between the VFD and the field mounted cooling module per instruction beginning on page 14 6 For VFD Wye Delta and solid state starters connected to six or multiple of six terminal motors the conductors between the starter and motor carry phase current and their ampacity must be based on 58 percent of the motor rated load amperes RLA times 1 25 Wiring of free standing starter must be in accordance with the NEC and connection to the compressor motor termin
122. s per phase Table 12 575V Incoming Outgoing Terminal Size Range VFD Size Incoming VFD 029 PF700H 1 P 600 MOM 2 3 0 250 MCM Incoming Molded Case Switch Incoming High Int 2 3 0 250 MCM Incoming Ultra GS Int Outgoing Terminals 2 3 0 250 MCM 1 P 600 MCM VFD035 PF700H 1 P 600 MCM 2 2 500 MCM 2 2 500 MCM 2 2 500 MCM 1 P 600 MCM VFD 038 PF700H 1 P 600 MCM 2 2 500 MOM 2 2 500 MCM 2 2 500 MCM 1 P 600 MCM Continued next page IOMM 1159 21 22 VFD Size Incoming Incoming Molded Incoming Incoming Outgoing N High Int Ultra High Int Model Family Power Block Case Switch CB CB Terminals VFD 042 PF700H 1 P 600 MCM 2 2 500 MCM 2 2 500 MCM 2 2 500MCM 1 P 600 MCM VFD 045 PF700H 1 P 600 MCM 2 2 500 MCM 2 2 500 MCM 2 2 500MCM 1 P 600 MCM PF700H 1 P 600 MOM 3 3 0 400 MOM 3 3 0 400 MCM 3 3 3 PF700H 1 P 600 MCM 3 3 0 400 MCM 3 3 0 400 MCM 3 3 0 400 MCM 1 P 600 MCM PF700H 1 P 600 MCM 3 3 0 400 MCM 3 3 0 400 MCM 3 Mounting Optional line reactors are VFD 011 to 027 RMA LRA factory mounted in the VFD enclosure on both free standing and factory mounted units VFD 033 to 043 RMA LRA field mounted and wired in separate NEMA 1 enclosures when the VFD is factory mounted on the chiller and mounted in the VFD when itis fr
123. servicing line load reactors and the drive to which the reactor is connected AGENCY APPROVALS UL 508 File E180243 Component Recognized 1 amp 2400 amps UL 508 File E180243 UL Listed Nema 1 units 1 amp 2400 amps CSA C22 2 File LR29753 13 CSA Certified 1 amp 1200 amps Class H 200 C File E66214 Type 180 36 UL Recognized Insulation System IOMM 1159 23 24 Remote Line Reactor Dimensions Figure 9 Line Reactor Dimensions Models VFD 033 037 D VFD Mi M2 Width W Depth D Height H Weight Connection Model In mm In mm in mm in mm in mm Ibs kg in mm ME 16 0 406 13 5 343 16 9 429 18 4 467 24 0 610 145 66 Front Face Cu Tab 0 41 10 31 Hole VFD 043 14 3 363 17 8 450 17 5 446 20 9 507 31 0 787 262 119 Side Face Cu Tab 0 41 10 31 Hole IOMM 1159 Figure 11 Line Reactor Dimensions LF Models VFD 060 072 VFD Model Width A Height B Depth Cc Mig D Mtg E Mtg Slot F Wire Range in mm in mm in mm in mm in mm in mm 060MW 26 5 673 47 0 1194 24 9 632 21 7 551 23 3 592 0 4x0 9 10x23 See Note 1 072MW 30 5 775 47 0 1194 24 9 632 21 7 551 27 3 693 0 4x0 9 10x23 See Note 1 090LW 120LW See Note 2 See Note 2 NOTES 1 Models 060MW through 072MW reactors ha
124. ss the fault gueue press the F4 key at the process display screen or see Figure 43 to access the fault gueue from the Main Menu Figure 44 Accessing the Fault Oueue PO SP600 stopped i Auto Main Menu Diagnostics Hi ii m it n Monitor Lang i 9 Highlight Diagnostics icon d Fito FAxxxxx View Fault Queue Device Version Accure 2 f OIM Yersion Fault Text String AV Highlight item IOMM 1159 85 Figure 45 Sample Fault Queue Entry FitQ B FHxxxxx FIQ HF xxxxx Fault1 Text String Fault2 Text String Accum Accum hours min sec hours min sec a F1 F2 F3 F1 Clear fault F2 Clear fault queue F3 Drive Reset Appears only when fault is active The drive can be reset as if the power were cycled by pressing the F3 Dres function key while in the View Fault Queue screens The reset function is active only while the drive is stopped During a reset drive communication with peripheral devices will stop until the reset function completes Z CAUTION Pressing F3 Dres will immediately cause the drive to be reset This may result in communication errors in other devices attached to the drive which could result in machine damage IOMM 1159 86 Operation LF The status of the drive can be viewed on the Operator Interface Module OIM or on various LEDs Using the Interface Figure 46 Keypad Display Dri
125. t digits of the clock data represent hours The last two digits represent minutes For example 10 17 PM would be 22 17 The clock can be reset using R030 Elapsed Time Meter Reset See page 46 for details on adjusting the time stamp All entries in the error log and the day and time data are retained if power is lost 92 Identifying Alarm Codes and Corrections VFD drive alarm codes are shown in Table 48 Note that the alarm code will only be displayed for as long as the problem exists Once the problem has been corrected the alarm code will disappear from the display Table 48 List of Alarm Codes Alarm Description Alarm Cause High DC bus The DC bus is charged voltage above the trip threshold If U 018 gt 415 DC bus is above 741 VDC If U 018 lt 415 DC bus is above 669 VDC Correction Action Increase the deceleration time in P 0002 P 018 Install optional snubber resistor braking kit Verify that the AC input is within specification Install an isolation transformer if required Check the actual line voltage against U 018 V Hz identification V Hz identification procedure active procedure is enabled and in progress Allow identification procedure to finish Press keypad STOP RESET to cancel identification procedure if desired V Hz identification H 020 On V Hz procedure identification procedure enabled has been enabled but not started Proceed with V Hz identification pr
126. tory Mounted extra cost option The VFD is mounted on the chiller unit with the back of the VFD against the motor terminal box and wired directly to the motor This arrangement is only available on WSC WDC 063 079 or 087 units Free standing standard Floor mounted separate from the chiller unit and field wired to the compressor motor This is available on all VFDs and is the only VFD arrangement available for WDC WCC 100 and 126 dual compressor units Brackets and cable extra cost option VFDs LF only for WSC 100 to 126 single compressor units may be shipped separately from the chiller unit and furnished with mounting brackets and interconnecting cables for field mounting and connection by others This option must be clearly specified when chillers are ordered since brackets are welded onto the evaporator during its construction Table 5 VFD Mounting Arrangements Chiller Air Cooled LiquiFlo LiquiFlo 2 0 Size Factory Mounted Free Standing Brackets amp Cables Free Standing WSC WDC 063 X WSC WDC 079 X WSC WDC 087 X WSC 100 126 WDC 100 126 WCC 100 126 Receiving Since factory mounted VFDs are mounted and wired at the factory this section will only apply to free standing units The unit should be inspected immediately after receipt for possible damage All McQuay centrifugal VFDs are shipped FOB factory and all claims for handling and shipping damage are the responsibility of the consignee
127. trol board 1 Restore defaults 2 Reprogram parameters 1 Replace control board Press the Start key within 20 seconds of enabing autotune Reset Fault Check connector Check for induced noise Replace I O board or Main Control Board Digital input functions are in conflict Combinations marked with a X will cause an alarm Jog 1 and Jog 2 Acc2 Dec Acc2 Dece2 Jog Jog Jog Fwd Fwd Rev Rev x x A digital Start input has been configured without a Stop input or other functions are in conflict combinations that conflict are marked with a X and will cause an alarm Jog1 and Jog 2 Stop Start CF Run X Run Fwd X Run Jog Jog Jog Fwd Rev 9 Fwd Rev Rev X X X More than one physical input has been configured to the same input function Multiple configurations are not allowed for the following inputs Forward Reverse Speed Select 1 Speed Select 2 Speed Select 3 Run Run Reverse Jog Forward Jog Reverse Bus Regulation Mode B Acc2 Dec2 Accel 2 Decel 2 Run Forward Table continued on next page Stop Mode B IOMM 1159 66 BipolarCnflct 143 TB Man Conflict 147 Start AtPwrUp 148 IntDB OvrHeat 149 Waking Sleep Config Anlg In Loss Description Action if appropriate Parameter 190 Direction Mode is set to Bipolar or Re
128. uide vanes control compressor capacity based on a signal from the microprocessor which is sensing changes in the leaving chilled water temperature The guide vanes vary capacity by changing the angle and flow of the suction gas entering the impeller The impeller takes a smaller bite of the gas Reduced gas flow results in less capacity Compressors start unloaded guide vanes closed in order to reduce the starting effort A vane closed switch VC signals the microprocessor that the compressor vanes are closed IOMM 1159 VFDs can be found on centrifugal chillers with the older MicroTech 200 controller sometimes referred to as MicroTech I or just plain MicroTech or the newer MicroTech I M controller The two MicroTech controller versions are easily differentiated as shown below The MicroTech II panel shown below is the initial version known as Panel 1 Panel 2 shown on page 47 replaced it in mid 2005 MicroTech 200 Control Panel MicroTech II Operator Interface Panel 1 LE E EW zm Liste 450F CATEGORY N ITEM ACTION em S 5 QUICK ACCESS S C Nu points MicroTech Operation and adjustment of the VFD involves settings on both the VFD itself and also to the chiller controller either MicroTech 200 controller or MicroTech II controller This manual consists of a section relating to VFD operation common to both chiller controllers and also separate sections for the settings specific to either of the chill
129. ve Status LEDs AUTO Forward WW sreco RUNNING MAN Reverse CD volts C REMOTE Monitor Mode Cams 0G BUN EE kw UN FORWARD C TORQUE C REVERSE Password LED LL Password MN PROGRAM STOP The front panel keypad display is used to monitor the drive The functions available at the keypad depend on what mode the keypad display is in and what is selected as the drive control source It operates in two modes 1 Monitor Mode the default mode used to monitor specific drive outputs as well as enter the speed or frequency reference for the drive 2 Program Mode used to view and adjust drive parameter values and examine the error log Regardless of the control source selection the keypad display can be used to stop the drive and reset drive faults See Table 46 for a description of the Drive status LEDs Note The STOP RESET key can be disabled by parameter R055 This must be done so that only the chiller MicroTech II controller can stop or start the drive compressor Monitor Mode Monitor mode is the keypad display s default mode during drive operation or it is entered by pressing the PROGRAM key until the PROGRAM LED turns off The following output data can be displayed in monitor mode e Speed e kw e Volts e Torque vector regulation only E a e Selected reference speed or torque e Z IOMM 1159 87 IOMM 1159 To select a value to monitor press the ENTER key until the LED turns on next to t
130. ve copper tabs with 1 0 656 hole 2 Model 090LW and 120LW reactors have 2 0 656 holes and are always shipped loose for field mounting and wiring to the VFD which is always remote mounted from the chiller Wiring is reguired to incoming terminals Reactor Mounting NEMA 1 enclosures designed for floor mounting must be mounted with the enclosure base horizontal for proper ventilation Wall mounting a floor mounted enclosure with the base against the wall will cause the reactor to over heat resulting in eguipment damage Allow a minimum side front and back clearances of 12 inches 305 mm and vertical clearances of 50 inches 1270 mm for proper heat dissipation and access Do not stack enclosures Do not locate the enclosure next to resistors or any other component with operating surface temperatures above 260 F 125 C Select a well ventilated dust free area away from direct sunlight rain or moisture where the ambient temperature does not exceed 45 C 113 F Do not install in or near a corrosive environment Avoid locations where the reactor will be subjected to excessive vibrations Where desirable enclosures may be mounted on vibration isolating pads to reduce audible noise Standard vibration control pads made from neoprene or natural rubber and selected for the weight of the enclosed reactor are effective Reactor Power Wiring The reactor is suitable for use on a circuit capable of delivering not more
131. verse Dis and one or more of the following digital input functions is configured Fwd Reverse Run Forward Run Reverse Jog Forward or Jog Reverse TB Man Ref Sel is using an analog input that is programmed for another function Start At PowerUp is enabled Drive may start at any time within 10 seconds of drive powerup The drive has temporarily disabled the DB regulator because the resistor temperature has exceeded a predetermined value The Wake timer is counting toward a value that will start the drive Check parameter settings to avoid problem Sleep Wake configuration error With Sleep Wake Mode Direct possible causes include drive is stopped and Wake Level lt Sleep Level Stop CF Run Run Forward or Run Reverse is not configured in Digital Inx Sel x MCB PB Config AutoReset Lim MicroWatchdog AutoT Enable Motor Stall AutoT Lm Rot Motor Therm AutoT MagRot MotorCalcData AutoT Rs Stat MotorOverload AutoT Saturat X gt lt X X gt New IO Option Auxiliary In NP Hz Cnflct BipolarCnflct NvsReadChksum BrakResMissng CAN Bus Fit OutPhasMissng OverCurrent Decel Inhibit OverSpd Limit Device Add OverVoltage Device Change Param Chksum Digln CnflctA Digln CnflctB Digln CnflctC ParamsDefault Periph Loss Port DPI Loss Fan
132. with equivalent attenuation 5 Different wire groups should cross at 90 degrees whenever power and control wiring cross Different wire groups should be run in separate conduits Adhere to local electrical codes 8 The National Electrical Code and Canadian Electrical Code require that an approved circuit disconnecting device be installed in series with the incoming AC supply in a location readily accessible to personnel installing or servicing this equipment If a disconnect switch is not supplied with the starter one must be installed 9 Wiring connections are made through the top of the enclosure See the General Wiring section beginning on page 17 and the dimension drawings beginning on page 29 for additional information Wire connections can be determined to best suit specific installations Wire runs should be properly braced to handle both starting and fault currents Size power cable per local electrical codes Long lengths of cable to the motor of over 150 feet must be de rated IOMM 1159 19 Terminal Sizes Compressor Motor Terminals Power wiring connections at the motor are spark plug type terminals with threaded copper bar sized per the following table Table 8 Chiller Compressor Motor Terminal Sizes Type Size Low Voltage to 750 A to 575V CE 063 126 0 635 11 UNC 2A 1 88 in long Figure 8 Power Wiring Over 750 Amps i i Pe ROUTE ALL 3 VA i PHASES IN 4 Y EACHCONDUT i vo 44 3 3
133. ype Auto Reset Description Run After a timed period the drive will restart if the fault is no longer present Resettable The fault can be reset manually as shown below Non resettable Normally requires a drive or motor repair Manually Clearing Faults Step 1 Press the Clear soft key to acknowledge the fault The fault information will be removed so that you can use the HIM 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared 3 After corrective action has been taken clear the fault by one of these methods Press Stop if running the drive will stop Cycle drive power Select the Clear soft key on the HIM Diagnostic folder Faults menu IOMM 1159 56 Troubleshooting For assistance in trouble shooting the VFD contact McQuay International service the contracted service organization or McQuay Technical Response Center at 540 248 0711 What You Need When You Call Tech Support When you contact Technical Support please be prepared to provide the following information Product catalog number and drives series number if applicable Product serial number Firmware revision level Fault code listed in P951 Last Fault Code Installed options and port assignments Also be prepared with A description of your application A detailed description of the problem A brief history of the drive installation Fi

IOMM 1159 Variable Frequency Drives

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