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Carrier 19XRV Air Conditioner User Manual

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1. 28 APPENDIX A WIRING SCHEMATICS cont CHILLER CONTROL SCHEMATIC cont Lem 1 1 TO TB G tz 02 CoM n CR OIL HEATER O 3 OPEN 230 4 O BLK BLK ws 4 CLOSE 2 12 BLK I x T 5 115v BLK BLK ae 1 d I ACTUATOR 1 E HT Momm celi 4 13 iit cec m du ieor eri 230 WIRING MODIFICATION d t COMP R OIL HEATER L J 1 BLK BLU 4 2 anii _ 5 j GAS Bypass d mo 1 RED o EL an BLK BLK I BLK 4 RED amr
2. 485 TERMINATOR OPN UPC JI EX 24V ac gt D Gnd D BACNET gt I MA o LI I Ee CONNECTION n Conductors Only Factory Batt a POWER LED BAS PORT zm 274 el E341 oH e7 CCN Por O BAS 1won CR2032 Tx1 LED 6 CTAC jg Peba Ya 1 D eT 1 LED Bo oy Ne oo i 2 Modbus 0 1 0 0 H H 22 Signal E 7 H H BAS PORT Tx2 LED EIA485 MODE 4 Boe gt O 3 Rx2 LED NM o H 38 4k me TI BAUD RATE en EIA 485 IPM C O DIP SWITCHES JUMPERS CS re e 281 ADDRESS h S o a E ROTARY b a5 m E SWITCHES LISTED 002106 Made USA Endlosed Energy Management Equipment RUN LED ERROR LED Fig A UPC Open Controller Sponsored by ASHRAE American Society of Heating Refrigerat ing and Air Conditioning Engineers 32 APPENDIX B OPTIONAL BACNET COMMUNICATIONS WIRING cont CONFIGURING THE BAS PORT FOR BACNET MS Use the same baud rate and communication setting
3. QA 00 00 00 Seooogoo DOO 000 000 000 000 00 oo 900 009 000 e 000 nj 0808 e b 09 6 5 iO o 4d m 0 cxe 0 0 e 1 g O MI A R L1 SL2 TL3 UT V T2 e eo w 9 LEGEND DESCRIPTION R L1 S L2 T L3 U T1 V T2 W T3 PE Grounding Studs Terminating point to chassis ground for incoming motor shield DC Bus and Brake DC DC BR1 BR2 Terminals PE A and PE B MOV and CMC Jumper Wires DC and DC Bus Voltage Test Points Fig 6 Frame 7 Drive Components O C EET i i LJ N P o o in lt 36 00 REF 40 00 FRONT VIEW Fig 7 Enclosure Dimensions Frames 6 and 7 START UP A DANGER Internal components and circuit boards of the drive are live when the drive is connected to incoming power Coming into contact with this voltage is extremely dangerous and will result in severe personal injury or death The mo
4. The components on the main control board MCB are shown in Fig 14 Note the location of the terminals labeled MCB I O The high pressure switch is wired to these terminals as shown in Fig 15 In the event of a high condenser pressure alarm the connections at these terminals should be checked i gt tightened if necessary Fig 13 Drive Module with Cover Removed A typical wiring schematic is shown in Appendix A DPI PORT 02 COMPUTER PORT DIGITAL INPUT TERMINAL BLOCKS SLOTS 04 amp 05 ETHERNET IP ADDRESS SWITCHES DIGITAL OUTPUT TERMINAL BLOCKS SLOTS 04 amp 05 EMBEDDED ETHERNET IP PORT MCB TERMINALS AUX FAULT HIGH PRESSURE FAULT 1241 L3 E 1 5 I ia 9559 E co E B Bal Cl c E L1 22 E EJ J 1 E 1 1 E ENABLE INPUT Fig 14 MCB Main Control Board Components POWERFLEX 755 MAIN CONTROL BOARD F24V POWER TB4 HIGH PRESSURE 4 1294 1 5 DIO 120 TB1 4 DI COMMON 1 3 DI 24 0 o 24 COEM 25 Located outside of starter connected by field wiring Fig 15 High Pressure Switch Wiring 10 Table 4 ICVC Alert Codes PRE START ALERTS These
5. Tr SUPPORT FROM BELOW j SIDE VIEW Fig 19 Enclosure Access for Removing Drive DRIVE POSITIONED FOR ooooo ooooo ooooo oooo ooooo ooooo ANS Fig 20B Rigging the Enclosure Frame 7 REPLACING THE GATEWAY 20 750 20 OPTION CARD The following are the steps for remov ing and replacing the existing gateway 1 Disconnect power to the drive Before removing the en closure open the access door on the front of the drive See Fig 16 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis is zero before proceeding See Fig 17 Remove the enclosure See Fig 18 Remove the 2 screws securing the mounting plate and re move the mounting plate and COMM card See Fig 21 Mount the new COMM card and mounting plate and at tach with the 2 screws removed in Step 4 See Fig 22 Use the shorter ribbon cable to connect the plug on the COMM card to the connector on the mounting plate See Fig 21 Install the enclosure See Fig 18 MOUNTING PLATE 0 45 0 67 N m 4 0 6 0 Ib in 3 PLACES Fig 22 Mount COMM Card Plate to Drive 25 CHILL PLATE FAN AND INTERNAL FAN REPLACE MENT The following are the steps to re
6. MULTIMETER Fig 3 Check DC Bus Terminals 21P 1 0248 3 3 0 0 C 21P PF755 VFD Voltage Rating 1 460 to 480 v 60 Hz 2 380 to 415 v 50 Hz 3 380 to 400 v 60 Hz 4 401 to 439 v 60 Hz PF755 Full Load Amp Rating Maximum Continuous Amps 0248 248 0361 361 0477 477 For Carrier applications maximum continuous amp ratings are 230 335 and 445 Customer C Carrier Meter Package 0 No Meter Package 1 Analog Meter Package Input Reactor 0 No Input Reactor 1 3 Input Line Reactor Disconnect Breaker Options 3 65 KAIC Capacity Breaker 4 100 KAIC Capacity Breaker Drive Assembly 3 Unit Mount NEMA 1 Liquid Cooled Fig 4 Drive Assembly Catalog Number Nomenclature 00000000000 o e LEGEND DESCRIPTION R L1 S L2 T L3 U T1 VT2 WT3 PE Grounding Studs Terminating point to chassis ground for incoming motor shield DC Bus and Brake DC DC BR1 BR2 Terminals PE A and PE B MOV and CMC Jumper Wires DC and DC Bus Voltage Test Points Fig 5 Frame 6 Drive Components 00000300000000000000000000000000000800000 AANA i A 20 m
7. N ICE BUILD F REMOTE START OIL IN R1 241 240 TB4 1 17 Eu SEE uM ANALOG RAN PRESSURE GE DETAIL RED REFERENCE 4 20mA OIL INT LOCK SHLD OIL_INT LOCK EVAP PUMP CR1 NO CRe NO 1 22 1011 CAP CB COM COMM COND CR DPI SI EA EMI EVAP FU GND JMPR M NC NO PE POD REM ROC SHLD TB EAI DETAIL A DRIVE CONTROL POD SLOT 6 COMMUNICATION RECOMM CARRIER RS485 DFI DPI SI SLOT 6 CARRIER GATEWAY CARD 6 TB4 83 CARRIER FACTORY WIRING CHASSIS GND 5 D SHIELD 4 SIGNAL COM 3 255 RED POS SIGNAL 2 SIGNAL A 1 TERM TRIP ALARM NO 1 22 NC 4VDC DELUXE 1 0 DPI SI SLOT 5 1220 1221 J3 20 COMM CARRIER ADAPTER CAT 20 750 20 TRIP ALARM 1228 1223 1 lee4 256 BLACK S COM 894 WHITE NEG POWERFLEX 755 us 1 20 A E MAIN CONTROL BOARD 20 23 242 1 2 20 RT 2 C 24V POWER Fi PUMP TRIP AARI TB1 5 0010 120VAC COND PUMP CR4 12s0 81 4 1281 1282 ODI COMMON 1 34 TOWER FAN LOW TOWER FAN HIGH ont Stine U 1 4 4 2 1291 1292 1293 DM 184 243 18 19 1 34 1 37 ni COND PUMP IE BLACK
8. PROTECTIVE LIMIT HIGH CONDENSER PRESSURE 235 Condenser Pressure VALUE exceeded limit of LIMIT PROTECTIVE LIMIT COMPRESS SURGE LOW SPEED 236 Compressor Surge Check condenser water temp and flow PROTECTIVE LIMIT SPARE SAFETY 237 gt 5 Safety Device DEVICE PROTECTIVE LIMIT EXCESSIVE COMPR 238 Compressor Surge SURGE Check condenser water temp and flow PROTECTIVE LIMIT TRANSDUCER VOLTAGE FAULT 239 Transducer Voltage Ref VALUE exceeded limit of LIMIT PROTECTIVE LIMIT LOW DISCHARGE SUPERHEAT 240 Check for Oil in Or Overcharge of Refrigerant PROTECTIVE LIMIT RECTIFIER 241 Rectifier Overcurrent OVERCURRENT Fault Check VFD Status LOSS OF WITH CCM MODULE 2421085 of Communica COMMUNICATION tion With CCM Check Comm Connectors POTENTIAL EVAP PRESS TEMP 243 Evaporator Refrig FREEZE UP TOO LOW Temp VALUE exceeded limit of LIMIT POTENTIAL FREEZE UP COND PRESS TEMP TOO LOW 244 Condenser Refrig Temp VALUE exceeded limit of LIMIT Check motor sensors wiring and accuracy Check motor cooling line and spray nozzle for proper operation or restrictions Check for excessive starts within a short time span Check oil heater for proper operation Check for low oil level partially closed oil supply valves or clogged oil filter Check oil cooler refrigerant thermal expansion valves Confirm that TXV thermostatic expansion valve bulb is sec
9. 5 Control Fuses 6 Control Relays CR1 CR5 SECONDARY SIDE TOWARD DOOR 5 20 Nem E3 46 Ib in 2 6 Nem 23 Ib in 2 6 Nem 23 Ib in PLATE FANS Fig 25 Chill Plate and Internal Fans Removal and Replacement Frame 7 LEFT SIDEWALL VIEW FROM INSIDE Fig 26 Assembly Parts 26 LEGEND PF750 Series Precharge Kit PF750 Series Gate Interface PF750 Series Power Interface PowerFlex 750 Series Flange Gasket PF755 Main Control Board PF750 Series Backplane Interface PF750 Series Type 4X 12 Chill Plate Heatsink Fan Kit Chill Plate Fan J1 ENABLE must be removed and the jumper marked J1 SAFETY must be 1 2 3 4 NOTE When replacing the Main Control Board Item No 1 the jumper marked i left in place f 8 Fig 27 Frame 6 Parts CN Aa We DS 6 3 b LEGEND Slot for Gateway Gateway Not Shown PF750 Series Backplane Interface PF750 Series Type 4X 12 Heatsink Fan Kit PF750 Series Power Interface PF750 Series Bus Cap Assembly PF750 Series Power Interface Cable PF750 Series Current Transducer Kit PF750 Series Precharge Kit Slot for 24V I O Module 24V I O Module Not Shown PF755 Main Control Board NOTE When replacing the Main Control Board Item No 1 the jumper marked J1 ENABLE must be removed and the jumper marked
10. J1 SAFETY must be left in place N OO D OO N _ oo Fig 28 Frame 7 Parts 27 APPENDIX A WIRING SCHEMATICS CHILLER CONTROL SCHEMATIC w SHIELD i i AUTO DEMAND LIMIT T 477 4 20mA OPTIONAL gt ee ee Cee miti EXT E CE ee un AUTO CHILLED WATER RESET OPTIONAL s l CLR SHIELD BLK kn Di TL Aimee J OUTPUT 1 1 ELE 600606 2 4 32 1 524321 5 J6 ENT REDD 1 WATER TEMP 3 aun 2 SWITCH POSITION EVAP LVG 3 uto 3 JAA SW ON EXT 4 20mA WATER TEMP Py guo 4 SW OFF EXT 1 5V amp twat COND ENT 5 92 1 1BLU1 WATER TEMP LAA AY tle 2 5 ov COND LVG DE WATER TEMP 8 2 2 Lio YEL 4 G V POSITION in 5 120 FEEDBACK 1 n DIFFUSER ACTUATOR r BLK EVAP REFRIG ud n SHIELD WHT LIOUID TEMP Lay iun 12 3o cun Te j mn 13 am _ INCREASE y OPTIONAL A AV 3 14 10 m V DECREASE 0 15 16 120 COMP R 802 GUIDE ACTUATOR DISCH TEMP 18 AA 1 19
11. THRUST 1o 20 BRG TEMP Pd al e CLR AA teu o on T RED 21 E COOLANT COMPR OIL 5 SOLENOID x BRN SUMP TEMP 3 uu 22 50 taR 8 5 bai P T CEN x 40 x HGBP OPTIONAL WHT COMP 2 uj 7 24 3o BLED MOTOR TEMP 40 NOISE LAA N O SPARED SUPPRESSOR m 20 unt COMP R OIL PUMP nr 1 RED 10 tom XS mn COMP R OIL HEATER SPARE TEMP 2 wn 25 GRY OPTIONAL LVV 4 26 unn SPARE TEMP a2 0 21 OPTIONAL LAAA 28 BLED 1 CCM gt 3 cun 2 t 3 REDD z 3 8 4 OIL PUMP DISCH PRESS em 4 3 umi MEL NOTE GND SHIELDS AT THIS END ONLY I SHIELD SHIELD LOAD RESISTOR RELATIVE ER A 4 5 RED Q RED MUMIDIIY D rn c V 10 ALL SWITCHES SET LOAD RESISTOR TO OFF POSITION 0 7 10K 13 IGRT LOAD RESISTOR 15 A 16 JUMPER 5 815 ALARM Jo LOAD RESISTOR 20 5 N n _ 2 RED RED 5 ICVC 4 36 81 GRY 4 2 1 H ciim 52 3 s 23 CLR 2 6 JUMPE Aa RED 11 STOP wee oa PRESS gt cun 2 RED 3 BLK 7 COND PRESS 3 n 5 3 REDD
12. High volt age may be present on the motor leads even though the motor is not run ning Open the power supply disconnect before touching motor leads or terminals A WARNING DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant liquid and vapor has been removed from chiller Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated Refrigerant in contact with an open flame pro duces toxic gases DO NOT work on high voltage equipment unless you are a qualified elec trician DO NOT WORK ON electrical components including control panels switches VFD or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid state components LOCK OPEN AND TAG electrical circuits during servicing IF WORK IS INTERRUPTED confirm that all circuits are deenergized before resuming work AVOID SPILLING liquid refrigerant on skin or getting it into the eyes USE SAFETY GOGGLES Wash any spills from the skin with soap and water If liquid refrigerant enters the eyes IMMEDIATELY FLUSH EYES with water and consult a physician DO NOT ATTEMPT TO REMOVE fittings covers etc while chiller is under pressure or while chiller is running Be sure pressure is at 0 psig 0 kPa before breaking any refrigerant connection A CAUTION TO AVOID an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before
13. Imbalance in VFD_CONF screen PROTECTIVE LIMIT MOTOR OVERLOAD TRIP 217 Motor Overload Trip Any phase current gt 106 Rated Load Amps Check VFD configurations Can result from significant load side current imbalance when running at full load Check entering condenser water temperature and water flow rate Check Motor Rated Load Amps in VFD_CONF screen PROTECTIVE LIMIT VFD RECTIFIER 2185 VFD Rectifier Temp Check that VFD refrigerant isolation valves are OVERTEMP Exceeded Check Cooling and open VFD Config Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage PROTECTIVE LIMIT VFD INVERTER 2195 VFD Inverter Temp Check that VFD refrigerant isolation valves are OVERTEMP Exceeded Check Cooling and open VFD Config Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage LIMIT is shown on the as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped NOTE ICVC Alarms 212 226 are declared as a result of VFD Faults 15 Table 5 ICVC Alarm Codes cont CHILLER PROTECTIVE LIMIT FAULTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY
14. Pump Off Check Check power supply to pump Pump Transducers Check pump operation Check transducer calibration 228 PROTECTIVE LIMIT LOW OIL PRESSURE 228Low Operating Check transducer wiring and accuracy Pressure VALUE Check Oil Check power supply to pump Pump and Filter Check pump operation Check oil level Check for partially closed service valves Check oil filters Check for foaming oil at start up Check transducer calibration 229 PROTECTIVE LIMIT LOW CHILLED WATER 229Low Chilled Water Flow Perform pump control test FLOW Check Switch Delta P Config Check optional transducer calibration and amp Calibration wiring Check Evaporator Refrigerant Temperature sensor Check chilled water valves Check for evaporator saturation temperature lt 34 if not in Pumpdown Lockout mode Place unit in Pumpdown mode before removing charge 230 PROTECTIVE LIMIT LOW CONDENSER 230Low Condenser Water Perform pump control test WATER FLOW Flow Check Switch Delta P Check optional transducer calibration and Config amp Calibration wiring Check condenser water valves Check for COND PRESS OVERRIDE 5 psig 231 PROTECTIVE LIMIT HIGH DISCHARGE TEMP 231 Comp Discharge Temp Check for closed compressor discharge isola VALUE Exceeded Limit of tion valve LIMIT Check if chiller was operating in surge Check sensor resistance or voltage drop Check for proper wiring Check for proper condenser flow and t
15. Remote Reset Check for proper wiring to CCM connector J4 Sensor OPTION SENSOR AUTO CHILLED WATER 156 Sensor Fault Option Check sensor resistance or voltage drop FAULT RESET Disabled Auto Chilled Water Check for proper wiring to CCM connector J5 Reset OPTION SENSOR AUTO DEMAND LIMIT 157 gt Fault Option Check sensor resistance or voltage drop FAULT INPUT Disabled Auto Demand Limit Check for proper wiring to CCM connector J5 Input SENSOR ALERT SPARE TEMPERATURE 158 gt 5 Temperature 1 Check sensor resistance or voltage drop 1 VALUE exceeded limit of Check for proper wiring to CCM connector J4 LIMIT Check Spare Temp 1 Limit in SETUP1 screen LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 13 Table 4 ICVC Alert Codes cont CHILLER ALERTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE M SSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 159 SENSOR ALERT SPARE TEMPERATURE 159 gt 5 Temperature 2 Check sensor resistance or voltage drop 2 VALUE exceeded limit of Check for proper wiring to CCM connector J4 LIMIT Check Spare Temp 2 Limit in SETUP1 screen 161 LOSS OF WITH WSM 161 WSM Cool Source settings WSMDEFME screen COMMUNICATION Loss of Commu
16. VALUE Check that VFD refrigerant isolation valves ALERT INVERTER TEMP exceeded limit of LIMIT are open Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage LIMIT is shown on the ICVC as temperature pressure voltage etc predefined or selected by the operator as an override or an alert VALUE is the actual pressure temperature voltage etc at which the control tripped 11 Table 4 ICVC Alert Codes cont NORMAL RUN WITH OVERRIDES PRIMARY SECONDARY MESSAGE MESSAGE HIGH CONDENSER PRESSURE ICVC FAULT STATE 120 121 122 123 124 125 126 127 128 PRIMARY CAUSE 1205 Condenser Pressure VALUE exceeded limit of LIMIT RUN CAPACITY LIMITED RUN CAPACITY LIMITED HIGH MOTOR TEMPERATURE 121 Comp Motor Winding Temp VALUE exceeded limit of LIMIT RUN CAPACITY LIMITED LOW EVAP REFRIG TEMP 122 Evaporator Refrig Temp VALUE exceeded limit of LIMIT RUN CAPACITY LIMITED 123 gt 5 Prevention Override Lift Too High For Compressor HIGH COMPRESSOR LIFT RUN CAPACITY MANUAL GUIDE VANE 124 Run Capacity Limited LIMITED TARGET Manual Guide Vane Target RUN CAPACITY LOW DISCHARGE No Alert message LIMITED SUPERHEAT RUN CAPACITY HIGH RECTIFIER TEMP 1265 Rectifier Temperature LIMITED VALUE exceeded limit of LIMIT RUN CAPACITY MANUAL SPEED N
17. etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped OUT OF RANGE SENSOR ICVC FAULT PRIMARY SECONDARY ani MESSAGE MESSAGE PRIMARY PRIMARY CAUSE ADDITIONAL CAUSE REMEDY SENSOR FAULT LEAVING CHILLED WATER 260 gt 5 Fault Check sensor resistance or voltage drop Leaving Chilled Water Sensor Check for proper wiring Check for disconnected or shorted wiring 261 SENSOR FAULT ENTERING CHILLED 261 gt Fault Check Check sensor resistance or voltage drop WATER Entering Chilled Water Check for proper wiring Sensor Check for disconnected or shorted wiring 262 SENSOR FAULT CONDENSER PRESSURE 262 gt Fault Check Check sensor wiring Condenser Pressure Sensor Check for disconnected or shorted wiring Check for condensation in transducer connector 263 SENSOR FAULT EVAPORATOR 263 Sensor Fault Check Check sensor wiring PRESSURE Evaporator Pressure Sensor Check for disconnected or shorted wiring Check for condensation in transducer connector 264 SENSOR FAULT COMPRESSOR BEARING 264 gt Fault Check Check sensor resistance or voltage drop TEMP Comp Thrust Brg Temp Sensor Check for proper wiring Check for disconnected or shorted wiring 265 SENSOR FAULT COMPRESSOR MOTOR 265 Sensor Fault Check Check sensor resistance or voltage dro
18. than the circuit breaker may be used Table 1 Wire Lugs CIRCUIT STANDARD DUC CABLE ALTERNATE BREAKER LUG RANGE ABB LUG RANGE 65 KAIC Standard 3 2 0 400 2 250 500 K6TH 100 KAIC Sn MCM MCM Optional Verify Installation Record the following job information 1 Job Name 2 Job Number 3 City 4 State 5 Zip Code Record the following nameplate information 1 From the Allen Bradley nameplate Fig 1 located inside the VFD enclosure a Allen Bradley ID or CAT NO b Allen Bradley Serial Number c Carrier Part Number 2 From the machine nameplete Fig 8 located inside the VFD enclosure a Chiller Serial Number Chiller Model Motor rated load amps Motor nameplate rpm Motor nameplate kW Motor nameplate voltage IPWM pulse width modulation frequency Voltage 3 From the drive module label Fig 9 located on the drive module a Model or Cat Number b Serial Number 4 From the ICVC control panel screen a Carrier Part Number and Revision b ICVC Software Number Rockwell PowerFlex 750 drive start up must be registered on the Rockwell website Rockwell Registration site URL http www automation rockwell com warp default asp Carrier A United Technologies Company MODEL NUMBER SERIAL NUMBER MACHINE NAMEPLATE SUPPLY DATA VOLTS PHASE HERTZ LOCKED ROTOR AMPS OVERLOAD TRIP AMPS MAX FU
19. 220 PROTECTIVE LIMIT GROUND FAULT 220 Ground Fault Trip Check for condensation on motor terminals Check Motor and Current Check motor power leads for phase to phase or Sensors phase to ground shorts Disconnect motor from VFD and megger motor Call Carrier Service 221 PROTECTIVE LIMIT UNUSED 221 5UNUSED 222 PROTECTIVE LIMIT LINE FREQUENCY TRIP 222 gt Line Frequency If operating from a generator check generator VALUE exceeded limit of size and speed LIMIT Check Power Supply Check utility power supply 223 WITH VFD GATEWAY 223 gt 1055 of SIO Comm with Check VFD communication wiring and COMMUNICATION MODULE VFD Gateway Check VFG connectors on VFD Gateway and DPI board Module and Power Check for compatibility between ICVC and Gateway software 224 PROTECTIVE LIMIT VFD COMMUNICATIONS 224 gt 1055 of DPI Comm with Check VFD communication wiring and VFD Gateway Check VFG to connectors VFD Comm Check status lights on DPI Communications Interface Board Call Carrier Service 225 PROTECTIVE LIMIT MOTOR CURRENT 225 Motor Current Imbal Check Motor Current 96 Imbalance in IMBALANCE ance Check VFD Fault VFD CONF screen History for Values 226 PROTECTIVE LIMIT LINE PHASE REVERSAL 226 Line Phase Reversal Reverse connections of any two line conductors Check Line Phases to circuit breaker 227 PROTECTIVE LIMIT PRESS SENSOR 227 Oil Pressure Delta Check transducer wiring and accuracy VALUE
20. 485 terminator has no polarity associated with it To order a 485 terminator consult Commercial Products i Vu Open Control System Master Prices MS TP WIRING RECOMMENDATIONS Recommen dations are shown in Tables C and D The wire jacket and UL temperature rating specifications list two acceptable alterna tives The Halar specification has a higher temperature rating and a tougher outer jacket than the SmokeGard specification and it is appropriate for use in applications where the user is concerned about abrasion The Halar jacket is also less likely to crack in extremely low temperatures NOTE Use the specified type of wire and cable for maximum signal integrity Table C MS TP Wiring Recommendations SPECIFICATION RECOMMMENDATION Cable Single twisted pair low capacitance CL2P 22 AWG 7x30 TC foam FEP plenum rated cable Conductor 22 or 24 AWG stranded copper tin plated Insulation Foamed FEP 0 015 in 0 381 mm wall 0 060 in 1 524 mm O D Color Code Black White Twist Lay 2 in 50 8 mm lay on pair 6 twists foot 20 twists meter nominal Shielding Aluminum Mylar shield with 24 AWG TC drain wire Jacket SmokeGard Jacket SmokeGard PVC 0 021 in 0 5334 mm wall 0 175 in 4 445 mm O D Halar Jacket E CTFE 0 010 in 0 254 mm wall 0 144 in 3 6576 mm O D DC Resistance 15 2 Ohms 1000 feet 50 Ohms km nominal Capacitance 12 5 pF ft 41 pF meter nominal conductor to conductor Characteristic Impedance 100 Ohms
21. Failure to observe these precautions could result in bodily injury DO NOT VENT refrigerant relief valves within a building Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI ASHRAE 15 American National Standards Insti tute American Society of Heating Refrigerating and Air Conditioning Engineers The accumulation of refrigerant in an enclosed space can dis place oxygen and cause asphyxiation PROVIDE adequate ventilation in accordance with ANSI ASHRAE 15 especially for enclosed and low overhead spaces Inhalation of high con centrations of vapor is harmful and may cause heart irregularities uncon sciousness or death Misuse can be fatal Vapor is heavier than air and reduces the amount of oxygen available for breathing Product causes eye and skin irritation Decomposition products are hazardous DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose Oxygen gas reacts violently with oil grease and other common substances NEVER EXCEED specified test pressures VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate DO NOT USE air for leak testing Use only refrigerant or dry nitrogen DO NOT VALVE OFF any safety device BE SURE that all pressure relief devices are properly installed and func tioning before operating any chiller THERE IS A RISK OF INJURY OR DEATH by electrocution
22. OPTIONAL BACNET COMMUNICATIONS WIRING cont Table G Network Points List POINT DESCRIPTION ron ZONE 3 OBJECT NAME Tat Current Alarm Sate a om wa amo Aetive Demand Limit DEV LM RW 3 NA meoo ave denim Actual Guide Vane Postion GV POS R NA oero awr opi Actual FD Speed veo ACT R NA ocimo wi I Cale Evap Sat Temp EN R F NA 4626 et Chilled Water Deadband 10 05 020 cwdb_1 Chilled Water Delta P CHWPD R F NA 67 42 5 chwpd_1 Chilled Water Delta T cHWDT R chw dt 1 Chilled Water Pump CHP R NA OF BV chip 1 Chilled Water Temp CHWTMP R NA 400245 217 chwtmp 1 Chiller Start Stop chil s s 1 Comp Discharge Temp CMPD R NA 40025 avas cmpd_1 Comp Motor Winding Temp MrRW R NA 40 24 wao mtrw_1 CompThrustBrg Temp R NA 40 24 w20 mtrb_1 Cond Water Flow R NA NO Noves Bve cdw_flow_1 Cond Water Pump COP NA or 7 cdp 1 Condenser Pressure cm R Ps NA 67090 1 Condenser Refrig Temp R F NA 40t0245 AV 22 ert 1 CondenserWaterDetaP CDWPD R PS 67to420 Av23 cdwpd 1 Control Point m NA v lcw stpt 1 Current CHW Setpoint SWEET Demand Level 1 Demand Level 2 Deman
23. RED RED RED ORM 50 wey n 12 13 lt Bii BLK zave p I 2avac i 0 BLK 1 GRN TO VFD lt T BRN BRN BRN BRW BRW BRM BLU 1 COMP R DISCH RED e HIGH PRESS e 800 1 BLED 4 RED HGBP lt RED A 1 I 1 SOLENOID RED RED RED 1 Ig EET x CLR SHOWN WIRED FOR 115v BLK BRN e 23 I I R GRN 7 959 Z WHT wc BLU COMP R OIL PUMP MOTOR RED WINDING HIGH TEMPERATURE LU RED WHT e YEL SOLENOID RED w BLK GRY BLK BLK YEL a x I 230 WIRING MODIFICATION L HOT GAS BYPASS FR al 6 HT EXCH YEL 5 o N VOLTAGE 2 5 2 BLK 1 172 HP PER JOB BLK N M COMP R OIL REOM T x PUMP MOTOR RED 2 Ks RED N LEGEND CB Circuit Breater enotes Control Panel Terminal CCM Chiller Control Module HGBP Hot Gas Bypass A Denotes Oil Pump Terminal ICVC International Chiller Visual Controller D P Paral Terminal RHS Relative Humidity Sensor L enotes Power Panel Termina UPC Universal Protocol Controller Denotes Motor Starter Panel Conn VFD Variable Frequency Drive Denotes Component Terminal e Wire Splice gt gt Denotes Conductor male Fema
24. alerts only delay start up When alert is corrected the start up will continue No reset is necessary ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 100 PRESTART STARTS LIMIT 100 gt compressor starts Depress the RESET softkey if additional start ALERT EXCEEDED 8 in 12 hours is required Reassess start up requirements 101 PRESTART HIGH BEARING 101 Comp Thrust Brg Temp VALUE Check oil heater for proper operation ALERT TEMPERATURE exceeded limit of LIMIT Check for low oil level partially closed oil sup ply valves clogged oil filters Check the sensor wiring and accuracy Check Comp Thrust Brg Alert setting in SETUP1 screen 102 PRESTART HIGH MOTOR 102 Comp Motor Winding Temp Check motor sensors for wiring and accuracy ALERT TEMPERATURE VALUE exceeded limit of LIMIT Check motor cooling line for proper operation or restrictions Check for excessive starts within a short time span Check Comp Motor Temperature Override setting in SETUP1 screen 103 PRESTART HIGH 103 Comp Discharge Temp VALUE Allow discharge sensor to cool ALERT DISCHARGE exceeded limit of LIMIT Check sensor wiring and accuracy TEMP Check for excessive starts Check Comp Discharge Alert setting in SETUP1 screen 104 PRESTART LOW 104 Evaporator Refrig Temp VALUE Check transducer wiring and accuracy ALERT REFRIGERANT exceeded limit of LIMIT Check for low chilled fluid
25. for oil loss or excessive refrigerant If oil level is low refrigerant charge may be too low resulting in ineffective oil reclaim Excessive refrigerant charge may cause liquid carryover into compressor Check calibration of evaporator pressure and con denser pressure sensors Check calibration of compressor discharge temper ature sensor Check for high water temperatures or changes in water flow rates Check wiring and control power to CCM Confirm that all CCM SW1 switches are in the OFF position Check for proper refrigerant charge Check float valve operation Check for proper fluid flow and temperature Confirm that condenser water enters bottom row of condenser tubes first Check Evaporator Refrigerant Temperature sensor Check for division plate gasket bypass Check for fouled tubes Condenser water too cold or chiller shut down with brine below 32 F in cooler so equalization tempera ture in chiller approached 32 F Check condenser pressure transducer Check refrigerant charge LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 17 Table 5 ICVC Alarm Codes cont CHILLER PROTECTIVE LIMIT FAULTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE M SSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 245 PR
26. or accessory Navigator handheld device Configuration CCN A CCN Address Configuration CCN CCN B CCN Bus Number The following configurations are used to set the CCN Ad dress and Bus Number in the UPC Open controller These con figurations can be changed using the accessory BACview dis play Navigation BACview CCN Home Element Comm Stat Element 1 Bus 0 TROUBLESHOOTING If there are problems wiring or addressing the UPC Open controller contact Carrier Technical Support Fig F BACview Device Connection 35 APPENDIX OPTIONAL BACNET COMMUNICATIONS WIRING cont COMMUNICATION LEDS The LEDs indicate if the controller is communicating with the devices on the network See Tables E and F The LEDs should reflect communication traffic based on the baud rate set The higher the baud rate the more solid the LEDs become See Fig B for location of LEDs on UPC Open module REPLACING THE UPC OPEN BATTERY The UPC Open controller s 10 year lithium CR2032 battery provides a minimum of 10 000 hours of data retention during power outages IMPORTANT Power must be ON to the UPC Open when replacing the battery or the date time and trend data will be lost Remove the battery from the controller making note of the battery s polarity Insert the new battery matching the battery s polarity with the polarity indicated on the UPC Open controller NETWORK POINTS
27. servicing Check the DC bus voltage at the Power Terminal Block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three mea surements THE USER is responsible to conform with all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment THIS DRIVE contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed For static control procedures reference Rockwell publication Guarding Against Electrostatic Damage or any other applicable ESD protection handbook DO NOT alter the setting of any jumper Failure to observe this precaution could result in damage to or destruction of the equipment USE OF power correction capacitors on the output of the drive can result in erratic operation of the motor nuisance tripping and or permanent dam age to the drive Remove power correction capacitors before proceeding Failure to observe this precaution could result in damage to or destruction of the equipment MOST CODES require that upstream branch circuit protection be pro vided to protect input power wiring If fuses are chosen as the protection method refer to th
28. 00 Serial Number 13865136 Fig 9 Drive Module Label Configure the VFD configurations required by the VFD are supplied by the ICVC through the VFD Gateway Any configuration changes necessary and possible are made on the ICVC screens A complete set of configurations 15 transmit ted to the VFD each time the controls are powered up The following is from the 19XRV PIC III ICVC screen Pa rameters in italics are to be entered or confirmed at start up Pa rameters in bold are to be changed only after consulting with Carrier service engineering See Table 2 Table 2 VFD Configurations PARAMETER DEFAULT VALUE Motor Nameplate Voltage 460 Compressor 100 Speed Line Freq 60 Hz No 50 Yes Rated Line Voltage 460 Rated Line Amps 200 Rated Line Kilowatts 100 Motor Rated Load kW 100 Motor Rated Load Amps 200 Motor Nameplate Amps 100 Motor Nameplate RPM 3456 Motor Nameplate KW 100 Inverter PWM Frequency 0 4 kHz 1 1 2 kHz Skip Frequency 1 Hz 102 0 Skip Frequency 2 Hz 102 0 Skip Frequency 3 Hz 102 0 Skip Frequency Band Line Hz 0 0 Voltage Imbalance 10 Line Volt Imbalance Time sec 10 Line Current Imbalance 40 Line Current Imbal Time sec 10 Motor Current Imbalance 40 Motor Current Imbal Time 10 Increase Ramp Time sec 30 Decrease Ramp Time sec 30 Single Cycle Dropout DSABLE ENABLE DSABLE Parameters marked with an are not downloadable to the VFD but are used in other calc
29. 19XRV with PIC III Controls Rockwell PowerFlex 755 VFD Option Start Up and Service Instructions SAFETY CONSIDERATIONS Centrifugal liquid chillers are designed to provide safe and reliable service when operated within design specifica tions When operating this equipment use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel Be sure you understand and follow the procedures and safety precautions contained in the chiller instructions as well as those listed in this guide A 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 DO NOT install modification kits with power applied to the drive Discon nect and lock out incoming power before attempting such installation or removal Failure to observe this precaution could result in severe bodily injury or loss of life UNUSED WIRES in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages Also if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled to eliminate the possible shock hazard from cross coupled motor leads
30. Catalog No 04 53190012 01 Printed in U S A Form 19XRV 3SS Pg 1 711 841 Replaces New CONTENTS Page SAFETY CONSIDERATIONS 1 INTRODUCTION 2 ABBREVIATIONS AND EXPLANATIONS 2 Required Publications 2 Getting Assistance from Rockwell Automation 2 IDENTIFYING DRIVE COMPONENTS 2 5 Opening the VFD Access Door 3 Drive Assembly Catalog Number 3 Components and Physical Data 3 START UP oue ERE 5 8 Alternate Wire Lugs 5 Verify Installation 5 Configure the VFD 6 Commissioning the Unit 6 Check Internal Jumpers 7 8 27 Troubleshooting the 8 ICVC ALERT CODES 1 ALARM CODES TEST EQUIPMENT NEEDED TO TROUBLESHOOT VERIFYING THAT DC BUS CAPACITORS ARE DISCHARGED HIGH TEMPERATURE ALARMS MAIN CONTROL BOARD MCB COMPONENTS Checking Power Modules and Motor Input with Input Power Off 22 Servicing the 23 REMOVING THE DRIVE RIGGING THE ENCLOSURE REPLACING THE GATEWAY A B20 750 20COMM OPTION CARD CHILL PLATE FAN AND INTERNAL FAN REPLACEMEN
31. E exceeded limit of Check for proper wiring LIMIT Check for excessive starts Check Comp Discharge Alert setting in SETUP1 162 163 SENSOR ALERT Screen 168 SENSOR ALERT HUMIDITY SENSOR 168 Sensor Fault Check Check humidity sensor wiring on CCM connec INPUT Humidity Sensor Input Sensor tors J3 and J5 CCM switch SW2 1 must be in OFF position Check Humidity Sensor Input in Controls Test LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 14 Table 5 ICVC Alarm Codes CHILLER PROTECTIVE LIMIT FAULTS ICVC FAULT STATE 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 PRIMARY SECONDARY MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY PROTECTIVE LIMIT RECTIFIER POWER 200 Rectifier Power Fault Malfunction within VFD Power Module FAULT Check VFD Status Call Carrier Service PROTECTIVE LIMIT INVERTER POWER FAULT 201 gt Inverter Power Fault Malfunction within VFD Power Module Check VFD Status Call Carrier Service PROTECTIVE LIMIT MOTOR AMPS 202 Motor Amps Not Check main circuit breaker for trip Increase SENSED Sensed Average Load Current Imbalance in VED CONF screen Current VALUE FA
32. ILURE TO START MOTOR ACCELERATION 203 Motor Acceleration Fault Check that inlet guide vanes are fully closed at Average Load Current start up VALUE Check Motor Rated Load Amps in VFD CONF screen Reduce unit pressure if possible FAILURE TO STOP VFD SHUTDOWN FAULT 2049VFD Shutdown Fault VFD Circuit Board malfunction Check Inverter Power Unit Call Carrier Service PROTECTIVE LIMIT HIGH DC BUS VOLTAGE 205 gt DC Bus Voltage Verify phase to phase and phase to ground line VALUE exceeded limit of voltage Monitor AC line for high transient volt LIMIT age conditions VFD Circuit Board malfunction Call Carrier Service PROTECTIVE LIMIT VFD FAULT 2065 VFD Fault Code See VFD Fault Code description and corrective VALUE Check VFD Fault action Code List PROTECTIVE LIMIT HIGH CONDENSER 207 High Cond Pressure Check Compressor Discharge High Pressure PRESSURE trip VALUE exceeded Switch switch wiring and accuracy Trippoint Check for high condenser water temperatures low water flow fouled tubes Check for division plate gasket bypass Check for noncondensables in refrigerant PROTECTIVE LIMIT EXCESSIVE MOTOR 208 gt Load Current Check Motor Rated Load Amps in VFD_CONF AMPS VALUE exceeded limit of screen Percent Load Current gt 110 LIMIT Check Motor Rated Load Amps setting PROTECTIVE LIMIT LINE CURRENT 209 Line Current Imbal Check phase to phase and phase to grou
33. LIST The points list for the control ler is shown in Table Table E LED Status Indicators LED STATUS Lights when power is being supplied to the controller The UPC Open controller is protected by internal solid state polyswitches on Power the incoming power and network connections These polyswitches are not replaceable and will reset themselves if the condition that caused the fault returns to normal Rx Lights when the controller receives data from the network segment there is an Rx LED for Ports 1 and 2 Tx Lights when the controller transmits data to the network segment there is a Tx LED for Ports 1 and 2 Run Lights based on controller status See Table F Error Lights based on controller status See Table F Table F Run and Error LEDs Controller and Network Status Indication RUN LED STATUS 2 flashes per second Normal 2 flashes per second Five minute auto restart delay after system error 2 flashes per second Controller has just been formatted 2 flashes per second Controller is alone on the network 2 flashes per second Exec halted after frequent system errors or control programs halted 5 flashes per second Exec start up aborted Boot is running 5 flashes per second Firmware transfer in progress Boot is running 7 flashes per second 14 flashes per second 36 7 flashes per second alternating with Run LED Ten second recovery period after brownout 14 flashes per second alternating with Run LED Brownout APPENDIX B
34. OTECTIVE LIMIT HIGH VFD SPEED 245 4Actual VFD Speed Actual VFD Speed on COMPRESS screen must exceeded limit of Target VFD not exceed Target VFD Speed by more than Speed 10 10 246 PROTECTIVE LIMIT INVALID DIFFUSER 246Diffuser Control Invalid Check 25 50 and 75 Guide Vane and Dif CONFIG Configuration Check SETUP2 fuser Load Point entries in SETUP2 screen Entries 24 7 PROTECTIVE LIMIT DIFFUSER POSITION 247Diffuser Position Fault Confirm that Diffuser Option in SETUP 2 screen Check Guide Vane Diffuser has not been Enabled if compressor does not Actuator have a split ring diffuser May indicate rotating stall condition Check rotating stall transducer wiring accuracy and sealing Check diffuser schedule and guide vane sched ule in SETUP2 screen Check for proper operation of diffuser and inlet guide vane actuators including inlet guide vane calibration Check diffuser actuator coupling for rotational slip Check RC snubber on CCM J4 23 and J4 24 Check 4 3k ohm resistor between CCM termi nals J3 7 and J3 8 Check for electrical noise in CCM Diffuser Pres sure wiring Do not continue to operate com pressor except for diagnostic purposes 248 PROTECTIVE LIMIT SPARE TEMPERATURE 1 248 gt 5 Temperature 1 Spare Temperature Enable and Spare 1 VALUE exceeded limit of Temperature Limit in SETUP1 Screen LIMIT 249 PROTECTIVE LIMIT SPARE TEMPERATURE 1 249 gt 5 Temperature 42 Chec
35. P SEE BROWN 1 1 24 es 96 27 24V COMMON x 2 W WC cong a TOWER FAN TOWER FAN LOW LOW 1 28 CRS NO 1 29 1340 NC 1360 TOWER FAN CR6 NO 1 29 HIGH LEGEND Capacitor Circuit Breaker Common Communication Condenser Control Relay Internal Communication Protocols Connections Electrical Assembly Electro Magnetic Interference Evaporator Fuse Ground Jumper Motor Normally Closed Normally Open Potential Earth Ground Card Mounting Slot Board Remote Relay Output Common Shield Terminal Block Located outside of starter connected by field wiring 31 TOWER FAN HIGH DETAIL B POWER MAIN TB4 PANEL CIRCUIT UNIT BREAKER DRIVE 35 loe HP RATING CBI SIZE 200 248 600 6 19 Power S00HP 361A 600A 7 CARRIER CARRIER PANEL 400HP 477A 600A 7 WIRING COMN 611 APPENDIX B OPTIONAL BACNET COMMUNICATIONS WIRING Optional BACnet Communications Wiring The following section is used to configure the UPC Open con troller which is used when the BACnet communications option 15 selected The UPC Open controller is mounted in a separate enclosure below the main control box TO ADDRESS THE UPC OPEN CONTROLLER The user must give the UPC Open controller an address that 15 unique on the BACnet network Perform the following proce dure to assign a
36. RMINALS gt LOCATED INSIDE ACCESS DOOR DC DC MULTIMETER SLIDE e ENCLOSURE LOOSEN ett FORWARD ENCLOSURE FASTENERS Fig 18 Removing Enclosure When replacing the drive reverse the procedures and tight en to the torques for the Frames 6 and 7 Power Terminal Block referred to in Table 8 Table 8 Frames 6 and 7 Power Terminal Block MAXIMUM LUG RECOMMENDED TERMINAL WIDTH TORQUE BOLT SIZE 34 6 mm 1 36 in 11 3 Nem 100 in Ib M8 x 1 25 43 5 mm 1 71 in 11 3 Nem 100 in Ib M8 x 1 25 RIGGING THE ENCLOSURE Where overhead room and or clearance in front of the drive enclosure is insufficient to allow the drive to be safely removed from the enclosure the entire enclosure may have to be removed from the chiller The dimensions and weights specified must be taken into consideration when removing the enclosure The total weight for Frames 6 and 7 including drive weight and enclosure is 720 16 All lifting equipment and lifting components hooks bolts lifts slings chains etc must be properly sized and rated to safely lift and hold the weight of the enclosure and drive while removing See Fig 20A and Fig 20B DRIVE RIGGING ACCESS DRIVE WIDTH 4 IN FRONT VIEW B 2 IN DRIVE RIGGING CCESS VERTICAL LIFT DRIVE EXTENDS BEHIND MAIN ENCLOSURE oOo y
37. RW h NA 0t032767 AV 36 s hrs 1 Surge Line Delta T DETATX R F NA 0 to 200 AV 38 delta tx 1 1 Normal System Alert Alarm SYS_ALM R N NA 2 Alert 3 Alarm AV 40 sys_alm_1 37 611 APPENDIX B OPTIONAL BACNET COMMUNICATIONS WIRING cont Table G Network Points List cont CCN READ DEFAULT BACNET BACNET POINT DESCRIPTION point UNITS var ug RANGE OBJECTID OBJECT NAME System Demand Limiting R NA NA OFFON evs dem mac i Target Guide Vane Position Gv TRG R NA 0010 Target VFD Speed R NA 0650 vd out 1 Tower Fan Relay High TFR_HIGH R NA Orr OFFON TowerFanRelyLow TFRLOW R NA OFF orron evia UserDefnedAmlogi Na NA AV291 _user_analog 1 1 User Defined Analoga R NA NA NA AV292 user analog 2 1 User Defined Analog3 R Na NA NA AV293 user analog 3 1 User Defined Analoga NA NA AV2904 user analog 1 User Defined Analog R NA NA NA AV295 user analog 5 1 User Defined NA R NA NA NA Bv29 user 1 1 UserDefinedBimry2 R NA NA NA BV292 userbina 21 User Defined NA R NA NA NA BV2013 user binary 91 User Defined Binaya R NA Na NA user binary 41 User D
38. SE CIRCUIT BREAKER SIZE MIN SUPPLY CIRCUIT AMPACITY MACHINE ELECTRICAL DATA MOTOR NAMEPLATE VOLTAGE COMPRESSOR 100 SPEED RATED LINE VOLTAGE RATED LINE AMPS RATED LINE KILOWATTS MOTOR RATED LOAD KW MOTOR RATED LOAD AMPS MOTOR NAMEPLATE AMPS MOTOR NAMEPLATE RPM MOTOR NAMEPLATE KW INTERTER PWM FREQUENCY SAFETY CODE CERTIFICATION THE COMPRESSOR MOTOR CONTROLLER AND OVERLOAD PROTECTION MUST BE IN ACCORDANCE WITH CARRIER SPECIFICATION Z 420 19XV05008701 REV 3 Fig 8 Machine Nameplate Nameplate 1 Specifications and Custom Catalog Number representing options installed at factory See Nameplate 2 Located behind HIM for equivalent base catalog number and separate options Cat No 20GYA N D 477 ANONNNNNQBQ UL Open IP00 Series A 400 Class 480V Class Power ND HD 270kW 200kW 400 HP 300 HP Input 3 Phase 47 63Hz AC Voltage Range 342 440 432 528 Amps ND HD 467 3 350 5 447 8 338 9 Output 3 Phase 0 400 Hz AC Voltage Range 0 400 0 460 Base Frequency default 50Hz 60 Hz Continuous Amps ND HD 477 387 477 361 60 Sec Ovid Amps ND HD 524 7 550 5 524 7 541 5 3 Sec Ovid Amps ND HD 715 5 884 7185 5 649 8 COOLANT Treated Water R134A RATED PRESSURE 185 PSIG Mfd on 2010 08 09 Original Firmware 1 018 Alen Bradiey PRODUCT OF USA FAC 11
39. T Parts Identification and Location 26 APPENDIX A WIRING SCHEMATICS 28 31 APPENDIX B OPTIONAL BACNET COMMUNICATIONS WIRING 32 38 INTRODUCTION The Carrier option Start Up and Service Manual is in tended for trained and qualified service personnel and is to be used during start up operation and maintenance of Rockwell Allen Bradley PF755L drive ABBREVIATIONS AND EXPLANATIONS Frequently used abbreviations in this manual include CCM Chiller Control Module DC Direct Current DPI Drive Peripheral Interface Ethernet ICVC International Chiller Visual Controller IGBT Insulated Gate Bipolar Transistor 1 0 Inputs Outputs IP Internet Protocol IPWM Inverter Pulse Width Modulation MCB Main Control Board MOV Metal Oxide Varistor PE Protective Earthing Conductor SIO Sensor Input Output STS Status 711 Required Publications The Carrier VFD option Start Up and Service Manual must be used with the following manuals The latest version of the PowerFlex 750 Series AC Drives manuals The latest revision of the Start Up Operation and Main tenance Instructions for the 19XRV with PIC III Controls Getting Assistance from Rockwell Automa tion Contact the local Rockwell Automation sales office with any questions or problems relating to the products de scribed in this manual For technical support on driv
40. asurement of the capacitor bank and power after finalizing the installation to ensure all connections are good 9 Ifa ground fault occurs then do the following a Check for a ground in the motor or motor wiring b Check for damage to wiring insulation and that wiring is dry c Verify the motor wiring is separated from ground and there is no connection between phases d Check for failed IGBTs 10 Ifan Overcurrent fault occurs then do the following a Check for excessive load and verify load limit set tings on the ICVC b Check motor and wiring insulation c Check parameter settings on CONF screen in the ICVC Check Internal Jumpers On the Main VFD Con trol board there are two jumpers labeled HARDWARE EN ABLE and J2 SAFETY ENABLE J1 should be removed and J2 should be in place See Fig 10 There are two jumper wires that connect a particular termi nal to chassis ground The MOV and AC EMI jumper should be connected to the PE A terminal The COMMON MODE CAPACITORS to GROUND jumper should be connected to a standoff rather than the PE B terminal Use the recommended tools as follows when connecting jumper wires in Frame 6 and in Frame 7 e Recommended torque screws and nuts 1 36 Nem 120 0 Ib in Recommended hex socket 7 mm Recommended screwdriver T20 star type See Fig 11A and Fig 11B for the correct positions of th
41. ck Motor terminals Phase WU Short Replace drive 206 Phase UNot Check the wiring between the drive and the Lm Phase VNot ToGnd GROUND FAULT no LF2 equivalent COS otorten 206 PhaseWNot WNot Replace drive LN temperature sensor on the main control Check that VFD refrigerant isolation valves are NONE board detected excessive heat open Check VFD refrigerant strainer 206 Shear Pin 1 See VFD Fault Code 15 See VFD Fault Code 15 Shear Pin 2 See VFD Fault Code 15 See VFD Fault Code 15 Check for high entering water temperature or low 206 Drive Overload Drive is overloaded condenser water flow Check current settings in VFD_CONF screen OW TrqLviTimeout See VFD Fault Code 15 See VFD Fault Code 15 IR Volts Range See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 Check that guide vanes are closed completely 206 Excessive Load Motor did not come up to speed in the allotted creck for high entering water temperature or low Repeat Autotune See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 Press ICVC reset 206 Parameter Chksum b ard does not Check VFD CONF parameters Cycle power to the drive NONE Replaced MCB PB The main control board was moved to a different Pu D ONE parameters power structure Data set to default values Cycle power to the
42. d Level 3 wa NA 00010999 AV 25 chwstpt 1 0010 M 1 1 NA 00910 AV2 dmv M 2 perct 1 0t0100 dmv 3 element stat 1 BV 20 comm lost alm 1 ENABLE ENABLE EMSTOP emstop 1 Ew R 40 to 245 AV 26 ecw 1 Entering Condenser Water ECDW 40 to 245 27 ecdw 1 1 Evaporator Pressure I 6 7 to 420 AV 28 erp 1 Evaporator Refrigerant Temp Lc ER A 40 to 245 AV 13 ert 1 Element Comm Status Element Communications Alarm Emergency Stop EMSTOP Entering Chilled Water Leaving Chilled Water Leaving Condenser Water LCDW 40 to 245 AV 32 Icdw 1 Line Active Current AMPS ACT 0 0 to 99999 0 amps act 1 Line Active Voltage _ R v NA 0 01099999 0 volt act 1 Line Frequency LINEFREQ R Hz NA 009 AV30 linefreq 1 Line Power Factor LNEPF R 0001200 AV34 line pf 1 Local Schedule NA R NA schedule 1 Occupied OCC rR NA NO noves oco 1 Oil Sump Temperature OILT R F NA 400245 AV 33 oilt 1 Remote Start Contact REM CON OPEN OPEN CLOSE BV 11 rem_con_1 O Timeout 1 Ready 2 Reoyle 3 Startup 4 Running 5 Demand 6 Ramping Run Status STATUS N A N A za Autorest AV 35 status_1 8 Override 9 Tripout 10 Control Test 11 Lockout 12 Pumpdown 13 Prestart N A Service Ontime SHRS
43. drive 206 Tracking DataEr Tracking DataEr internal data error data error internal data erro 5 drive m isi s daga Verify application version See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 21 VFD FAULT CODE Table 6 Powerflex 755 Fault Code Descriptions and Corrective Actions cont ON VFD HIST FAULT TYPE DESCRIPTION CORRECTIVE ACTION SCREEN N Heatsink temperature sensor is reporting a value 168 206 HoatSinkUnder below 18 7 C 1 66 F or the sensor feedback cheek heat sink temperature sensor Check heat circuit is open p 210 HW En Jumper See VFD Fault Code 15 See VFD Fault Code 15 211 See VFD Fault Code 15 213 See VFD Fault Code 15 291 See VFD Fault Code 15 292 See VFD Fault Code 15 293 See VFD Fault Code 15 294 See VFD Fault Code 15 295 See VFD Fault Code 15 296 See VFD Fault Code 15 315 See VFD Fault Code 15 316 See VFD Fault Code 15 Checking Power Modules and Motor Input Table 7 Diode Checks with Input Power Off Use the following procedure METER LEAD to check the drive s power module circuitry with power off METER READING 1 Turn off and lock out input power Wait five minutes R 0 5 V 2 Verify there is no voltage at the drive s input power termi S 0 5 nals 0 5 V 3 Using a voltmeter check the DC bus potential as de H DC infinite OL scribed above to ensure the DC bu
44. e jumpers LEGEND NO DESCRIPTION 1 HIM Connector DPI Port 1 HIM Cradle connection 2 Fan Connector Power supply for internal cooling fan Frames 2 amp 3 Battery User installed CR1220 lithium coin cell Receptacle battery provides power to the Real Time 3 09 4 DPI Port 2 Cable connection for handheld and remote HIM options Embedded EtherNet Rotary switches for setting lowest octet 5 IP Address Selectors of EtherNet address forces address to 192 168 1 xxx 6 Embedded EtherNet Network cable connection IP Connector 7 Jumper J2 SAFETY Safety enable jumper Removed when safety option is installed Jumper J1 ENABLE Hardware enable jumper Removed 8 when a hardware enable configuration is utilized 9 terminal block Clock Optional not supplied TB1 I O Terminal Designations TERMINAL NAME Connections for AC power supply Digital input common Connections for DC power supply Connections for drive supplied 24V power 24 Volt Common DESCRIPTION IMPORTANT Wiring to pluggable terminal block connectors should be supported by wire ties or other means to help pre vent unintentional disconnection Fig 10 PF755 Main Control Board WANG Fig 11B Jumper Wire Locations Frame 7 SERVICE AX WARNING DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5
45. e Current Imbal Power loss has been detected in any phase PENDING IMBALANCE ance Check VFD Fault His Chiller automatically restarting tory for Values LINE VOLTAGE 144 Single Cycle Line A drop in line voltage has been detected within DROP OUT Voltage Dropout 2 voltage cycles Chiller automatically restarting if Auto Restart is enabled in OPTIONS screen AUTORESTART HIGH LINE VOLTAGE 145 gt Percent Line Check phase to phase and phase to ground line PENDING Voltage VALUE power AUTORESTART LOW LINE VOLTAGE 146Low Percent Line Check phase to phase and phase to ground line PENDING Voltage VALUE power VFD MODULE RESET 147 2 VFD Module Power On VFD Module has detected a hardware fault due Reset When Running to electrical noise power loss or software and has reset Chiller automatically restarting Check for power loss and sources of electro magnetic interference AUTORESTART POWER LOSS 148 Control Power Loss Check 24 vac control power supply to ICVC PENDING When Running SENSOR ALERT HIGH DISCHARGE TEMP 149 gt Discharge Temp Check sensor resistance or voltage drop VALUE Exceeded Limit of Check for proper wiring LIMIT Check for proper inlet guide vane and optional diffuser actuator operation Check for proper condenser flow and temperature Check for high lift or low load Check for fouled tubes or noncondensables in the chiller SENSOR ALERT HIGH BEARING 150 Comp Thrust Brg Temp Check senso
46. e PowerFlex 750 user manual Failure to observe this precaution could result in damage to or destruction of the equipment DO NOT route signal and control wiring with power wiring in the same conduit This can cause interference with drive operation Failure to observe this precaution could result in damage to or destruction of the equipment DISTRIBUTION SYSTEM short circuit capacity shall not exceed the rat ing of the drive Failure to observe this precaution could result in damage to or destruction of the equipment DO NOT STEP on refrigerant lines Broken lines can whip about and release refrigerant causing personal injury DO NOT climb over a chiller Use platform catwalk or staging Follow safe practices when using ladders USE MECHANICAL EQUIPMENT crane hoist etc to lift or move inspection covers or other heavy components Even if components are light use mechanical equipment when there is a risk of slipping or losing your balance BE AWARE that certain automatic start arrangements CAN ENGAGE THE TOWER FAN OR PUMPS Open the disconnect ahead of the VFD tower fans or pumps USE only repair or replacement parts that meet the code requirements of the original equipment PERIODICALLY INSPECT all valves fittings and piping for corrosion rust leaks or damage Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations
47. efined Binary NA R NA NA NA BVeois userbinary 5 1 LEGEND CHW Chilled Water R Read VFD Variable Frequency Drive w Write 38 Copyright 2011 Carrier Corporation 1 E s4 a s 7 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53190012 01 Printed in U S A Form 19XRV 3SS Pg 40 711 3 11 Replaces New
48. emperature Check compressor discharge isolation valve Check for proper inlet guide vane and optional diffuser actuator operation 232 PROTECTIVE LIMIT LOW REFRIGERANT 232 Evaporator Refrig Temp Check for proper refrigerant charge TEMP VALUE exceeded limit of Check float valve operation LIMIT Check for closed condenser liquid line isolation valve If problem occurs at high load check for low condenser pressure which causes inade quate flasc orifice differential pressure Check for proper water flow and temperature Confirm that condenser water enters bottom row of condenser tubes first Check Evaporator Refrigerant Temperature sensor Check for division plate gasket bypass Check for fouled tubes LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 16 Table 5 ICVC Alarm Codes cont CHILLER PROTECTIVE LIMIT FAULTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 233 234 235 236 237 238 239 240 241 242 243 244 PROTECTIVE LIMIT HIGH MOTOR TEMPERATURE 233 Comp Motor Winding Temp VALUE exceeded limit of LIMIT PROTECTIVE LIMIT HIGH BEARING TEMPERATURE 234 Comp Thrust Brg Temp VALUE exceeded limit of LIMIT
49. es between the hours of 7 00 am and 6 00 pm CST M F call 1 262 512 8176 For information about after hours phone support and on site support call 1 800 800 0522 Before calling have the following information available from the Allen Bradley data nameplate located inside the en closure on the right wall See Fig 1 Allen Bradley ID or CAT NO Carrier Code Allen Bradley serial number Allen Bradley ID No 21P 104773 4 0 0 Input Rating 480VAC 454A 60Hz 3PH Output Rating 0 460VAC 477A 0 325Hz 3PH Short Circuit Rating 65kA 480V Max Interrupt Capacity Rating 100kAIC Enclosure Type TYPE 1 Coolant Type Refrigerant R134a Design Pressure 185 PSIG Carrier Part Number 19XVR0445335A1F VFD Serial Number Carrier Dwg Number 19XV04021001 Mfd On 08 13 10 FAC LOC 1100 Max Ambient Temperature 40 C ORDER NO 0001772838 00001 Made in USA for Carrier Corporation Syracuse NY 13221 4808 Fig 1 Allen Bradley Data Nameplate IDENTIFYING DRIVE COMPONENTS A chiller control schematic and a VFD schematic are in cluded in Appendix A A WARNING 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 rated for the DC bus voltage to ensure the DC bus capacitors are discharged before touching an
50. ing Check for disconnected or shorted wiring 19 FAULT CODE ON VFD HIST SCREEN NONE 0 12 13 14 15 17 20 21 24 33 36 Table 6 Powerflex 755 Fault Code Descriptions and Corrective Actions FAULT TYPE DESCRIPTION CORRECTIVE ACTION 206 Processor memory fault Consult VFD manual to resolve generic fault No Enty pi Check Compressor Discharge High Pressure switch wiring and accuracy Check for high condenser water temperatures low water flow fouled tubes Check for division plate gasket bypass Check for noncondensables in refrigerant Temporary loss of voltage Disable Single Cycle 210 Line voltage dropout Dropout in VFED CONF sceen Verify phase to phase and phase to ground line 215 Undervoltage Low DC bus voltage voltage VFD Circuit Board malfunction Call Carrier Service Verify phase to phase and phase to ground line 166 Overvoltage High DC bus voltage voltage Monitor AC line for high transient voltage conditions Any phase current 10696 RLA Can result from significant load side current imbalance when running at full load 217 Motor Overload An internal electronic overload trip has occurred Check entering condenser water temperature and water flow rate Check Motor Rated Load Amps in VFD CONF screen Check that VFD refrigerant isolation valves are open Heat sink temperature has exceeded the maxi Check VFD refrigerant cooling
51. k Spare Temperature Enable and Spare 2 VALUE exceeded limit of Temperature Limit in SETUP1 Screen LIMIT 250 UNUSED UNUSED 250 Unused State 251 PROTECTIVE LIMIT VFD CONFIG CONFLICT 251 VFD Config Conflict VFD CONF table in the Gateway does not VFD Uploaded Verify to match that which is in the ICVC This is a normal Reset Alarm fault if an ICVC has been uploaded with soft ware when it was not attached to the CCM Enter VFED CONF screen and then exit VFD CONF screen by pressing EXIT then CANCEL Re enter the VFD CONF screen press EXIT then SAVE Parameters stored in the Gateway will be uploaded into the ICVC Confirm valid settings in VFD CONF screen 252 PROTECTIVE LIMIT VFD CONFIG CONFLICT 252 VFD Config Conflict The VFD CONF table in the Gateway does not VFD Downloaded Verify to n match that which is in the ICVC Reset Alarm 253 PROTECTIVE LIMIT GUIDE VANE 253 Guide Vane Fault Enter CONTROL TEST and execute Guide CALIBRATION VALUE Check Calibration Vane Calibration Check COM guide vane feedback terminals J4 9 and J4 10 Check guide vane feedback potentiometer Alarm before start indicates guide vane opening is not less than 4 Alarm running indicates guide vane position is lt 1 or gt 103 or feed back voltage is 045 or 3 15 VDC 254 PROTECTIVE LIMIT VFD CHECKSUM ERROR 254 Checksum Error Actual VFD checksum does not match calcu Press Reset to Restore lated value Configu
52. lation and User Guide for instruc tions on connecting and using the BACview device To order a BACview Handheld BV6H consult Commer cial Products i Vu Open Control System Master Prices CONFIGURING THE UPC OPEN CONTROLLER S PROPERTIES The UPC Open device and ComfortLinkTM controls must be set to the same CCN Address Element num ber and CCN Bus number The factory default settings for CCN Element and CCN Bus number are and 0 respectively P e BACview UPC OPEN gt LOGIN gt UserPw 03 05 2010 01 39 28 pm NETWORK BACnet ClockSet C CN 22 AWG single twisted shielded pair low capacitance CL2P TC foam FEP plenum rated See MS TP Installation Guide for W221P 22227 25160PV Network RS 485 24 AWG single twisted shielded pair low capacitance CL2P TC foam FEP plenum rated See MS TP Installation Guide 4 conductor unshielded CMP 18 AWG plenum rated W184C 2099BLB 6302UE 21450 LEGEND American Wire Gage RECOMMENDED VENDORS AND PART NUMBERS Connect Air Contractors International RMCORP RMCORP wie and Cable CLPO520LC W241P 2000F 82841 25120 OR CLP0442 If modifications to the default Element and Bus number are required both the ComfortLink and UPC Open configurations must be changed The following configurations are used to set the CCN Ad dress and Bus number in the ComfortLink control These con figurations can be changed using the scrolling marquee display
53. le 4 ICVC ALARM CODES An alarm condition is also indi cated by a message at the top of the ICVC default screen If an alarm occurs the drive coasts to stop The STS status light on the drive will turn from Green to Red or Yellow see Table 3 The detected fault message is maintained on the display until it Is cleared by pressing the RESET softkey See Table 5 TEST EQUIPMENT NEEDED TO TROUBLESHOOT An isolated multimeter adequately rated for the DC bus volt age will be needed to measure DC bus voltage and to make resistance checks Note that dedicated troubleshooting test points are not provided owe mee Fig 12 Drive Status Indicator Table 3 Drive Status Indicator Descriptions NAME COLOR STATE DESCRIPTION Green Flashing Drive ready but not running and no faults are present Drive running no faults are present Yellow Flashing Drive is not running A type 2 non configurable alarm condition exists and the drive cannot be started Steady Drive is not running a type 1 alarm condition exists The drive can be started Flashing A major fault has occurred Drive cannot be started until fault condition is STS Status cleared Steady A non resettable fault has occurred Red Yellow Flashing Alternately A minor fault has occurred When running the drive continues to run System is brought to a stop under system control Fault must be cleared to conti
54. le Connector Option Wiring Standard on LF2 drive optional on machines equipped with other VFDs 29 APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical POWERFLEX 755 POWER MODULE MEE SEE MAIN s coMPRESSORCONTINUED CIRCUIT BREAKER EAT DRIVE 5126 CHART MOTOR FACING PAGE ue 1030 __12____ 1050 480V 3PH 60HZ MOV AC x IN L3 N 1060 AC UNES SETTINGS CAP JUMPER OUT AMPS SEE CHARTA AS SHIPPED COMMON MODE IN 600VDLTS CAP JUMPER OUT OC LINE PE 2L J1 HARDWARE ENABLE CHASSIS SETTINGS ENCLOSURE ENCLOSURE AS SHIPPED J2 SAFETY ENABLE EMBEDDED ETHERNET 4 HUNDREDS 1062 EMBEDDED ETHERNET ADAPTER ROTARY SWITCHES Ju PORT 2 AS SHIPPED SETTINGS CONTROL BREAKER CB2 221B TB4 YELLOW 48 ep 18 BLACK OIL PUMP re CONTACTOR ap 184 RED 15 AMPS 50 600 VOLTS 240 480 3000 1 110 120 VAC Q 224 120VAC H FU 226 BLACK Tl 20A OIL HEATER 600V CONTACTOR 38 40 CLASS 225D WHITE 2 TB4 s p 42 43 CLASS CC USED FAN 2250 Tm 45 46 Bony 145 CFM 145 CFM CLASS CC 115 VAC 115 VAC ENCLOSURE FANS 611 30 APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical cont EA1 DRIVE CONTROL POD SLOT 4 CONTROL 1 0 4VDC DELUXE 1 0 DPI SI SLOT 4 1010 SPARE SAFETY
55. 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 touch ing any internal components Failure to observe this pre caution could result in severe bodily injury or loss of life Troubleshooting the Drive The drive can display two kinds of error codes on the ICVC called the Alert and Alarm codes These codes signal a problem detected during self tuning or drive operation Alert and Alarm codes are locat ed in the 19XRV Start Up Operation and Maintenance Instruc tions Note the following differences between Carrier and Allen Bradley terminology A warning message on the ICVC is an ALERT Thesame warning viewed with Rockwell Drive Explorer is a VFD ALARM A failure resulting in a shutdown is seen as an ALARM on the ICVC and as a VFD FAULT when viewed with Drive Explorer CONDITION CODES ICVC ALERT VFD ALARM ICVC ALARM VFD FAULT See Tables 3 6 and Fig 12 ICVC ALERT CODES An alert condition is indicated by a message at the top of the ICVC default screen In addition an exclamation point will appear next to any affected point on an ICVC display screen The drive will continue to operate during the alert condition Investigate the cause of the alert to ensure it does not lead to a fault condition The alert code will automatically be cleared from the ICVC when the condition causing the alert no longer exists See Tab
56. n address 1 Ifthe UPC Open controller is powered pull the screw ter minal connector from the controller s power terminals la beled Gnd and HOT The controller reads the address each time power is applied to it Using the rotary switches see Fig A and B set the con troller s address Set the Tens 10 s switch to the tens dig it of the address and set the Ones 1 s switch to the ones digit As an example in Fig B if the controller s address is 25 point the arrow on the Tens 10 s switch to 2 and the arrow on the Ones 1 s switch to 5 10 s 18 e Fig B Address Rotary Switches BACNET DEVICE INSTANCE ADDRESS The UPC Open controller also has a BACnet Device Instance address This Device Instance MUST be unique for the complete BAC net system in which the UPC Open controller is installed The Device Instance is auto generated by default and is derived by adding the MAC address to the end of the Network Number The Network Number of a new UPC Open controller is 16101 but it can be changed using i Vu Tools or BACView device By default MAC address of 20 will result in a Device In stance of 16101 20 which would be a Device Instance of 1610120
57. nd IMBALANCE ance Check VFD Fault His power distribution bus voltage tory for Values Check Line Current Imbalance VFED CONF screen Consult power company PROTECTIVE LIMIT LINE VOLTAGE DROPOUT 210 Single Cycle Line Volt Temporary loss of voltage Disable Single Cycle age Dropout Dropout in CONF screen PROTECTIVE LIMIT HIGH LINE VOLTAGE 211 8High Percent Line Volt Check phase to phase and phase to ground dis age VALUE tribution bus voltage Consult power company PROTECTIVE LIMIT LOW LINE VOLTAGE 212Low Percent Line Volt Check phase to phase and phase to ground dis age VALUE tribution bus voltage Consult power company PROTECTIVE LIMIT VFD MODULE RESET 2135 VFD Module Power On Temporary loss of VFD control voltage Check Reset When Running VFD control power breaker transformer and fuses PROTECTIVE LIMIT POWER LOSS 214 Control Power Loss Check phase to phase and phase to ground dis When Running tribution bus voltage Check VFD fuses Check 24 vac power supply to ICVC Consult power company PROTECTIVE LIMIT LOW DC BUS VOLTAGE 215Low DC Bus Voltage Verify phase to phase and phase to ground line VALUE exceeded limit of voltage VFD Circuit Board malfunction LIMIT Call Carrier Service PROTECTIVE LIMIT LINE VOLTAGE 216Line Voltage Imbal Check phase to phase and phase to ground IMBALANCE ance Check VFD Fault His distribution bus voltage Increase Line Voltage tory for Values
58. nication Check CCN communications link with WSM Water System Manager Module Check Supervisory Part of WSM SENSOR ALERT EVAPORATOR 162 Evaporator Approach Check that refrigerant charge level is adequate APPROACH VALUE Exceeded Limit of waterbox division plate gaskets are sealing LIMIT evaporator tubes are not fouled and that oil reclaim system is working Check sensor resistance or voltage drop Check for proper wiring Check Evap Approach Alert setting in SETUP1 Screen CONDENSER APPROACH 163 gt Condenser Approach Check sensors resistance or voltage drop VALUE Exceeded Limit of Check for proper wiring LIMIT Check Cond Approach Alert setting in SETUP1 screen Check for noncondensable gas in the condenser Check that the condenser tubes are not fouled 164 VFD SPEED ALERT LOW VFD SPEED 164 Actual VFD Speed Actual VFD Speed on COMPRESS screen must exceeded limit of Target VFD be at least 90 of Target VFD Speed Speed 10 165 AUTORESTART LOW DC BUS VOLTAGE 165Low DC Bus Voltage Verify phase to phase and phase to ground line PENDING VALUE Exceeded Limit of voltage LIMIT 166 AUTORESTART HIGH DC BUS VOLTAGE 166High DC Bus Voltage Verify phase to phase and phase to ground line PENDING VALUE Exceeded Limit of voltage Monitor AC line for high transient volt LIMIT age conditions 167 SYSTEM ALERT HIGH DISCHARGE TEMP 167 gt Discharge Temp Check sensor resistance or voltage drop VALU
59. nominal Weight 12 16 1000 feet 17 9 kg km UL Temperature Rating SmokeGard 167 F 75 C Voltage 300 Vac power limited Listing UL NEC CL2P or better LEGEND American Wire Gage CL2P Class 2 Plenum Cable DC Direct Current FEP Fluorinated Ethylene Polymer NEC National Electrical Code O D Outside Diameter TC Tinned Copper UL Underwriters Laboratories 34 Halar 40 to 302 F 40 to 150 C APPENDIX OPTIONAL BACNET COMMUNICATIONS WIRING cont Table D Open System Wiring Specifications and Recommended Vendors WIRING SPECIFICATIONS Wire Type Description MS TP specifications for specifications Rnet AWG CL2P Class 2 Plenum Cable CMP Communications Plenum Rated FEP Fluorinated Ethylene Polymer TC Tinned Copper LOCAL ACCESS TO THE UPC OPEN CONTROL LER The user can use a BACview handheld keypad dis play unit or the Virtual BACview software as a local user inter face to an Open controller These items let the user access the controller network information These are accessory items and do not come with the UPC Open controller The BACview unit connects to the local access port on the UPC Open controller See Fig F The BACview software must be running on a laptop computer that is connected to the local access port on the UPC Open controller The laptop will re quire an additional USB link cable for connection See the BACview Instal
60. nue Use parameter 950 Minor Config to enable If not enabled acts like a major fault Drive is flash updating Adapter and or network is not powered adapter is not properly connected to the network or adapter needs an IP address An EtherNet IP connection has timed out nas Adapter failed the duplicate IP address detection test Red Green _ Red Green Flashing Alternately Adapter is performing a self test Green Flashing Adapter is properly connected but is not communicating with any devices on the network Adapter is properly connected and communicating on the network Adapter is not powered or is not transmitting on the network LINK Flashing Adapter is properly connected and transmitting data packets on the network Steady Adapter is properly connected but is not transmitting on the network NOTES 2 A Type 2 alarm indicates that a configuration error exists and 1 A Type 1 alarm indicates that a condition exists Type 1 alarms the drive cannot be started Type 2 alarms are not configurable are user configurable VERIFYING THAT DC BUS CAPACITORS ARE DIS CHARGED The drive s DC bus capacitors retain hazard ous voltages after input power has been disconnected Perform the following steps before touching any internal components 1 Turn off and lock out input power Wait five minutes 2 Verify that there is no voltage at the drive s input power terminals 3 Measure the DC b
61. o Alert message LIMITED CONTROL RUN CAPACITY HIGH INVERTER TEMP 128 Inverter Temperature LIMITED VALUE exceeded limit of LIMIT ADDITIONAL CAUSE REMEDY Check condenser water pump operation Check for high condenser water temperatures or low flow rate Verify that isolation valves are open Check Cond Press Override setting in SETUP1 Check for closed valves or restriction in motor cooling lines Check for closed refrigerant isolation valves Check Comp Motor Temp Override setting in SETUP1 Check refrigerant charge Check that optional cooler liquid line isolation valve is fully open Check for excessive condenser flow or low chilled water flow Check for low entering cooler temperature Check that condenser inlet and outlet water nozzles are piped correctly Check for waterbox division plate gasket bypass Check for high condenser water temperature or low suction temperature Check for high Evaporator or Condenser approaches Check surge prevention parameters in OPTIONS screen Target Guide Vane Position has been forced in the COMPRESS screen Select and RELEASE force to return to normal automatic operation Check for oil loss or excess refrigerant charge Verify that the valves in the oil reclaim lines are open Check Rectifier Temp Override in SETUP1 screen Check that VFD refrigerant isolation valves are open Check VFD refrigerant cooling solenoid Check for proper VFD cooling fan ope
62. o not subject the drive to high rates of acceleration or deceleration while transporting to the mounting lo cation or when lifting Do not allow personnel or their limbs directly underneath the drive when it is being lifted and mounted ANWARNING 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 touch ing any internal components Failure to observe this pre caution could result in severe bodily injury or loss of life 1 Using recommended screwdriver 6 4 mm 0 25 in flat or 20 star open access door See Fig 16 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis 1s zero before proceeding See Fig 17 3 Remove the enclosure See Fig 18 REMOVING THE DRIVE The dimensions and weights specified must be taken into consideration when removing the drive lifting equipment and lifting components hooks bolts lifts slings chains etc must be properly sized and rated to safely lift and hold the weight of the drive while removing it See Fig 19 The drive weights are as follows Drive weight for Frame 6 85 Ib Drive weight for Frame 7 160 249 Ib Fig 16 Open Access Door 4 LOCKOUT TAGOUT 2 A DC BUS TEST TE
63. orifice and refrig mum operating temperature erant strainer Check for proper VFD cooling fan operation and air flow blockage Check that VFD refrigerant isolation valves are open The output transistors have exceeded the maxi Check VFD refrigerant cooling orifice and refrig mum operating temperature erant strainer Check for proper VFD cooling fan operation and air flow blockage Check for high entering water temperature or low 286 HW Overcurrent The drive output current has exceeded the hard condenser water flow Check current settings in 207 Auxiliary Input Input is open Heat Sink Over 219 iemp Transistor Over 219 iomp ware current limit VFD CONF screen grounded condition 206 Ground Warning The une current has exceeded the level set If this fault appears there may be a problem with check ICVC VFD CONF settings and save set software configuration tings when exiting VFD CONF screen The DC bus ripple Check phase to phase and phase to ground dis 216 has exceeded a Line Voltage imbalance tribution bus voltage Increase Line Voltage preset level Imbalance in VFD CONF screen Spd See VFD Fault Code 15 See VFD Fault Code 15 Verify input voltage is within drive specified limits u The drive is not following a commanded decelera dou dresse Cm follows proper 204 Decel Inhibit because it is attempting to limit the bus volt Disable bus regulation P186 and o
64. p TEMP Comp Motor Winding Temp Check for proper wiring Sensor Check for disconnected or shorted wiring 266 SENSOR FAULT COMP DISCHARGE TEMP 266 gt Fault Check Check sensor resistance or voltage drop Comp Discharge Temp Sensor Check for proper wiring Check for disconnected or shorted wiring 267 SENSOR FAULT OIL SUMP TEMP 267 gt Fault Check Oil Check sensor resistance or voltage drop Sump Temp Sensor Check for proper wiring Check for disconnected or shorted wiring 268 SENSOR FAULT COMP OIL PRESS DIFF 268 Sensor Fault Check Oil Check sensor resistance or voltage drop Pump Delta P Sensor Check for proper wiring Check for disconnected or shorted wiring 269 SENSOR FAULT CHILLED WATER FLOW 269 Sensor Fault Check Check sensor wiring and accuracy Chilled Water Delta P Sensor Check for disconnected or shorted wiring If pressure transducers are not installed check for presence of resistors and jumpers on lower terminal block J3 270 SENSOR FAULT COND WATER FLOW 270 gt Fault Check Check sensor wiring and accuracy Cond Water Delta P Sensor Check for disconnected or shorted wiring If pressure transducers are not installed check for presence of resistors and jumpers on lower CCM terminal block J3 271 SENSOR FAULT SATURATION TEMP 271 Sensor Fault Check Check sensor resistance or voltage drop Evap Saturation Temp Sensor Check for proper wir
65. place the chill plate fan and internal fan in Frames 6 and 7 Frame 6 1 Disconnect power to the drive Before removing the en closure open the access door on the front of the drive See Fig 16 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis 1s zero before proceeding See Fig 17 Remove the enclosure See Fig 18 Remove and replace the chill plate fan See Fig 23 Remove and replace the internal fan See Fig 24 Install the enclosure See Fig 18 gt CHILL PLATE FAN POWER CONNECTION 2 6 Nem 23 Ibsin Fig 23 Chill Plate Fan Frame 6 P INTERNAL FAN 2 6 Nem 23 si Fig 24 Internal Fan Frame 6 711 Frame 7 1 Disconnect power to the drive Before removing the en closure open the access door on the front of the drive See Fig 16 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis is zero before proceeding See Fig 17 3 Remove the enclosure See Fig 18 4 Remove and replace the Heat Sink and Internal and fans See Fig 25 Install the enclosure See Fig 18 Part Identification and Location See Fig 26 28 for parts descriptions and locations FRONT VIEW DOOR REMOVED LEGEND 1 Power Module 2 Input Circuit Breaker 3 15 Amp Control Circuit Breaker 4 Control Transformer
66. r add dynamic ge brake resistor and or extend deceleration time P537 and P538 AuRsts Exhausted See VFD Fault Code 15 See VFD Fault Code 15 Check the motor motor terminals and external A current path to earth ground greater than 25 ii 220 Ground Fault of drive rating has occurred wiring to the drive output terminals for a To reset the processor cycle power to chiller 206 Load Loss Check VFD parameters with Drive Explorer The current in one or more phases has been lost Check Motor Current Imbalance in Output PhaseLoss remains below a preset level VFD_CONF screen The drive output current has exceeded the 1 ms Check for excess load improper DC boost set 20 FAULT CODE ON VFD HIST SCREEN 38 39 40 41 42 43 44 45 46 5 61 62 64 65 77 78 79 80 87 91 93 94 95 96 97 100 107 113 124 141 142 143 144 145 Table 6 Powerflex 755 Fault Code Descriptions Corrective Actions cont FAULT TYPE DESCRIPTION CORRECTIVE ACTION Gnd to Gnd Check the wiring between the drive and the motor Phase Vto Gnd Vila Phase Vto Gnd GROUND FAULT Check motor for grounded phase Phase W to Gnd Check Motor terminals d Replace drive Phase UV Short UV Phase UV Short Check the wiring between the drive and the Phase VW Phase VW Short Phase VW Short GROUND FAULT motor Che
67. r resistance or voltage drop TEMPERATURE VALUE exceeded limit of Check for proper wiring LIMIT Check for partially closed service valves Check oil cooler TXV Check oil level and oil temperature CONDENSER PUMP RELAY 151 Condenser Pres sensor wiring and accuracy PRESSURE ALERT ENERGIZED sure VALUE Pump Ener Check condenser flow and water temperature gized to Reduce Pressure Check for fouled tubes alarm is not caused by the High Pressure witch RECYCLE ALERT EXCESSIVE RECYCLE 152Excessive recycle Chiller load is too low to keep compressor on STARTS starts line and there has been more than 5 starts in 4 hours Increase chiller load adjust hot gas bypass increase RECYCLE RESTART DELTA T from SETUP1 Screen no message no message ALERT only 153 Lead Lag Disabled Illegal chiller address configuration in Lead Lag ALERT Config Duplicate Chiller screen Both chillers require a different address only Address POTENTIAL COND PRESS TEMP FREEZE UP TOO LOW 154 Condenser freeze up The condenser pressure transducer is reading a prevention pressure that could freeze the condenser tubes Check for condenser refrigerant leaks Check fluid temperature Check sensor wiring and accuracy Place the chiller in PUMPDOWN mode if the vessel is evacuated OPTION SENSOR REMOTE RESET 155 gt Fault Option Check sensor resistance or voltage drop FAULT SENSOR Disabled
68. ration 255 PROTECTIVE LIMIT VFD DEW PREVENTION 255 Dew Prevention Cool VFD COLDPLATE TEMP is too close to dew ant Too Cold Check Solenoid point based on ENCLOSURE TEMP and amp Cond T RELATIVE HUMIDITY in POWER screen Check for moisture in VFD enclosure Check Humidity Sensor in CONTROLS TEST Check for contamination on CCM J3 7 and J3 9 Humidity Sensor Check that VFD refrigerant cooling modulating valve is closing 256 PROTECTIVE LIMIT INDUCTOR OVERTEMP 256lnductor Overtemp Trip Check for cooling fan air flow obstructions Check Temp Switch and Cool ing Fans 257 PROTECTIVE LIMIT VFD START INHIBIT 257 VFD Start Inhibit Check The VFD Start Inhibit is derived from the Alarm VFD Diagnostic Parameters bit being set in the VFD The conditions causing 212 214 the alarm must be corrected in the VFD to enable subsequent starts and operation See VFD parameters 212 214 258 UNUSED STATE LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 18 Table 5 ICVC Alarm Codes cont CHILLER PROTECTIVE LIMIT FAULTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 259 PROTECTIVE LIMIT OVERRIDE STOP 259 gt Emergency CCN has
69. ration and blockage Chiller is not in automatic temperature control Check Inverter Temp Override in SETUP1 screen Check that VFD refrigerant isolation valves are open Check VFD refrigerant cooling solenoid Check for proper VFD cooling fan operation and blockage LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 12 Table 4 ICVC Alert Codes cont CHILLER ALERTS ICVC FAULT STATE 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 PRIMARY SECONDARY MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY SENSOR ALERT LEAVING COND WATER 140 Sensor Fault Check Check sensor resistance or voltage drop TEMP Leaving Cond Water Sensor Check for proper wiring SENSOR ALERT ENTERING COND WATER 141 gt Fault Check Check sensor resistance or voltage drop TEMP Entering Cond Water Sensor Check for proper wiring LOW OIL CHECK OIL FILTER PRESSURE ALERT 142 Oil Pressure Alert Check for partially or closed shut off valves Check Oil Filter Check oil filter Check oil pump and power supply Check oil level Check for foaming oil at start up Check transducer wiring and accuracy AUTORESTART LINE CURRENT 143 Lin
70. s capacitors are dis 5 Infinite OL charged T DC Infinite OL 4 Disconnect the motor from the drive u 95v 5 Check all AC line and DC bus fuses ick zd M W 0 5 V 6 Use a multimeter to check the input diodes and output U DC infinite OL IGBTs if a fuse is open V Infinite OL 7 Check motor impedance W DC Infinite OL 8 Reconnect the motor to the drive DC Infinite OL 9 Reapply input power See Tables 7 and 8 Infinite OL DC Infinite OL DC 0 5 V zs TR DC 0 5 V diode checks DC Infinite OL DC Infinite OL DC 0 5 V DC 0 5 V DC 0 5 V NOTE Digital meters require a special diode check function because the current sourced by the meter during a normal resis tance Ohms test is too low to accurately test a diode Make sure the meter is set to the diode test function Voltage readings may not be exact as shown in above tables but look for consistency during each of the 4 tests When performing a test that should return infinity OL as shown in above tables you may see a value slowly climbing toward infinity This is a result of the meter charging a capacitor and is normal 22 Servicing the Drive ANWARNING To guard against possible personal injury and or equipment damage 1 Inspect all lifting hardware for proper attachment be fore lifting drive 2 Do not allow any part of the drive or lifting mecha nism to make contact with electrically charged con ductors or components D
71. s for all controllers on the network segment The UPC Open con troller is fixed at 8 data bits No Parity and 1 Stop bit for this protocol s communications If the UPC Open controller has been wired for power pull the screw terminal connector from the controller s power termi nals labeled Gnd and HOT The controller reads the DIP Switches and jumpers each time power is applied to it Set the BAS Port DIP switch DS3 to enable Set the BAS Port DIP switch DS4 to EIA 485 Set the BMS Protocol DIP switches 058 through 055 to MSTP See Table A Table A SW3 Protocol Switch Settings for MS TP DS8 DS7 056 DS5 DS4 033 Off Off Verify that the 485 jumpers below CCN Port are set to EIA 485 and 2W The example in Fig C shows the BAS Port DIP Switches set for 76 8k Carrier default and MS TP Set the BAS Port DIP Switches DS2 and DS1 for the appro priate communications speed of the MS TP network 9600 19 2k 38 4k or 76 8k bps See Fig C and Table B Table B Baud Selection Table BAUD RATE DS1 9 600 Off 19 200 Off 38 400 On 76 800 On WIRING THE UPC OPEN CONTROLLER TO THE MS TP NETWORK The UPC Open controller communicates using BACnet on an MS TP network segment communications at 9600 bps 19 2 kbps 38 4 kbps or 76 8 kbps Terminator BACnet MS TP m 485 Enable 76 8k baud rate Fig C DIP Switches Wire the controllers on an MS TP ne
72. signaled the chiller to stop This fault Override Stop must be manually reset from the default screen of the ICVC 282 PROTECTIVE LIMIT INVALID VFD CONFIG 282Line Frequency LINE FREQUENCY in POWER screen must be VALUE Exceeded Configura maintained between 45 52 Hz if LINE tion Range 60 2 is set to NO 50 Hz LINE FRE QUENCY must be maintained between 55 62 Hz if LINE FREQ 60Hz is set to YES 60 Hz Check high pressure switch and connections to 4 24 TB4 25 283 PROTECTIVE LIMIT INVALID VFD CONFIG 283 Compressor 100 COMPRESSOR 100 SPEED in VFD CONF Speed Config Ranges 50 Hz screen must be set between 45 52 Hz if LINE 45 52 60 Hz 55 62 FREQ 60HZz is set to 50 Hz COMPRES SOR 100 SPEED must be set between 55 62 Hz if LINE FREQ 60Hz is set to YES 60 Hz 284 VFD GATEWAY COMPATIBILITY 284 VFD Gateway Compati VFD Gateway and VFD software versions are CONFLICT bility Conflict Check VFG not compatible VFD Versions Call Carrier Service 285 VFD GATEWAY COMPATIBILITY 2855 VFD Gateway Compati VFD Gateway and ICVC software versions are CONFLICT bility Conflict Check VFG not compatible ICVC Versions Call Carrier Service 286 PROTECTIVE LIMIT INVERTER 286 Inverter Overcurrent Check for high entering water temperature or OVERCURRENT Fault Check VFD Status low condenser water flow Check current settings in VFD_CONF screen LIMIT is shown on the ICVC as the temperature pressure voltage
73. supply TEMP temperatures Check refrigerant charge Check Refrig Override Delta T in SETUP1 Screen 105 PRESTART LOW OIL 105 0il Sump Temp VALUE Check oil heater contactor relay and power ALERT TEMPERATURE exceeded limit of LIMIT Check oil level and oil pump operation 106 PRESTART HIGH 106 Condenser Pressure VALUE Check transducer wiring and accuracy ALERT CONDENSER exceeded limit of LIMIT Check for high condenser water PRESSURE temperatures Check high condenser pressure switch wiring 107 PRESTART LOW LINE 107 Percent Line Voltage VALUE Check voltage supply ALERT VOLTAGE exceeded limit of LIMIT Check voltage transformers and switch gear Consult power utility if voltage is low 108 PRESTART HIGH LINE 108 Percent Line Voltage VALUE Check voltage supply ALERT VOLTAGE exceeded limit of LIMIT Check power transformers Consult power utility if voltage is high 109 PRESTART GUIDE VANE 109 4Actual Guide Vane Pos Press STOP button on ICVC and perform ALERT CALIBRATION Calibration Required Before Startup Guide Vane Calibration in Controls Test Screen Check guide vane actuator feedback potentiometer 110 PRESTART HIGH 110 Rectifier Temperature VALUE Check that VFD refrigerant isolation valves ALERT RECTIFIER exceeded limit of LIMIT are open TEMP Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage 111 PRESTART HIGH 111 Inverter Temperature
74. tor terminals U V W and the DC link brake resis tor terminals B R R are live when the drive is con nected to incoming power even if the motor is not running Do not make any connections when the drive is connected to the incoming power After having disconnected the drive wait until the indica tors on the keypad go out 1f no keypad is attached see the indicator through the keypad base Wait 5 more minutes before doing any work on drive connections Do not even open the cover before this time has expired Before connecting the drive to the incoming power make sure that the switchgear enclosure door is closed ANWARNING The control I O terminals are isolated from the mains potential However the relay outputs and other I O termi nals may have a dangerous control voltage present even when the drive is disconnected from incoming power Coming into contact with this voltage could result in severe personal injury CAUTION If other than refrigerant cooling is used before connecting the drive to the incoming power make sure that the coolant is circulating and has no leaks A CAUTION When working with the Drive Explorer never use the Rotate function as the motor will immediately start and severe compressor damage could result Alternate Wire Lugs In the case where the incoming power wire size does not fit the standard lug alternate lugs may be used See Table 1 Note that lugs rated for a higher current
75. twork segment in a dai sy chain configuration Wire specifications for the cable are 22 AWG American Wire Gage or 24 AWG low capacitance twisted stranded shielded copper wire The maximum length is 2000 ft Install a BT485 terminator on the first and last controller on a network segment to add bias and prevent signal distortions due to echoing See Fig B D and E To wire the UPC Open controller to the BAS network 1 Pull the screw terminal connector from the controller s BAS Port 2 Check the communications wiring for shorts and grounds 3 Connect the communications wiring to the BAS port s screw terminals labeled Net Net and Shield NOTE Use the same polarity throughout the network segment 4 Insert the power screw terminal connector into the UPC Open controller s power terminals if they are not current ly connected 5 Verify communication with the network by viewing a module status report To perform a module status report using the BACview keypad display unit press and hold the FN key then press the Key BT485 Terminator Fig D Network Wiring 33 APPENDIX OPTIONAL BACNET COMMUNICATIONS WIRING cont BACnet Shield 2 ne 2 Port S1 0 BACnet MS TP EIA 485 12222 485 2wire Fig E 485 Terminator Installation To install a 485 terminator push the 485 terminator on to the 485 connector located near the BACnet connector NOTE The
76. ulations and algorithms in the ICVC OTES 1 Parameters in italics are to be entered or confirmed at start up 2 Parameters in bold are to be changed only after consultation with ser vice engineering Commissioning the Unit The commission proce dure is as follows 1 If the chiller has been stored outdoors allow at least 24 hours room temperature stabilization prior to commis sioning Ensure any condensation that occurs as a result of the ambient temperature is allowed to evaporate Enter parameters in the VFD CONF screen Install surge suppression devices if required Review the power wiring and grounding to ensure that it has been properly connected 5 Visually examine the inside of the drive enclosure to a Look for signs of corrosion or moisture residue b Remove any dirt or debris c Make sure all vents are clear 6 Apply power to the drive and take thermal measurements of the capacitor bank and power connections Do this again before start up 7 Measure and record the incoming line voltage Line to line voltages should be balanced within 3 as calculated by Rockwell s procedure below Measure voltages phase to phase and phase to ground AWN Vmax Maximum measured phase to phase voltage A to B B to C C to A Vmin Minimum measured phase to phase voltage Imbalance Calculation Formula VBC Vavg E Imbalance Vmax Vmin x 100 Vavg 8 Take a final thermal me
77. ured in place and insulated Check for sensor wiring and accuracy This fault can result from extended operation at low load with low water flow to the evaporator or condenser Check for high condenser water temperatures low water flow fouled tubes Check for division plate gasket bypass Check for noncondensables Check transducer wiring and accuracy Check for high condenser water temperatures low water flow fouled tubes Check for division plate gasket bypass Check for noncondensables Check surge prevention parameters in OPTIONS screen Increase VFD Increase Step in SETUP2 Check VFD Minimum Speed in SETUP2 screen Spare safety input has tripped or factory installed jumper is not present on Terminal Block 4 terminals 17 and 20 in the VFD enclosure Check for high condenser water temperatures low water flow fouled tubes Check for division plate gasket bypass Check for noncondensables Check surge prevention parameters in OPTIONS screen Check cooling tower control settings and perfor mance to design selection temperatures across the entire operating range of the chiller Check cooler approach and water flow Check that CCM transducer voltage reference is between 4 5 v and 5 5 v Check that pressure transducers are not shorted to ground This fault is normally declared the first time an ICVC is powered up if it was downloaded with software when it was not connected to a CCM Call Carrier Service Check
78. us potential with a voltmeter while standing on a non conductive surface and wearing insu lated gloves 1000 V Measure the DC bus potential See Fig 5 for the 248 amp drive and Fig 6 for the 361 and 477 amp drives The voltage between DC and DC and from each DC terminal to the chassis must be zero before proceeding 4 Once the drive has been serviced reapply input power HIGH TEMPERATURE ALARMS Coolant flow through the cold plate is controlled by an orifice in the refriger ant line leaving the cold plate The orifice looks like one of the O ring face seal connectors and in fact is used as one of the connections on the coolant tubing The difference is that the passage through the fitting is 0 375 in 9 5 mm If the orifice Is present and condenser liquid flow is present the liquid will flash to cooler temperature at the orifice This temperature dif ference is great enough to be easily felt MAIN CONTROL BOARD MCB COMPONENTS Figure 13 shows the drive module with the cover removed To access the control boards loosen the screw on the face of the keypad mount and swing the keypad mount upward O O O SWING UP KEY PAD MOUNT TO ACCESS CONTROL BOARDS
79. y internal components Fail ure to observe this precaution could result in severe bodily injury or loss of life An isolated multimeter will be needed to measure DC bus voltage and to make resistance checks The drive s DC bus capacitors retain hazardous voltages after input power has been disconnected Opening the VFD Access Door ANWARNING Before removing the drive enclosure open access door and verify that the DC bus voltage has dropped to zero by checking the terminals behind the access door Failure to observe this precaution could result in severe bodily injury or loss of life 1 Using recommended screwdriver 6 4 mm 0 25 in flat or 20 star open access door See Fig 2 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis is zero before proceeding See Fig 3 Drive Assembly Catalog Number See Fig 4 for an example Catalog Number Components and Physical Data The Allen Bradley PF755 Frame 6 drive is used for the 230 amp rated ap plication carrier Part No 19XRV0230 See Fig 5 The Allen Bradley PF755 Frame 7 drive is used for the 335 amp and 445 amp rated application Carrier Part No 19 0335 and 19XVR0445 respectively See Fig 6 See Fig 7 for the dimensions of Frames 6 and 7 Fig 2 Opening Access Door o LOCKOUT TAGOUT Z AN DC BUS TEST TERMINALS gt LOCATED INSIDE ACCESS DOOR

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