Marley Premium Variable Speed Cooling Tower Drive User Manual
Contents
1. WNOS AO 2W14 ABNVINDO3S Vn9 an EATTA iAdVNIdd IVA0E2 802 vn83 A0 2W14 AdVUNHH S Wno3 30 TAMA AdVMIdd JVA09 S3Sf4 LN3W32OV dai 8 1 NIG 2G WOW 00E v 33 v3sd div See Gel d NI vy DAV 9 8 NI 22 9AV8 vT 33 v3a88 div OOT ST 254 Salva JAM NI ASN 559071 1ndNI ala zT SN Hal AR a ral La 9NIarA 7314 X04 3S DL 10 NI 81GE 3N040L SED nl XOT TWO Samar LE 9N7 NrHaD YDLON C de a wikis 1 1 Ba 88 1515 NO onT8 1 S3LON3C gt 1 1 1 3dwnr 1 1 HOLIAS 19 21v Y AVI y NO X39078 WNIHN3L S310N31 avo aan aizi 8 z s v e a t 2154 ND 1 Nvd SaI N3 au 19 uz e19 T Y w WE ers ete rm ens ete adnnr uH ms s LVaaIA OF 4 4 eu grx nrma 810 Horas 8H 2 1071 lt Dida 7 NHI1VaHI ZEX aanval E2. VFD System Features Interface Connection for Vibration Switch The Marley Premium Variable Speed Drive package has been designed to operate with a vibration switch to prevent unnecessary damage If the tower experiences excessive vibration and the vibration switch is installed correctly the vibration switch will trip and disable the drive panel The VFD will not oper ate in drive or bypass mode when the vibration fault condition occurs The owner must inspect and if necessary correct the cause of the vibration fault The owner will have to manually reset the vibration switch at the cooling tower before the VFD fault can be cleared allowing the motor to be restarted The normally closed vibration switch will need be wired into the drive at user terminals 7 and 8 From the factory a jumper has been installed across user terminals 7 and 8 This jumper assists in testing and start up of the drive system This jumper should be removed and the appropriate vibration circuit wired in it s place before operating the cooling tower Use 16 AWG Copper wire from terminal 7 to common on vibration switch Use 16 AWG Copper wire from the normally closed contact on the vibration switch to terminal 8 Interface connection for Remote Enable Disable of VFD External Run Inhibit The Marley Premium Package may be disabled from a remote location A normally closed circuit is provided to allow a Building Auto mation System BAS the ability to
3. Marley Premium Variable Speed Drive User Manual 04 155C Marley AN SPX BRAND Note A Warning A Caution Note Contents This manual contains vital information for the proper installation and operation of your cooling tower and accessories Carefully read the manual before installation or operation of the tower and accessories and follow all instructions Save this manual for future reference litroduet ON gs Marley s Premium Variable Speed Drive Features List Typical Connection Layout Storage and Handling Shipment Arrival Installation Enclosure Dimensions Wiring REQUIFOMOMS ssccssis ceeace s aaa da a na a aa i i a pia mada 11 Setup Requirements Temperature Sensor Installation 13 User Controlled Operators Door Mounted Operators Lighted Operation Indicators Keypad Display Motor control using operators VFD System Features VFD and Automatic Temperature Controlled Bypass 18 Interface Connection for Vibration Switch Interface Connection for VFD Enable Disable Automatic DE ICE Feature ss iscate act ac ta e aa ca Start up and Trouble shooting Water Setpoint Temperature and Drive Parameters Changing Water Setpoint Temperature Locking and Unlocking the Keypad Setup Parameter Parameter Values List Fan Rotation Commo
4. in drive mode and in bypass mode to ensure the 3 phase input and output wiring are correct Fan Rotation If the fan rotates backwards in both the drive and bypass mode power down wait 5 minutes then swap any two of the motor output leads If the fan rotates backwards in bypass mode but forward in drive mode power down wait 5 minutes then swap any two of the AC line input leads If the fan rotates backwards in drive mode but forward in Bypass mode power down wait 5 minutes then swap any two of the AC line input leads AND any two of the motor output leads Common Warnings and Faults Below are a selection of the most common warnings and faults likely to be seen during the start up of the Marley Premium System This is not a compre hensive list Please reference the ACS800 Marley Cooling Technology Firmware Manual for a complete list of faults and warnings After a fault condition has been fixed the Reset button on the keypad will need to be pressed to clear the fault and allow the drive to resume operation WARNING If the ABB keypad indicates an erroneous temperature readout of greater than MEAS TEMP1 110 F or a reading of the RTD is probably not connected properly These or readings represent the likelihood of the RTD having a broken or damaged con WARNING necting cable the possibility of being wired incorrectly or of not having the RTD TEMP1 LOSS installation completed FAULT The modular
5. keypad is disconnected from the drive panel or has lost com PANEL LOSS munication to the drive more motor leads not connected to the drive or there is an open MOTOR PHASE Circuit in the motor FAULT VIBRATION SW The vibration switch circuit is open The vibration switch could be tripped missing or the jumper for operating without a vibration switch is missing The External Run Inhibit circuit is open The Building Automation System BAS WARNING has told the drive not to run or the jumper for operating without a BAS system RUN DISBEED is missing Note the drive will still operate in Hand mode Sleep Mode is a normal operation warning The water temperature is below the level requiring the fan motor to operate Unnecessary energy consumption WARNING cee i s i ii would result even if the fan operated at minimum speed An increase in the SLEEP MODE heat load drive will automatically cause the drive system to restart the fan and lower the temperature VFD Start up and Troubleshooting Maintenance Precautions Read and understand the Caution and Warning statements on page 3 of this manual before proceeding with any maintenance or troubleshooting procedures The following procedures are intended for use by qualified electrical mainte nance personnel and should not be viewed as sufficient instruction for those who are not otherwise qualified to operate service
6. AUTO REF2 SELECT 4 20ma signal Terminate customers Speed Reference wires to terminal prgram to read Al2 block X21 located on the face of the VFD and behind the 0 10vde signal plastic swing out door prgram to read Alt 4 20ma connect to points 5 and 6 or 0 10vde connect to points 3 and 4 16 01 RUN ENABLE Di5 Enable from VFO Output Contactor 35 02 TEMP1 RTD SELECT NOT IN USE Disables all Water Temperature signals 41 02 BYPASS ENABLE SEL 018 Internally Wired Signal to Allow Bypass 41 03 BYPASS TEMP CTRL CONSTNT SPD Disables Temp Modulation in Bypass 41 06 VIBRATION DI SEL DI9 NC Vibration Signal required to operate Indicates that these parameter settings are essential to the operation of the Pre mium System and should not be changed To view the BAS remote speed reference signal from the VFD keypad make the following change Using the SINGLE arrow on the keypad move the flashing curser to the second line then press ENTER Press the SINGLE arrow key until the second line down from the top changes to 19 AI2 ma when using a 4 20ma signal or 19 1 V when using a 0 10VDC signal Press ENTER to save this change This line will now show the signal value of the customer s remote speed reference signal 4 33 34 Optional Control Configurations With selector switch in VFD position and H O A in AUTO position e If the remote speed reference signal is active and bet
7. Place the VFD OFF BYPASS switch in the BYPASS position When this switch is in the Bypass position the contactor will control the motor and function as a full voltage non reversing starter Place the HAND OFF AUTO switch in either Hand or Auto In the Hand mode the fan will run continuously at full rpm 60Hz In the Auto mode the fan will cycle on full rom and off zero rpm to maintain temperature set point To stop the motor in either VFD or BYPASS Turn the VFD OFF BYPASS switch to Off position When the VFD is running and the keypad is in the L local mode of operation the drive can also be stopped by pressing the stop button on the keypad Q 17 18 VFD System Features VFD and Automatic Temperature Controlled Bypass Normal automatic operation of the Marley Premium drive package requires that the VFD OFF BYPASS switch be in the VFD position and HAND OFF AUTO switch in the Auto position These switch positions enable the VFD package to control the heat load demands based on the user s programmed set point For water setpoint adjustment see Changing Water Setpoint Temperature on page 21 under VFD Startup and Trouble Shooting The rpm of the variable frequency drive will vary according to the amount of cooling necessary heat load In the standard configuration a Marley furnished RTD sensor supplies the reference signal relative to temperature Optional configurations are pro vi
8. disable the cooling tower motor by opening this circuit The drive controller and the isolation bypass contactor will both become inoperable with the opening of the External Run Inhibit circuit For the drive bypass panel to operate the motor one of the following condi tions must be true The factory supplied jumper between terminal points 17 and 18 must be present or The user must supply a closed dry contact wired between terminals 17 and 18 to complete the circuit Note 20 VFD System Features Automatic DE ICE Feature All Marley Premium packages come equipped standard with a DE ICE switch located in the front panel and wired to the control system However the DE ICE functionality comes disabled from the factory and each user must determine if the De icing functionality is appropriate for that specific application If the user wants De icing enabled parameter 41 01 will need to be changed to Enable In seasons that cause ice to form on the cooling tower fill the generated warm air can be circulated through the cooling tower in reverse to cause ice on the fill to melt The De icing operation is more than an off on switching action The De icing switch enables a pre programmed operation within the drive system When De icing is actuated the motor will reverse for 3 minutes at half speed and then will automatically revert back to the correct direction at the commanded reference speed Before you enable th
9. drives Do not run in the same conduit e When drilling conduit holes in enclosure DO NOT allow metal shavings to fall into drive controller or surrounding controls Do not drill directly above drive controller e tis recommended that whenever possible all wiring into the VFD en closure be routed through the bottom of the cabinet This will eliminate condensation and moisture from traveling though the motor and power conduit cabling into the enclosure Output Wiring If a wire conductor is undersized it restricts the current flow to the motor thus causing a voltage drop The motor has been sized to produce a certain amount of torque which requires power If the motor current is limited it will reduce the amount of power available to operate a load The motor will continue to attempt to produce enough torque for the given load but internal tempera tures will increase If the load is too great the conductor insulation will break down due to excessive heat which could lead to a motor short circuit motor conductor failure wire short or wire conductor failure 11 Note 12 Wiring Requirements The drive is sensitive to the amount of capacitance either phase to phase or phase ground present on the output power conductors If excessive ca pacitance is present the drive may trip When selecting output cables follow these guidelines e The cable selected must have alow capacitance DO NOT use mineral impregnated cable because
10. it has a very high capacitance Capaci tance is also increased by immersion of the cable in water Thelongerthe cable the greater the capacitance Cable lengths greater than 100 ft will be considered as possible candidates for motor filters and should be discussed with engineering for specific applications Output filters can easily be added to the output of the drive where appropriate Because of the high frequency switching and increased capacitance the drive may fault under some conditions if the output cables are close to output cables from other drives e DO NOT use lightning arrestors or power factor correction capacitors on output of VFD e careful when pulling wire through conduit DO NOT DAMAGE the wire insulation Typically wire damage occurs at elbows or bends in the conduit run Based on VFD requirements and operational characteristics re search has been done to design cabling that will provide the best product available for output switching devices Motor cabling has been produced and is available with reduced capacitive coupling and common mode noise reduction One example is Belden 1000V UL Flexible Motor Supply Cable Cable designed specifically for VFD applications Belden 1000V UL Flexible Motor Supply Cable Grounding For safe dependable operation drives must be grounded according to na tional and local codes Setup Requirements Temperature Sensor Installation In order to p
11. or maintain the equipment discussed Preventive Maintenance Before performing preventative maintenance remove all power and check the DC bus voltage see the ABB Hardware Manual 3AFE 64681338 The following preventive maintenance procedures are recommended at six month intervals Check the condition and tightness of connections Make sure the ventilation is effective and temperature around the drive controller remains at an acceptable level f necessary remove any dust and debris from the drive system If anything unusual occurs when putting the drive controller into service or during operation be sure all recommendations relating to the environment mounting and connecting the drive controller have been followed 27 e1nso ou3 ZL VIN3N SNv3 3YNSOTONS ZL VW3N SSVdAB LO3NNOOSIQ N3 v3H8 LINDYID HLM Add 008SOV 88V 8 2IN 3 3d dH 29VA 12W N d Q3118IHDBd SI CISNA JV 1 d a HONDSHL SLINIYIID ONIZION3N338 YO Sa MV J8 AINDSID 30 SNISD1238 3A1IL3d38 JHL 321933N3 3 5 38 NYI 1109319 ANY IN3WdIn03 JHL C3NIWY3L3C N338 SVH LI TIIN 321933N333 38 LON AWW LINJA 30IA30 3AILO31UBd 11023192 A8 3ZI1983N330 SI 1102010 V 3314V 1 310N 97 Ebl 0 9 SdWY 008 111 I NI S8 DMV 2 9 SdMNV 011 18 1 NI Ob DMY 1 8 SdWV 08 EE 8 I NIPI vI 8 SdMV 2 E 0 Yad 254 d 1Vd 3HI NI ISN WNIWASL VH14 AH
12. 8 SdWV 2E 0 O3N ddd 2S4 Galva FYIA NI ISN TWNIWH31 AO 2W14 ABVINDO3S 1vn93 ao ead AaVWIad IVA0E2 802 7WnO3 AO eW14 AdVINHH S 7Wn83 A0 td AWW ad QVAO9Y S 3SN43 1N3W32V 1d33 NI 8 GE 3N0 01L 9n OLOW T1314 404 G3SN 38 OL LON TBNVd OL TVNa INI 320718 TVNINa 1 S310N3I X93078 TVNINa 1 S3LON3T NO 32018 TWNIWAGL S310N3I 911 NO 32018 1VNINd 1 13NVd S310N31 Xnv WE 017 155 321 31 55 CNVH TSS anvad NOLLVSSIA 171093 1 3 831V3H 31VSN3TN02 aava SSVdAg 30143A0 SSVdAg AON 983M NO SSVdAg dn1OV1NHO SSVdAg NO O123V1ND2 AIad 49 5 erx nna 81 IN_ Has 81 NOILVAEIA Ed SSVdAH 1 NISZ2 WOW 00 v d 2V da div S22 SeT 8 1 NI vy E 9 1 NI 22 DAV8 3 v3s8 OOT ST NI 81SE 3N0301 964 Salv FAIA NI 3SN 5n1 ANNDXD LNdNI SINT 1ndNI eiu NH3 v388 17212 ATWOIILVWOLNY 1491 VN 1 41 SSVdA8 JI1VMHITV iNDILNYI 29 30 Standard Mode of Operation Method 1 Default ABB has preloaded this VFD with custom firmware per SPX Cooling Technolo gies requirements Specific motor parameters listed on page 25 are entered via the keypad during start up The pr
13. ER depend on the operation mode of the panel For detailed information concerning the keypad please refer to Overview of the Panel in the firmware manual ACS 800 Marley Cooling Tower Application program Note User Controlled Operators To turn the control panel On Turn the VFD OFF BYPASS switch and the HAND OFF AUTO switch to the OFF position Next turn the main disconnect switch to the on position This sup plies power to the control panel and initiates start up of the drive The keypad will first display and identify the software and version number that the drive system has installed To operate the motor using the Variable Frequency Drive Place the VFD OFF BYPASS switch in the VFD position Place the HAND OFF AUTO switch in either Hand or Auto In the Hand mode the drive is operated in the manual mode To change the speed in Hand mode press the REF button on the keypad Then use the arrow keys of the keypad to change the rpm By arrowing up or down with the double arrow on the left causes a fast change Up or down arrow on the right causes small change In the Auto mode the drive responds to a temperature reference signal from a RTD sensor This sensor normally located in the outlet piping of the cooling tower monitors the temperature and signals for any required rpm changes due to heat load To operate the motor in the Bypass Mode
14. Notes For single enclosure installations allow 6 minimum clearance from VFD cabinet sides and 1 minimum from top and bottom For multiple enclosure installations mounted side by side allow 12 minimum clearance between VFD cabinets NEMA Dimensions A B C 208V 230V 380V 460V R2 24 18 12 1 3hp 1 8 hp 2 75 hp 2 10 hp R3 R4 12 5 20 hp 5 20hp 10 30hp 15 40hp R5 48 2 25 40hp 25 40hp 40 60hp 50 75 hp R6 48 36 20 50 60hp 50 60hp 70 120hp 100 150 hp R6 60 36 20 75hp 75 hp ili Increase B dimension by 3 for each rain hood The R2 enclosure 24 x 18 x 12 has rain hoods on the left side only R2 through R6 enclosures have rain hoods on both left and right sides Installation Notes For single enclosure installations allow 6 minimum clearance from outer most width dimension including the rain hoods and 1 minimum from top and bottom For multiple enclosure installations mounted side by side allow 12 minimum clearance from outer most width dimension including the rain hoods 10 Questions Contacting SPX Cooling Technologies When contacting with questions regarding the Marley Premium Package reference the following numbers Marley Order No ABBS N Job No An example of the label located on
15. R 76 9F I e Statuie ow WATERTMP 10 START STOP DIR Parameter group SPEED Actual signal 01 EXT1 STRT STP DIR CURRENT names amp values Parameter 2 Parameter value Direction of rotation gt Forward Drive ID number Reverse TR gt 769 T Status row Drive control status L Local for Keypad Entry control R Remote Front of Cabinet control operators FUNCTION MODE DRIVE SELECTION MODE Function Mode Drive Selection Made Drive Selection Selection Not used ID numer change Selection v v EN v Function Enter Change Start Mode amp Accept New Value 1 R 76 9F I Status row ACS 800 75 KWI Motor Setup Application Macro List of ASAA7000 Speed Control EXT1 functions Device type ID NUMBER 342 Application amp ID number Note Note VFD Start up and Troubleshooting Parameter Values 99 04 Should indicate DTC If this reads scalar change to DTC 11 05 Enter motor slip speed Do not enter 1800 RPM 12 02 Set DE ICE time from 20 to 1 minutes Factory pre set 3 min 20 02 Enter motor slip speed Do not enter 1800 RPM 20 03 Max current Enter motor nameplate FLAs at 1 00 service factor supply voltage 25 Record Critical speed lockouts if any 30 07 Motor load curve Enter 119 40 22 Enter 600 seconds This keeps VFD from over cycling on low h
16. TRT STP DIR 06 Auto Start Stop Command 11 02 HAND AUTO SELECT Da 2 Pos Selector Switch for Hand Auto 11 03 HAND REF1 SELECT KEYPAD Hand Speed Ref from VFD Keypad 11 06 AUTO REF2 SELECT KEYPAD Auto PID Setpoint from Keypad 15 01 ANALOG OUTPUT1 RTD SUPPLYmA Excitation current for RTD 16 01 RUN ENABLE Di5 Enable from VFO Output Contactor 35 02 TEMP1 RTD SELECT 1 x RTD 100 RTO directly connected to Alt 40 07 TEMP1 FDBK Al SEL 0 10 Analog Input 1 used for RTD temp Fdbk Group40 PID CONTROL See Params Configure the PID Temp Ctrl Loop 41 02 BYPASS ENABLE SEL 018 Internally Wired Signal to Allow Bypass 41 03 BYPASS TEMP CTRL ENABLED Allows Temp Modulation in Bypass 41 06 VIBRATION DI SEL Dg NC Vibration Signal required to operate TEMP1 LOSS FUNC FitNoBypass Defines the Temp Signal Loss Function Indicates that these parameter settings are essential to the operation of the Pre mium System and should not be changed 31 32 Optional Control Configurations Method 2 Remote Speed Reference Signal Deviation from Default Design The Marley temperature control system is de activated and the VFD is config ured to follow a remote speed reference signal such as 4 20ma or 0 10vdc from a Building Automation System This signal would be the Speed Reference for the Drive to follow when in Auto mode The Marley RTD will no longer be used but could remain installed in the pipe and connected to the VFD for use as an emergency
17. X V D nw vNa31X NA NEY d 10 0103 ve Tl 131853 lt i gt 2N 9 4 q sm SSVdAa 4 zu 5 n XnV WE 9 T 4 DASS Haass Set 39I 3d ESS sarang 2y Vix e SSVdAd A 4 LLL AON3D83H3 Hg 1 NVH ISS ea avo 330 22X x E x No A ssvana O 440 IaaAn 10y or gd SSVdAg 09 6 AON39343 an1291N 9 1 SSVdAB uv 103 a3dwnr No Uv I ao e Tex m Agad cas Li an12VIN tex ATan 2 IA dA gm end SSVdAH DANY A 1 ain 440 AYTA 9__96N s inva 19 21v asia ers n mA a 1915 BE 3009 2X WA 027 UN ji n Aaaa 235 13 INI NI 8 ISE 3NOADL dB 5n NHa InaNI n Na nJ 123 ATWOIILVWOLNY 15915 1N NdIr10 SSVdAd JILYWOLNY iNDILOVO 28 eunso 5u3 Ye VININ JOOD1nO SNVJ tSdl HUM 3YNSOTONS dc VW3N SsvdAg INNOOSIQ YINVIYA UNIJI HUM JAYO O08SOV 88 8 23E 3ed dH 2VA 12W N d 1I8IHHdd SI CISNA 39v 1433 HONOYHL SLINISID ONIZION3N33M YO S33iv3N8 AINDAID 30 SNISOD 1234 3ALIL3d33 JHL 1371943 733 5 38 LINIAID CNV 1N3WdInO3 JHL AWHL Q3NIMN313I N338 SVH LI TILNN 13219343N334 38 LON LINIYID IHL 39IA31 3AIL23103d LINDAI V AH SENA SI LINIJI V 3149 97 DMY 0 9 SdMV 002 111 1 NI S8 DAV 2 9 SdMV 011 18 1 NI Ob DAV 1 8 SdWV 08 EE 97 OAV vi
18. anging the second line to Group 16 Press single arrow keys changing third line to Parameter 02 Press ENTER key once brackets will appear OPEN Press single arrow key to change OPEN to LOCKED Once LOCKED is displayed press ENTER key once to save the change Brackets should disappear confirming keypad is locked LOCKED Press ACT once to return to normal viewing screen Setup Parameters The Marley Premium package is pre engineered and programmed from the factory to require only a minimum of setup parameters to run as designed Begin by changing or verifying that the VFD Off Bypass switch Hand Off Auto switch and DE ICE switch is in the Off position These are the main switches located on the front of the VFD control cabinet Next check the VFD parameters by using the control keypad By using the mode and arrow keys on the control keypad the LCD screen will display cur rent parameter settings and any changes necessary for the proper operation of the drive 23 24 VFD Start up and Troubleshooting AUTUAL SIGNAL DISPLAY MODE PARAMETER MODE Actual Signal Parameter Display Mode Display Mode Actual Signal Actual Signal Group Selection Parameter Selection Fault History Fault Message Fast Slow Selection Scrolling Fe low Value Change Value Change v y Enter Selection Enter Change amp Accept New Mode amp Accept New Value Signal 1 R Status row 1
19. as been displayed on the readout press the ENTER button This is important Pressing the ENTER button confirms the change by removing the brackets and enters the new temperature into memory 21 A Warning 22 VFD Start up and Troubleshooting The effect of changing the setpoint temperature The temperature of the water leaving the tower is constantly being monitored When the setpoint is changed the drive will be instructed to run the motor at an appropriate rpm to bring about additional cooling or slow and stop the fan motor to eliminate cooling If the water leaving the tower remains below setpoint the drive system will go into a sleep mode This is an energy sav ing mode that turns off internal components that are not necessary during prolonged periods of inactivity At this time for extended periods when water cooling is not necessary a Warning Sleep Mode indication will appear on the display screen This is simply an indication that the drive is in an energy saving condition The drive s processor will continue to monitor the water temperature Before the drive goes into a sleep condition the system will wait for 6 minutes This default time delay setting is a programmed by the factory and can be adjusted has necessary When the water temperature rises above the setpoint the drive system will wake up and instruct the fan motor to run at the needed rpm For instructions on changing the sleep dela
20. backup The Build ing Automation System would have a REMOTE START contact closure to tell the drive when to operate in the Auto Mode This signal would be wired to the Customer terminal blocks located in the Premium Package terminals 17 and 18 By default from the factory these terminals have a jumper across them the jumper shall be removed and BAS Relay Output will be placed across these terminals which passes 120VAC from Terminal 17 through the BAS Run Contact then back to Terminal 18 allowing it to run in Auto In Auto operation the drive will simply follow the speed reference commanded from the BAS If the drive were to fault and automatically transfer to bypass opera tion the fan would run at full speed with no temperature modulation If Hand operation is desired the Selector Switch located on the Premium Package can be placed in Hand and the Speed Reference will be controlled by the VFD s keypad The parameters to configure the control scheme are listed on the following page Optional Control Configurations Method 2 Parameters Parameter Parameter Name Parameter Setting Comments 99 02 APPLICATION MACRO HAND AUTO Required for External BAS Control 10 01 HAND STRT STP DIR Dit Hand Start Stop Command 10 02 AUTO STRT STP DIR DIG Auto Start Stop Command 11 02 HAND AUTO SELECT DU 2 Pos Selector Switch for Hand Auto 11 03 HAND REF1 SELECT KEYPAD Hand Speed Ref from VFO Keypad 11 06
21. c tor twisted pair cable is recommended for greater noise immunity Ground the shield wire at the drive end only Do not ground the shield at both the RTD and drive ends The sensor should not be in the same conduit with power or control wiring However multiple sensors can be run in the same conduit A thermistor or thermocouple can not be used in place of a RTD User Controlled Operators Door Mounted Operators and Indicators VFD OFF BYPASS Switch selects operation for either Variable Frequency Drive operation or Bypass operation The bypass operation supplies power to the fan motor directly from the supplied line voltage The VFD operation supplies power to the motor through the Variable Frequency Drive HAND OFF AUTO Switch selects operation that enables VFD manual control or selects operation that places the VFD in automatic mode VFD manual allows the operator to manually scroll arrow up or down to raise or lower the rpm of the motor by using the keypad When the switch is placed in the VFD Automatic position the desired set point temperature is entered by way of the keypad and the drive automati cally controls the speed of the motor proportional to the heat load of the cooling tower The temperature reference signal is supplied to the drive by the RTD sensor DE ICE Switch provides the option in cooler climates of reversing the direction of the fan motor In seasons that cause ice to form on the cooling tower fil
22. ded for special applications when interfacing the drive package with Building Automation Systems There are four special methods given for configuring the Premium Drive system beginning on page 32 for these special applications If additional information is needed contact SPX Cooling Technologies control department for explanation and assistance If the system should encounter a drive fault and the control system deter mines that the fault is a non dangerous conditional fault then the control will switch to an automatic temperature controlled bypass This mode of operation provides a continuation of temperature control by cycling the motor on and off in bypass Programmed operation will continue to operate the fan motor relative to the heat load by energizing the bypass contactor The temperature monitoring components continue to function and provide the necessary input to cycle the fan motor off and full rpm on The motor will continue to cycle until the fault has been cleared The drive is capable of automatically resuming operation once certain faults have been cleared The drive faults that will clear automatically are undervolt age overvoltage input output phase loss drive overtemperature and motor overload There will be approximately a 30 second time delay between bypass and transfer to drive operation All other faults must be manually reset to resume operation in drive mode Refer to the troubleshooting guide for resetting faults
23. djustable automatic reverse de icing followed by immediate return to normal operation Factory preset at 3 minutes Hand or Auto selection made easily by using the front mounted drive panel Hand operation allows operator direct control of motor speed Easy readout of actual water and setpoint temperature has been incorporated into the integrated keypad display F or C select able Bypass override switch internal to the panel allows running the motor during startup to check motor wiring e Pre wired terminals provide wiring connections for a remote vibration switch This prevents the motor from running with normal drive control or in bypass mode 39 line impedance is standard with optional increase to 5 total Onthe door status indicators and selector switch give the operator straightforward indication and easy control of drive and bypass operation modes ULListed Drive is designed and pre programmed to Marley specifications at the factory specific motor data required at installation Thedrive keypad is accessible on the front of the NEMA 12 enclosure and located inside for protection when equipped with a NEMA 3R rated enclosure Warranty is 3 years from date of startup or 38 months from date of VFD shipment which ever is less Warranty includes parts labor and travel when a certified startup is purchased This exclusive 3 year Marley ABB warranty is for USA locations only Warranty is 2 years from VFD shi
24. e De icing operation the VFD Off Bypass switch must be in the VFD position and the Hand Off Auto switch must be in either the Hand or Auto Position To enable the De icing operation turn the DE ICE selector switch to ON This will cause the motor to run at half speed in the reverse direction for a period of 3 minutes At the end of the 3 minute period the drive will resume what ever operation it was in prior to the DE ICE switch selection at which time the DE ICE switch should be rotated back to the Off position The DE ICE operation cannot be selected again until the DE ICE switch is rotated to the Off position and then again back to the On position If the DE ICE switch is turned off before the 3 minutes is complete the drive will resume what ever operation it was in prior to the DE ICE switch selection If either of the VFD Off Bypass or Hand Off Auto switches is changed during the 3 minute DE ICE operation the DE ICE operation will be canceled If the drive is powered up with the DE ICE switch in the On position the control system will ignore the DE ICE command until the DE ICE switch is rotated off and then back on again Note VFD Start up and Troubleshooting Water Setpoint Temperature and Drive Parameters The keypad is used to change the temperature setpoint and to enter the ap propriate operating parameters Note there is a significant difference between these types of ent
25. eat loads 41 01 DE ICE enabled or disabled this is location customer dependant 99 05 Enter motor nameplate voltage 99 06 Enter motor nameplate FLAs at 1 00 service factor supply voltage 99 07 Enter supply frequency in HZ 99 08 Enter motor slip speed from motor nameplate do not enter 1800 RPM 99 09 Enter motor horsepower 16 02 Change OPEN to LOCKED Locks the keypad 16 03 358 unlocks keypad After completion of entering parameters 99 05 through 99 09 the display screen will show the warning WARNING ID MAGN REQ This is the warning indicating that the drive is ready to initialize the motor for the first time The drive will send current through the motor windings but not spin the motor Before continuing make sure the fan blades are stationary and not windmilling To initialize the ID MAGN Run move the VFD Off Bypass switch to the VFD position and then move the Hand Off Auto switch to the Hand position This will initialize the ID MAGN run which will last for 10 to seconds Upon successful completion of the ID MAGN run the screen will show WARNING ID DONE To finish the Motor setup the Hand Off Auto Switch must be cycled to Off and then back to Hand The Fan will start spinning at this point 25 26 VFD Start up and Troubleshooting The drive package is now configured fully to run Check the rotation of the fan
26. imary intent for the Marley Premium System is to provide tower motor control that combines the efficiency of a variable frequency drive VFD with the exclusive needs and enhancements for cooling tower operation The Pre mium System incorporates priority design and software development specific for stand alone control of cooling towers This standard configuration will maximize tower operation minimize energy consumption and provide the most state of the art control system for cooling towers All of the exclusive temperature and motor control features designed into the Premium system is incorporated into this first design By incorporating this configuration in operating cooling towers the Marley Premium System guarantees one of the most reliable and efficient field tested controlling methods Description for 1 In AUTO the industrial ABB ACS800 VFD operates in a temperature PID mode Placing the selector switch in the AUTO position utilizes the direct connection from the water temperature RTD to the drive The VFD s processor compares the actual water temperature measured by the RTD to the setpoint temperature and drives the motor at the appropriate rpm By automatically tracking the heat load of the cooling tower Marley s Premium System efficiently maintains the temperature setpoint Operating in AUTO also provides regulated bypass as a back up precaution in the unlikely event that the drive initiates a non cri
27. l the generated warm air can be circulated through the cooling tower in reverse to cause ice on the fill to melt The De icing operation is more than an off on switching action The De icing switch enables a pre programmed operation within the drive system When De icing is actuated the motor will reverse for 3 minutes at half speed and then will automatically revert back to the correct direction at the commanded reference speed The DE ICE function is disabled as shipped from the factory Please refer to page 20 for more informa tion Lighted Operation Indicators VFD Green indicates the variable frequency drive is functioning and in operation BYPASS Yellow indicates the bypass circuit is closed and that the motor is getting power directly across the line EMERGENCY BYPASS OVERRIDE Yellow indicates the Emer gency Bypass Override switch located inside the control panel is in the on position This switch is used for maintenance diagnostics and overrides control and fault circuitry for the drive and should not be used under normal operating conditions FAULT Red indicates an external fault LE overload relay vibration switch safety etc Note 16 User Controlled Operators Keypad Display Under normal operating conditions the keypad displays the actual water temperature the speed of the motor and the motor current Also in the upper left portion of the screen or L is displayed along
28. motor or motor cables Measure the voltage between terminals UDC and UDC to ensure that the drive is discharged DO NOT SHORT across DC bus capacitors or touch unshielded com ponents or terminal strip screw connections with voltage present Install all covers and close door before applying power or starting and stopping the drive controller Userisresponsible for conforming to all applicable code requirements with respect to grounding all equipment DO NOT switch the circuit breaker to the Off position while drive is running Doing so may damage the drive or personnel Use only tools that are electrically insulated Before servicing drive controller Disconnect ALL POWER Placea DO NOT TURN label on drive controller disconnect Lock disconnect in open position Failure to observe these precautions may cause shock or burn result ing in severe personal injury or death Motor Overheating and Damage The ABB ACS800 packaged system gives indirect thermal protection and also has an independent solid state overload to provide protection for the motor The customer can add a optional thermal sensor in the motor but is not required Consideration should be givento installations that require long distance hookup to the fan motor When the distance between the variable frequency drive and the motor is in excess of 100 feet actual wire length a motor output filter is recommended Any operation beyond the
29. n Warnings and Faults Maintenance Precautions Preventive Maintenance Electrical Schematic Standard Mode of Operation Optional Control Configurations The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product Indicates presence of a hazard which can cause severe personal injury death or substantial property damage if ignored Indicates presence of a hazard which will or can cause personal injury or property damage if ignored Indicates special instructions on installation operation or main tenance which are important but not related to personal injury hazards A Warning A Warning ZN Caution Hazardous Voltage Read and understand this manual and the ABB ACS800 Series Manual in its entirety before installing or operating the Marley Premium Variable Speed Drive system Qualified personnel must perform installation adjustment re pair and maintenance of this VFD system or all warranties will be void Any modifications to VFD system not approved by SPX Cooling Technologies will void all warranties Many parts in this drive controller operate at line voltage DO NOT TOUCH Disconnect all power before servicing the drive controller After switching off the input power always WAIT FIVE MINUTES to let the intermediate circuit capacitors discharge before you start working on the drive
30. ng hardware and terminal connection hardware to ensure they are securely fastened and undamaged The Variable Speed Drive system is mounted in a NEMA 12 enclosure rated for indoor use or is available in a NEMA 3R enclosure for outdoor use To prevent thermal fault or equipment damage do not locate the Drive Controller in an area which will receive direct sunlight The drive controller will operate in ambient temperatures ranging from 0 to 40 C 32 to 104 F Do not mount the Drive Control system near heat radiating equipment under leaking pipes or in an environment where the air is corrosive Electrical current through the drive controller will result in heat that must be dissipated into the ambient air immediately surrounding the drive The ventilation openings on the drive enclosure must not be obstructed Installation of adjoining drives must provide space for heat dissipation and ambient air circulation Allow a minimum distance of 12 between drive en closures and 6 between the side of a drive and an adjoining wall Enclosure Dimensions NEMA 12 Dimensions i RED 208V 230V 380V 460V R2 24 18 12 1 3 3 5 hp 2 7 5 hp 3 10 hp R3 R4 36 12 5 20hp 5 20hp 10 30hp 15 40hp R5 48 20 25 40hp 25 40hp 40 60hp 50 75 hp R6 48 36 20 50 75hp 50 75hp 70 120hp 100 150 hp Installation
31. parameters set during the initial start up by Marley can cause motor damage and or personal injury Introduction This manual covers the features operation and setup parameters of the drive system Marley and ABB jointly designed this variable speed drive package specifi cally for cooling tower applications Available exclusively through SPX Cool ing Technologies this Marley Premium Drive System is built around ABB s Industrial ACS800 Series drive The ACS800 Series is a family of adjustable frequency AC drives offered for Marley applications from 3 to 250 hp Sophis ticated state of art technology and circuitry provided in the ACS800 Series incorporates Marley s specific cooling tower knowledge and requirements into a unique package for the cooling tower industry This ultimate drive package has been tested and designed as a stand alone drive control with all the necessary components to provide the most complete and efficient cooling tower drive available Additional input controls such as a temperature reference signal are not required And the Marley Premium Drive does not use an add on temperature controller By combining the ACS800 s state of the art firmware with custom proprietary software this premium drive offers the most efficient designed controller without requiring an additional temperature control device or building automation Features List PWM drive with IGBT switching and integrated bypas
32. pment without VFD startup This is for parts only Marley Premium ABB ACS800 Input VAC 3 Phase Power Marley Premium ABB ACS800 Water Outlet a SsE Note Storage and Handling Shipment Arrival Upon receipt of the Drive System report any damage to the carrier and SPX Cooling Technologies immediately Shipping damage is resolved by filing a freight claim with carrier Remove the Drive System from its packaging and visually inspect exterior for shipping damage Ensure that the reference number of the Drive which appears on the label agrees with the packing slip and corresponding purchase order Verify the correct hp and voltage of the unit If the Drive System is to be stored after receipt replace it in its original pack aging material Do not remove the Drive System from its carton until it is at the fi nal installation site The carton protects the system and prevents damage to its exterior The Variable Speed Drive System will be packaged in a NEMA 12 or NEMA enclosure however this rating is not obtained until installation is completed correctly Installation Precautions To avoid equipment damage follow these precautions when installing the drive controller Prior to installation Open the enclosure door Visually inspect all internal mounti
33. ries The temperature setpoint can be changed while in normal operation with the drive running Adjustments to this setting can be made to fine tune heat load regulation at anytime that is deemed necessary When operational parameters are entered the drive is not running and the keypad must first be unlocked The keypad will be changed to indicate L upper left corner of keypad display and required parameter changes com pleted before starting Changing Water Setpoint Temperature The setpoint temperature may be changed while the drive is running If the normal viewing screen is not present press the ACT button on the keypad once This will cause the display to look similar to 1R3 85 0F 1 Status row WATERTMP 78 7 F SPEED E m Parameter Information CURRENT 12 If the status row indicates L instead of R as the graphic shows press the LOC REM button once This will change the status letter to R and the control will reference the temperature RTD input The status letter must be R to change the setpoint Brackets 1R gt Status row WATERTMP SPEED Parameter Information CURRENT Press the REF button once and brackets will appear around the tempera ture reading on the top line This will allow a change to be entered for the temperature setpoint Use the Single and Double arrow keys to change the setpoint to the de sired temperature After the desired temperature h
34. rovide the variable speed drive with a temperature related refer ence signal a temperature sensor must be placed into the outlet piping as close as possible to the cold water basin The temperature sensor used with the Marley Premium drive package is a standard PT 100 Platinum 4 wire RTD The RTD sensor is furnished with an immersion thermowell and pro vides a NPT connection that accepts the RTD sensor unit By using the thermowell protection is given to the RTD and if necessary the sensor can easily be changed Consideration must be given to mounting the thermowell to insure immersion into the water flow Side installation or better still bottom installation will provide the temperature accuracy needed for proper operation Terminals for landing the 4 wire VFD connection are provided in the housing of the RTD unit M LU Note Note 14 Setup Requirements The sensor must be isolated from all power wiring The sensor and lead wires must be kept dry The supplied sensor must be connected to the drive package control panel using a 4 wire plus shield connection These four jacketed copper conductors should be stranded such as type MTW Machine Tool Wire Use 18 gauge wires to make the connection good choice and cable recommendation for the 4 wire connection to the RTD is Belden 9418 The connection can also be made using 4 single wires or multiconductor cable Shielded multicondu
35. s design Indoor NEMA 12 or outdoor NEMA enclosures available 3 300 hp available for 380 575 VAC 3 60 hp available for 208 230 VAC Main circuit breaker disconnect with thermal and short circuit protection No add on or external controller required The temperature controller is integrated into the drive system The RTD provided sensor is to be installed into the tower outlet water piping Maintaining the water temperature set point is accomplished by varying the speed of the fan motor or by cycling the bypass contactor in the automatic bypass mode To maintain setpoint water temperature in automatic bypass mode the motor will cycle on and off at full speed Automatic Bypass circuitry is standard on all premium packages This feature transfers the fan motor from the variable frequency drive to an across the line bypass contactor in the event of specific drive faults Fault conditions are evaluated for severity and possible damage to the drive system and motor Recognizing faults not detrimental to the motor mechanical and electrical system will allow transfer to the automatic bypass mode A critical condition such as a short circuit fault will not allow bypass operation Tripless design for the elimination of nuisance faults Nuisance faults caused by reverse rotation downdraft flying start drive start into high rpm undervoltage or overvoltage De icing function is standard with time a
36. the inside of the drive enclosure door SPX Cooling Technologies Type Premium Package Marley Order No ABB Part No MCT415 20 PRE N12 B ABB S N 20407000933 ABB Tech Support 1 800 435 7365 Then 94 UL TYPE 1 SCCR 5KAIC Refer to Dwg MCTPRE 10HP 415VAC 28 3FLA 3 Phase 60 Hertz Replacement Fuses Primary Bussmann FNOR 1 1 2 or Equal Secondary Bussmann FNM 2 or Equal Job No JO1425 Manufacturing UL File E209528 Wiring Requirements It is critical that the correct wire conductor size is used for input and output wiring to the VFD Good wiring practice requires the separation of control circuit wiring from all power line and load wiring General Wiring Practices Follow the wiring practices required by national and local electrical codes Use metallic conduit for all VFD wiring Do not run control and power wiring in the same conduit Metallic conduits carrying power wiring or low level control wiring must be separated by at least 4 inches 10 cm Nonmetallic conduits or cable trays used to carry power wiring must be separated from metallic conduit carrying low level control wiring by at least 12 inches 30 5 cm Wherever power and control wiring cross the metallic conduits and nonmetallic conduits or trays must cross at right angles Power wiring to the motor must have the maximum possible separa tion from all other power wiring whether from the same drive or other
37. tical fault Bypass is blocked on critical faults to prevent damage to mechanical and electrical hardware A non critical fault will enable continued operation by switching to a regulated bypass The Marley Premium System will continue to monitor the temperature and control motor operation While operating in auto bypass regulation continues as the microprocessor modulates the bypass contactor maintaining the water temperature within operation guidelines This emphasizes the importance of having the temperature signal interfaced directly to the Marley Premium Sys tem Should the temperature signal be lost the drive will perform the signal loss function defined in parameter 41 17 When switched to HAND mode by the selector the drive and motor speed will be directly controlled by the VFD keypad Pressing the appropriate up or down arrows on the keypad will manually change the speed of the motor Standard Mode of Operation Key parameter settings for this control method configuration are listed below This only represents a partial list of control signals and parameters that are configured for the Premium System Many other parameters are used and required for proper operation of the Marley Premium System Parameter Parameter Name Parameter Setting Comments 99 02 APPLICATION MACRO PID GTRL Required for PID Temp Loop 10 01 HAND STRT STP DIR DI Hand Start Stop Command 10 02 AUTO S
38. ween 4 20ma or 0 10vdc the VFD will follow this command and run the motor If the remote speed reference is lost or below the minimum range the VFD will run the motor at a minimum speed of 14 HZ until the speed reference signal is returned With selector switch in BY PASS position and the H O A in either the HAND or AUTO position The motor will run at full speed through the full voltage start by pass circuit Temperature modulation is not active in this mode because the internal temperature controller has been disabled A message will be displayed on the keypad as shown below and serves only as a warning that the VFD circuit is not operational because the VFD selector switch is not in the VFD position therefore missing it s run command WARNING RUN DISABLED FF54 35 SP COOLING TECHNOLOGIES 7401 WEST 129 STREET OVERLAND PARK KANSAS 66213 UNITED STATES 913 664 7400 spxcooling spx com spxcooling com In the interest of technological progress all products are subject to design and or material change without notice 2010 SPX Cooling Technologies Inc Printed in USA Manual 04 155C
39. with the ID number R symbolizes the drive is being referenced by a remote input i e tempera ture RTD and can be controlled by the front panel operators This is normal operation allowing automatic heat load regulation providing any changes to be made to the setpoint water temperature The L indicates the drive is being controlled manually by the keypad input and will not allow automatic heat load regulation In conjunction with manually controlling the drive the keypad is used to change the water setpoint temperature and entering the necessary operational pa rameters See Locking and Unlocking the Keypad This drive uses the ABB ACS 800 series The keypad is the same for all 800 Series drives The LCD type display has 4 lines of 20 characters e The language is selected at start up parameter 99 01 The control panel has four operation modes Actual Signal Display Mode ACT key Parameter Mode PAR key Function Mode FUNC Drive Selection Mode Drive key Actual Signal Display Mode Parameter Mode Function Mode Drive Mode Change between Local keyboard control Remote Door operators amp Indicators ACT PAR FUNC DRIVE Fault Reset Foward Direction of Rotation Reverse Direction of Rotation Activate Reference Setting Start In local L status mode only 209 Stop In local L status mode only 6 0909Q06ex0000 The use of single arrow keys double arrow keys and ENT
40. y time call the controls department of SPX Cooling Technologies Locking and Unlocking the Keypad Under normal operating conditions the keypad should remain locked A locked position prevents accidental changes or al terations made by unauthorized personnel Inappropriate program changes can be detrimental to personnel safety and or cause equip ment damage and malfunction After completing the appropriate startup configuration or completing necessary trouble shooting procedures return the keypad to a locked condition Unlocking the Keypad Press PAR once Press the double arrow keys changing the second line to Group 16 Press single arrow keys changing third line to Parameter e on the last line should now be displayed e Press ENTER key once brackets will appear 8 e Press double arrow and single arrow keys to change to 358 Double arrow key change s the value in large steps Single arrow key change s the value in small steps VFD Start up and Troubleshooting When 358 is displayed press ENTER key once to save the change ll should now be displayed on the last line confirming change has been made Press single arrow until 02 Parameter is displayed on line 3 The word OPEN should now be displayed on the last line confirming the keypad is unlocked Press ACT once to return to normal viewing screen Locking the Keypad Press PAR once Press the double arrow keys ch
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