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Operation & Installation Manual 09/2005

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1. 115V 24V UTBt m 85 REMOTE POWER e ONIOFF NOTE7 amp NOTE 5 NEUTRAL e o ee NOTE 10 MODE COOLING KET SWITCH NOTE8 TOWER IM T FOURTH 1 STARTER E gj E M EP2 NOTE 10 AER COOLING y PUMP TOWER 2 o 6 7 STARTERS I STAGE STARTER E if gei o NOTE 1 2 NOTE 10 EWM H 76 COOLING D TOWER IPE 75 SECONDH STAGE NOTE 6 NOTE 6 STARTER Ly SWITCH SWITCH NOTE 9 DELTAT DELTAT FLOW FLOW I be 1 VNOTEdG OREVAP OR COND H CP2 COOLING coins 7 DS ET NOTER AN FIRST EF STAGE e STARTER E cF COMMUN 81 CONDENSER ano __ ALARM RELAY WATER e BANC Lea NOTE 4 PUMP STARTERS POWER b NOTE 9 52 o COOLING TOWER b E 1 BYPASS VALVE 70 VOC Al omj 7 NOTE 11 COOLING TOWER VFD a F A CWI 1 MICROTECH eee COMPRESSOR CONTROL BOX TERMINALS CTB1 OTA 115 VAC STARTER LOAD SIDE TERMINBALS COMPRESSOR CONTROL SCHEMATIC 330342201 CP1 e L1 w 2 12 LEGEND 330343001 23 5A e 23 Ti Te T2 T4 T3 T5 COMPRESSOR 25 o Ja COMPRESSOR TERMINALS FIELD SUPPLIED ITEM MOTOR 25
2. Fault F OverVoltage Time Since Fault 0000 23 52 Drive is indicating an alarm The LCD HIM immediately reports the alarm F Power Loss condition by displaying the following Hz Alarm name Type 2 alarms only Main Menu Alarm bell graphic Diagnostics Parameter Device Select Manually Clearing Faults 1 Press Esc to acknowledge the fault The fault information will be removed so that you can use the HIM 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared 3 After corrective action has been taken clear the fault by one of these methods Press Stop Cycle drive power Set parameter 240 Fault Clear to 1 Clear Faults on HIM Diagnostic menu Table 35 Fault Alarm Types Description and Actions NOTE See Table 33 and Table 34 for definition of fault alarm types Description Action if appropriate Drive received a start command while in PrechargeActv Auxiliary In Power Loss Continued next page the DC bus precharge state Auxiliary input interlock is open DC bus voltage remained below Power Loss Volts for longer than Power Loss Time Enable Disable with Fault Config 1 Check remote wiring Monitor the incoming AC line for low voltage or line power interruption 81 82 UnderVoltage Description DC bus vo
3. User Dspy Lines fal Vv User Dspy Time Start Up Menu User Dspy Video Reset User Dspy Sen Press ED 0 move between menu items Press to select a menu item Press e to move 1 level back in the menu structure Press to select how to view parameters 79 Using the LEDs Drive LEDs Figure 40 Front Panel LED Indications La Description PWR when power is Power applied to the drive PORT 1 Status of DPI port internal communications if present Status of communications MOD 1 module when installed NET A 1 Status of network if connected Status of secondary network i NET B 1 if connected This section provides information to guide you in m troubleshooting the PF 700H control family Included is a listing and description of drive faults with possible solutions ST e po 3s when applicable and alarms ez La Faults and Alarms A fault is a condition that stops the drive There are three fault types Table 33 Fault Types When this type of fault occurs and Auto Rstrt Tries is set to a value greater than 0 a user configurable timer Auto Rstrt Delay begins When the timer reaches zero the drive attempts to automatically reset the fault If the condition that caused the fault is no longer present the fault
4. Installation Operation and Maintenance Manual IOMM VFD 2 Group Chiller Part Number 331375701 Effective Sept 2005 Supercedes IOMM VFD Variable Frequency Drives Air Cooled LiquiFlo and LiquiFlo 2 0 For Centrifugal Chillers With MicroTech 200 or MicroTech II Control lt b ap Pl McQuav Air Conditioning Table of Contents Introduction ire erre reote rero Paene oheeone d MicroTech 200 VFD Control 41 Environmental Conditions 5 Chiller Control States 41 Harmonic Distortion eeeeees 5 Control Sequence MicroTech 200 42 General Description ree WDC WCC Dual Compressor VFD Operation43 Air Cooled LiquiFlo LF Standard Features 6 MicroTech 200 Controller VFD Menu Screens43 LiquiFlo 2 0 LF 2 0 Standard Features 7 MicroTech II VFD Control 50 Codes Standards ssessssssss 7 General Description sessssseeee 50 Quality Assurance s essere 7 Sequence of Operation 50 A C LiquiFlo Nomenclature 7 Interface Panel Screens MT II 52 LiquiFlo 2 0 Nomenclature 7 Operation Small A C SP600 amp LF 2 057 Definition of Terms 9 Using the Initetiaces 4 se
5. Menu 11 Screen 1 Control Mode 11 Control Mode hh mm mon dd yy Mode Manual Off etc MinVFDSpeedSpt Max Speed Spt Menu 11 Screen 2 Control Mode Setpoints This entire screen only appears when a VED is used 11 Control Mode hh mm mon dd yy Sample Time XXSec Spd Step XX A Mod Limit X X F Lock VFD Speed Off On Deadband X X F Lock Speed XXX Menu 13 Screen 1 Motor Amp Setpoints 13 Motor Amp Spts hh mm mon dd yy Amp Reset No Reset Active Spt A Reset Signal XX Xma Min Amp Spt XXX Network Spt XXXA Max Amp Spt XXX IOMM VFD 2 Menu 13 Screen 2 Motor Amp Setpoints 13 Motor Amp Spts hh mm mon dd yy Soft Load Off Dual Speed Spt XXX Begin Amp Lim XX LagPDRateSpt X X M Ramp Time XXMin Y Menu 23 Screen 1 Dual Network Setpoints 23 Dual Net Spts hh mm mon dd yy Slave Address 01 01 Start up Unload LL Mode Auto LagStrtup DT X X F LL SwOver N A 00 00 LagShtdnOffst X X Y Menu 26 Screen 3 Unit Setu 26 Unit Setup hh mm Mon dd yy Full Load Amp XX Hi Mtr Cur Enable Vane Open Switch Yes No Str Tran Enable Low Mtr Cur Enable Starter Flt Enable Y Table 11 MicroTech 200 VFD Setpoints ltem BDefaultSetpoints Ranges MicroTech Keypad Menu Sample Time Sample Time 10 Sec 1 to 63 Sec Menu 11 Screen 2 0
6. NP Hz Conflict Fan pump mode is selected in Torq Perf Mode 53 and the ratio of Motor NP Hertz 43 to Maximum Freq 55 is greater than 26 Power Loss Drive has sensed a power line loss Prechrg Actv Drive is in the initial DC bus precharge state Sleep Config Speed Ref Cflct Sleep Wake configuration error When Sleep Wake Mode 178 Direct possible causes include Drive is stopped and Wake Level 180 Sleep Level 182 Digital Inx Sel 361 to 366 is not set to one of the following Stop CF Run Run Forward or Run Reverse Speed Ref A Sel 90 or PI Reference Sel 126 is set to Reserved Under Voltage The bus voltage has dropped below a predetermined value VHz Neg Slope Custom V Hz mode has been selected in Torq Perf Mode 53 and the V Hz slope is negative The wake timer is counting toward a value that will start the drive Table 22 Alarm Descriptions LF 2 0 NOTE Type 1 Auto resettable 2 Non resettable 3 User configurable Analog In Loss Description An analog input is configured for alarm on signal loss and signal loss has occurred Bipolar Conflict Dig In ConflictA Dig In ConflictB Continued next page Parameter 190 Direction Mode is set to Bipolar or Reverse Dis and one of more of the following digital input functions is configured Fwd Rev Run Fwd Run Rev Jog Fwd or Jog Rev Digital input functions are in conflict
7. Spare Table 17 Precharge Board LED Indicators Description Power ON Indicates when pre charge board power supply is operational Indicates one of the following alarms occurred causing the pre charge to momentarily stop firing Line Loss Low Phase single phase dropped below 80 of line voltage Input frequency out of range momentarily Note An alarm condition automatically resets when the condition no longer exists Indicates one of the following faults DC Bus short DC Bus not charged Input frequency out of range Overtemperature Note A fault indicates a malfunction that needs to be corrected prior to restarting A fault condition is only reset after cycling power LED Drive Status Figure 33 Location of the Ready LED IOMM VFD 2 59 Ready LED Table 18 Ready LED Status Functions State Description Flashing Drive ready but not running and no faults are present Stead Drive running no faults are present Flashing The drive is not ready Check parameter 214 Start Inhibits Yellow Steady An alarm condition exists Check parameters 211 Drive Alarm 1 and 212 Drive Alarm 2 An alarm condition exists Check parameters 211 Drive Alarm 1 and 212 Drive Alarm 2 Steady A fault has occurred Red Flashing Determining Drive Status Using the Status LEDs x DPIC ti Two stat
8. d on on lt IOMM VFD 2 38 LiquiFlo 2 0 Figure 19 VF 2037 2055 Free Standing NOTE Closed loop cooling module is also required Unit Shipping Weights Weight Ib kg 1600 726 1600 726 IOMM VFD 2 39 40 Figure 20 VF 2080 2110 Free Standing 75 11 35 43 REF 56 X 1 50 SLOT 12 PLACES NOTE Closed loop cooling module is also required Unit Shipping Weights Weight Ib kg 2000 908 2000 908 IOMM VFD 2 IOMM VFD 2 MicroTech 200 VFD Control Figure 21 MicroTech 200 Control Panel The MicroTech 200 unit mmm TUS controller has control wiring to larm x Dy Loca D Moro As 100 RLA 1 1 B Load the variable frequency drive Unioaded instead of to a motor starter CATEGORY ITEM ACTION The MicroTech controller Sieb AUG provides the speed setpoint eo an c signal to a hardwired input on gg S the VFD The output on the MicroTech AOX auxiliary Water Motor output board is configured QUICK ACCESS S i using jumpers to provide a 0 10 VDC signal to a hard wired analog input on the MicroTech There is no feedback signal required from the variable frequency drive to the MicroTech to indicate the speed of the motor The ac
9. 8 Fipure 2 LE 2 0 Taf ng Points iie Str RE HU etit ete URS roe a entes 12 Figure 3 VFD 047 through 072 Cooling Water Piping for Factory Mounted VFD 14 Figure 4 VFD 047 120 and all LF 2 0 Cooling Water Piping for Free Standing VFD 14 Figure 5 Cooling Module Dimensions eese 17 Figure 6 EX025 Display Panel irr rtr esp e Sadevt nay reso d eru trc etos 20 Figure 7 Line Reactor Dimensions Models VFD 009 017 essen nennen 27 Figure 8 Line Reactor Dimensions Models VFD 047 072 sss 27 Figure 9 Line Reactor WINN geis eerren eea a a neen eene etre eene tnter EREIN RTO 29 Figure 10 Control and Power Wiring Diagram rennen eene nennen 30 Figure 11 VFD 009LA 023LA Air Cooled Free Standing eere 32 Figure 12 VFD 024LA 028LA Air Cooled Free Standing eese 33 Figure 13 009MA 028MA Air Cooled Unit Mounted sese 34 Figure 14 VFD 047LW Water Cooled 35 Figure 15 060LW 072LW Water Cooled Free Standing eene 36 Figure 16 090LW 120LW Water Cooled Free Standing Only sees 37 Figure 17 VFD 047MW 072MW Water Cooled Unit 38 Figure 18 VE 2037 2033 Fr ee Standing en Dinner geo te ieu 39 Figure 19 VF
10. 3 Check wiring 71 72 Pwr Brd Chksum1 The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data Clear the fault or cycle power to the drive Pwr Brd Chksum2 Retfr I O Board Rctfr Not OK Rctfr Over Volt Rctfr Pwr Board Rectifier Base Temp Rectifier Dsat U V W Rectifier Ground Fault Rectifier IGBT Temp Rectifier IOC U W Rectifier Checksum The checksum read from the board does not match the checksum calculated Loss of communication to board Board failure A fault was detected in the rectifier other than one specifically decoded The bus voltage is too high Drive rating information stored on the power board is incompatible with the Main Control board The checksum read from the board does not match the checksum calculated Excessive rectifier temperature measured High current was detected in an IGBT Excessive ground current measured Excessive calculated IGBT temperature Rectifier overcurrent The checksum read from the board does not match the checksum calculated 1 Cycle power to the drive 2 If problem persists replace drive Cycle power 1 Cycle power 2 2 If fault repeats replace I O board Look at rectifier parameter 243 to see fault code Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend
11. Output phase to phase short Bus voltage line to line Ground fault Momentary overload Bad motor Torque boost V Hz too high V Hz Motor unknown to regulator V Hz Parameter settings vector Encoder wired incorrectly wrong PPR Check isolation between each output line Check transistor modules for correct output If incorrect possible board defect replace Possible Hall effect current sensor defective replace Check isolation between ground and output terminals Possible leakage current sensor defect replace sensor Check for motor overload reduce load on motor Check motor for correct operation Check parameters H 001 H 002 and or H 003 Enable Identification Request H 020 Check that regulator was updated with actual motor characteristics via Identification Request H 020 Check Encoder PPR U 001 Motor Poles U 002 Base Frequency U 003 Motor Nameplate Amps U 004 Magnetizing Current U 006 Speed Regulator Prop Gain U 012 Check encoder wiring Perform vector self tuning Overcurrent at acceleration Overcurrent condition occurred while accelerating Acceleration time too short See OC fault corrective actions Increase acceleration time POOI P017 P021 Overcurrent at DC braking Overcurrent at deceleration Continued on next page DC voltage too high Overcurrent condition occurred while decelerating Deceleration time t
12. Note If extensive troubleshooting or corrective actions are necessary only properly trained and qualified technicians should be used IOMM VFD 2 100 Accessing Reading and Clearing the Faults in the Error Log The following procedure shows how to access and clear the error log Note that you cannot clear a single entry from the error log The entire log including all of the fault codes and the day and time stamp of each fault will be cleared simultaneously using this procedure Step 1 Press the PROGRAM key Bons E D ae The First Menu General parameters are Co vots C rewore pe displayed The PROGRAM LED will turn on E IB ror CO Forward 06 L TORQUE C REVERSE Pasewors PROGRAM ENTER RELIANCE RESET ELECTRIC Step 2 Press the Wkey until Err is displayed Err W MMB speco C Running Co voirs C remote anes RUN Ss CJ kw ronwAno C Torque C reverse Password PROGRAM RELIANCE REBET ELECTRIC Step 3 Press the ENTER key 05 If no faults have occurred Err will be displayed again If only one fault has occurred the fault im code will be displayed as the first entry in the log Ele C If more than one fault has occurred the first entry Coke EH romano EI 7 Torave REVERSE is the latest fault that occurred CO Passwors PROGRAM STOP RESET START RELIANCE ELECT
13. multiple selections for the same function Install stop button to apply a signal at stop terminal Drive does not Start from HIM Cause s Drive is programmed for 2 wire control HIM Start button is disabled for 2 wire control Table 39 No Speed Change Indication Corrective Action If 2 wire control is required no action needed If 3 wire control is required program Digital Inx Sel for correct inputs Drive does not respond to changes in speed command Indication Corrective Action Cause s No value is coming from the source of the command Incorrect reference source has been programmed Incorrect Reference source is being selected via remote device or digital inputs Table 40 No Acceleration LCD HIM Status Line indicates At Speed and output is 0 Hz None 1 If the source is an analog input check wiring and use a meter to check for presence of signal 2 Check Commanded Speed for correct source 3 Check Speed Ref Source for the source of the speed reference 4 Reprogram Speed Ref A Sel for correct source 5 Check Drive Status 1 bits 12 and 13 for unexpected source selections 6 Check Dig In Statusto see if inputs are selecting an alternate source 7 7 Reprogram digital inputs to correct Speed Sel x option 87 88 Motor and or drive will not accelerate to commanded speed Cause s Indication Corrective Action Reprogram Accel Tim
14. 2 0 Terminal Size Range Incoming Terminals VFD Size VF2037 VF2055 Incoming connection is Outgoing Terminals 3 1 5 inch wide tab w 0 472 inch hole to the standard circuit VF2080 breaker See Table 9 VF2110 3 2 25 inch wide tab w 0 56 inch hole Table 8 Air Cooled LiquiFlo Outgoing Incoming Power Block Terminal Size Range Incoming VFD Size Power Block Terminals Outgoing Terminals VED 009 SP600 14 1 00 14 1 00 VFD 012 SP600 4 3 0 4 3 0 VED 015 SP600 14 250 017 SP600 14 250 14 250 14 250 VED 023 SP600 14 250 024 PF700H 4 0 350 14 250 4 0 350 VED 028 PF700H 4 0 350 VFD 047 2 4 500 4 0 350 2 6 300 VFD 060 2 4 500 2 4 350 VFD 072 2 84 500 2 4 350 2 in x 1 4 in bus VFD 090 2 84 500 1 9 16 in hole 2 in x 1 4 in bus VED 120 2 84 500 1 9 16 in hole Table 9 Incoming Terminal Size Range Disconnects amp Circuit Breakers Incoming Terminal Disconnect Switch or Circuit Breaker 1 6 300 1 6 300 1 6 300 1 4 0 500 2 3 0 500 2 3 0 500 3 1 0 500 4 250 500 5 300 600 5 300 600 NOTE X is the number of terminals per phase IOMM VFD 2 Optional Line Reactor Installation Air Cooled LF Only IOMM VFD 2 Mounting Options Optional line reactors can be m
15. 5 00 2 to 91 Menu 11 Screen 2 Mod Limit 2 5 F 1 0 to 10 F Menu 11 Screen 2 Maximum Speed Steps 2 1 to 5 Menu 11 Screen 2 Motor Current Compressor NA Menu 26 Screen 3 ameplate RLA 5 1 to 20 Menu 22 Screen 3 Minimum Amp Setpoint 10 5 to 100 Menu 13 Screen 1 Maximum Amp Setpoint 100 0 to 100 Menu 13 Screen 1 Locked VFD Speed On for Start up set up On Off Menu 11 Screen 2 Locked VFD Speed Off for VFD operation On Off Menu 11 Screen 2 Locked Speed 100 for Start up Set up NA Menu 11 Screen 2 NOTE Setpoints shown above apply only to Menu 11 Screen 1 through Menu 26 Screen 3 Table 12 MicroTech Unit Status vs VFD Status Unit Status MicroTech Menu 1 Screen 1 VFD Status MicroTech Menu 1 Screen 2 All Systems Off VFD Off Off Alarm VFD Off Off Ambient Lockout VFD Off Off Front Panel Switch VFD Off Off Manual VFD Off Off Remote Contacts VFD Off Off Remote Communications VFD Off Off Time Schedule VFD Off Start Requested VFD Off Waiting Low Sump Temperature VFD Off Evaporator Pump Off VFD Off Evaporator Pump On Recirculate used for chillers VFD Off Continued on next page IOMM VFD 2 45 46 Unit Status MicroTech Menu 1 Screen 1 VFD Status MicroTech Menu 1 Screen 2 Evaporator Pump On Cycle Timers used for chillers Off Evaporator Pump On Waiting For Load used for chillers Off Condenser Pump
16. Combinations marked with a will cause an alarm pate Accel2 Cecel2 Jog m oo Acc2 Dec2 x Accel2 Cecel2 Jog Jog Fwd Jog Rev Fwd Rev Digital input functions are in conflict Combinations marked with a will x cause an alarm Start Stop CF Run Run Fwd Run Rev Jog Rev Fwd Rev 63 64 Dig In ConflictC Drive OL Level 1 Drive OL Level 2 Flux Amps Ref Rang IntDBRes OvrHeat IR Volts Range MaxFreq Conflict Motor Type Cflct NP Hz Conflict Power Loss Prechrg Actv 2 1 1 2 Description More than one physical input has been configured to the same input function Multiple configurations are not allowed for the following input functions Bus Regulation Mode B Jog Forward Acc2 Dec2 Jog Reverse Accel 2 OIM Control Decel 2 Stop Mode B Run The calculated IGBT temperature requires a reduction in PWM carrier frequency If Drive OL Mode 150 is disabled and the load is not reduced an overload fault will eventually occur The calculated IGBT temperature requires a reduction in Current Limit If Drive OL Mode 150 is disabled and the load is not reduced an overload fault will eventually occur Forward Reverse Run Reverse Speed Select 1 Speed Select 2 Speed Select 3 Run Forward Result of autotune procedure 61 The drive has temporarily disabled the dynamic braking regulator bec
17. Fast Power Up Feature The fast power up feature bypasses the initialization screen at power up and the Main Menu is displayed immediately To select this feature select Fast PwrUp Mode from the Display menu Adjusting the Screen Contrast To adjust the screen contrast select Contrast from the Display menu 57 Resetting the Display Do not reset the display to factory settings as these may be the display manufacturer s settings and not the McQuay factory settings Figure 31 Display Description i Operational Status Line P0 LiquiFlo 2 0 i Device Selected Error Text Main Menu i Menu Programming Screen or Process User Display Function Key Line Function Key F1 F2 F3 F4 definitions Port peripheral identification Identifies port or peripheral on DPI about which the OIM is displaying information See section B 5 PI loop status PI PI control is active Operating status for example Running Stopped etc Alarm annunciation amp Alarm has occurred Auto Hand mode status Write protect password status C unlocked password disabled locked password enabled See section 8 4 Table 16 Key Descriptions INN 4 Scroll through options or user function keys move cursor to the left Nc Scroll through options or user functions keys move cursor to the right Scroll through options increase a value or toggle a bit Scroll through options decrease
18. NOTES 1 Press any F Key to acknowledge the fault 2 The fault screen is displayed until it is acknowledged by pressing any F key or cleared in the drive by other means About the Fault Queue The drive automatically retains a history of faults that have occurred in the fault queue The fault queue is accessed using the OIM or VS Utilities software The fault queue holds the eight most recent faults The last fault to occur is indicated in queue entry 1 As new faults are logged into the queue existing fault entries are shifted for example entry 1 will move to entry 2 Once the queue is full older faults are discarded from the queue as new faults occur All entries in the fault queue are retained if power is lost The Time Stamp For each entry in the fault queue the system also displays a fault code and time stamp value The time stamp value is the value of an internal drive under power timer at the time of the fault The value of this timer is copied to PowerUp Marker 242 when the drive powers up The fault queue time stamp can then be compared to the value in PowerUp Marker to determine when the fault occurred relative to the last drive power up The time stamp is cleared when the fault queue is cleared IOMM VFD 2 65 Clearing Faults A fault condition can be cleared by the following Step 1 Press the ESC Prog key or any F Key to acknowledge the fault and remove the fault pop up from the LCD OIM screen Step 2 A
19. Option Description Drive Identity Add text to identify the drive Change Password Enable disable or modify the password Select the display parameter scale and text for the User Display User Dspy Lines The User Display is two lines of user defined data that appears when the HIM is not being used for programming User Dspy Time Set the wait time for the User Display or enable disable it Select Reverse or Normal video for the Frequency and User Display lines Reset User Dspy eae all the options for the User Display to factory default User Dspy Video IOMM VFD 2 89 90 Operation LF The status of the drive can be viewed on the Operator Interface Module OIM or on various LEDs Using the Interface Figure 41 Keypad Display AUTO Forward spreco 1 RUNNING MAN Reverse C 0075 REMOTE amps C RUN Ex CI kw FORWARD C TORQUE C REVERSE Password LED C Password PROGRAM STOP The front panel keypad display is used to monitor the drive The functions available at the keypad depend on what mode the keypad display is in and what is selected as the drive control source It operates in two modes 1 Monitor Mode the default mode used to monitor specific drive outputs as well as enter the speed or frequency reference for the drive 2 Program Mode used to view and adjust drive parameter values and examine the error log Regardless of the control source selectio
20. Short Excessive current has been detected between these two output terminals 1 Check the motor and drive output terminal wiring for a shorted condition 2 Replace drive Port 1 6 DPI Loss DPI port stopped communicating An attached peripheral with control capabilities via Logic Source Sel 89 or OIM control was removed The fault code indicates the offending port number 81 port 1 etc 1 If adapter was not intentionally disconnected check wiring to the port Replace wiring port expander adapters Main Control board or complete drive as required 2 Check OIM connection Port 1 6 Net Loss The network card connected to DPI port stopped communicating The fault code indicates the offending port number 71 port 1 etc 1 Check communication adapter board for proper connection to external network 2 Check external wiring to adapter on port 3 Verify external network fault Power Loss DC bus voltage remained below 85 of nominal for longer than Power Loss Time 185 Enable disable with Fault Config 1 238 Monitor the incoming AC line for low voltage or line power interruption Power Unit One or more of the output transistors were operating in the active region instead of desaturation This can be caused by excessive transistor current or insufficient base drive voltage 1 Check for damaged output transistors 2 Replace drive Pwr Brd Chksum1 The checks
21. Stop WDC WCC Dual Compressor VFD Operation The MicroTech 200 controller has the capability to control a dual compressor VFD chiller or two stand alone VFD chillers with interconnecting network communications including all lead lag load balance functions The lead compressor starts and runs the same as a single VFD compressor controlling speed and vane position based on Leaving Evaporator Water Temperature LEWT When the capacity of the lead compressor reaches an equivalent user defined speed LEWT offset and pull down rate it indicates to the master control panel that it is time to enable the lag second compressor to satisfy additional cooling requirements When the master control panel sees the enable lag indication it checks the LEWT and if it is greater than the active setpoint plus the lag Start UP S U Delta T it will start the lag delay timer keypad adjustable At this time the MicroTech control will record the evaporator chilled water Delta T for reference to determine lag compressor shutdown NOTE Operation assumes constant chilled water flow for dual compressor VFD units The MicroTech is constantly looking at the recorded startup evaporator Delta T the user adjustable offset from the delta T and the active setpoint As the load decreases and the evaporator Delta T drops below the recorded Startup Delta T minus the user adjustable offset and the LEWT is below the active setpoint minus the control band p
22. and Canadian Electrical Code requires that an approved circuit disconnecting device be installed in series with the incoming AC supply in a location readily accessible to personnel installing or servicing this equipment If a disconnect switch is not supplied with the starter one must be installed 9 Supply lines and motor lines may enter the enclosure from the top bottom or sides Wire connections can be determined to best suit specific installations Wire runs should be properly braced to handle both starting and fault currents Size power cable per local electrical codes Long lengths of cable to the motor of over 150 feet must be de rated Terminal Sizes Compressor Motor Terminals Power wiring connections at the motor are spark plug type terminals with threaded copper bar sized per the following table Table 6 Chiller Compressor Motor Terminal Sizes TypelSize Low Voltage to 275 A to 575 V CE 050 0 375 16 UNC2A 0 94 in long Low Voltage to 750 A to 575V CE 063 126 0 635 11 UNC 2A 1 88 in long VFD Terminals For field wiring freestanding VFDs the outgoing terminals and incoming power block terminals are determined by the VFD size listed in Table 8 For factory mounted VFDs the outgoing terminals are factory connected to the compressor motor When wiring to a VFD with a disconnect switch or circuit breaker the incoming lug size is determined by the device size as shown in Table 9 23 Table 7 LiquiFlo
23. and a fault signal will appear in the chiller touchscreen A steady red LED indicates that it is non resettable Table 23 Fault Types Auto Reset Run Not used on McQuay units Fault Description If the drive is running when this type of fault occurs and Auto Rstrt Tries 174 is set to a value greater than 0 a user configurable timer Auto Rstrt Delay 175 begins When the timer reaches zero the drive attempts to automatically reset the fault If the condition that caused the fault is no longer present the fault will be reset and the drive will be restarted Non Resettable User Configurable This type of fault normally requires drive or motor repair The cause of the fault must be corrected before the fault can be cleared The fault will be reset on power up after repair These faults can be enabled disabled to either annunciate or ignore a fault condition using Fault Config 1 238 IOMM VFD 2 The drive indicates faults in the following ways e Ready LED on the drive cover see section 12 3 e Drive status parameters Drive Status 1 209 and Drive Status 2 210 e Entries in the fault queue see section 12 5 1 e Pop up screen on the LCD OIM See figure 12 4 The screen displays e Fault number e Fault name e Time that has elapsed since fault occurred Figure 34 Sample Fault Screen on the LCD OIM Fault Fxxxxx Fault Text String Time Since Fault XXXX XX XX ACKNOWLEDGE
24. between drive and motor Check connections and cable of all 3 phases and motor windings Replace any damaged cable Overspeed vector only RPM above 130 Maximum Speed P 004 speed regulator response not optimized Check Encoder PPR U 001 Motor Poles U 002 Base Frequency U 003 Motor Nameplate RPM Speed U 005 Check Reg Proportional U 01 2 Integral Gain U 01 3 Missing power module ID connector Bad or disconnected cable between Regulator and Power Module Check cables between Regulator board and Power Module Power module not Identified Drive power electronic overload Drive parameters have been restored to power up defaults Regulator has not been configured to match Power Module Power Module overloaded Too high DC Braking Current H 007 or Torque Boost H 003 Power Module must be configured by Reliance service personnel Check load to Power Module Check Power Module sizing versus application Check DC Braking Current value H 007 Check Torque Boost H 003 Self tuning status Vector only See parameter U 009 Communication loss between regulator PC OIM Serial Port communication cable PC or OIM communication port setup Check connection cable and communication port setup Spurious host PC comm interrupt Regulator board failure Replace Regulator board Asymmetrical bus charge Bad Power Module Contact McQuay
25. conflicting Exclusive functions i e direction control may have multiple inputs configured Stop if factory default and is not wired or is open Start or Run programming may be missing Program Digital In x Sel 361 366 for correct inputs Logic Source Sel is not set to Terminal Blk Continued next page Set Logic Source Sel to Terminal BIk 73 Table 27 No Start From Terminal Block Logic Continued Indication s Flashing yellow Ready LED and Digln CflctB indication on LCD OIM Drive Status 2 210 shows type 2 alarm s Cause s Incorrect digital input programming e Mutually exclusive choices have been made 2 wire and 3 wire programming may be conflicting Exclusive functions i e direction control may have multiple inputs configured Stop if factory default and is not wired or is open Start or Run programming may be missing Table 28 No Start From OIM Indication None Cause s Drive is programmed for 2 wire control and Logic Source Sel 89 All Ports OIM start and network start are disabled for 2 wire control Corrective Action Program Digital In x Sel 361 366 to resolve conflicts Remove multiple selections for the same function Install stop button to apply a signal at stop terminal Corrective Action If 2 wire control is required no action is necessary If 3 wire control is required program Digital Inx Sel 361 366 for
26. correct inputs Flashing or steady red Ready LED Active fault Reset fault Flashing yellow Ready LED Enable input is open Close terminal block enable input The terminal block stop input is open and control source is set to All Ports Close terminal block stop input Start inhibit bits are set Check status in Start Inhibits 214 Drive Status 1 209 indicates logic control source Logic Source Sel 89 is not equal to the desired OIM Local OIM DPI Port 2 or DPI Port 3 DPI Port 2 is required for remote OIM Verify setting of Logic Source Sel 89 The OIM Control digital input effectively sets the control source to the lowest attached OIM port Table 29 No Response to Changes in Speed Command Indication LCD OIM Status Line indicates At Speed and output is 0 Hz Cause s No value is coming from the source of the command Incorrect reference source has been programmed Corrective Action 1 If the source is an analog input check wiring and use a meter to check for presence of signal 2 Check Commanded Freq 2 for correct source 1 Check Speed Ref Source 213 for the source of the speed reference 2 Reprogram Speed Ref A Sel 90 for correct source Speed reference from analog input 74 Incorrect reference source is being selected via remote device or digital inputs Improper reference common signal wiring 1 Ch
27. evaporator refrigerant pressure is less than 31 0 psi default hold speed and close vanes Low evaporator pressure shutdown alarm setpoint is 26 0 psi default Note The above pressures must be set at unit design conditions High Discharge Temperature If the discharge temperature is higher than 170 F pulse the load solenoid if the vanes are not fully open If the vanes are full open increase command speed at the rate of 1 every five seconds 49 MicroTech II VFD Control General Description Figure 23 MicroTech II Operator Interface Panel 1 The following describes the software for centrifugal chillers with variable speed drive and the MicroTech II controller Complete information on the MicroTech II controller operation is contained in the Operating Manual OM CentrifMicro II Variable Frequency Drive VFD Control Digital output NOI terminal J12 on the compressor controller is wired to the CR relay Compressor Relay The CR relay energizes the MCR Motor Control Relay which enables the variable frequency drive instead of a standard motor Analog output Y1 terminal J4 on the compressor controller provides the speed setpoint signal to the VFD The output is a 0 10 VDC analog output signal hard wired to I o VIEW B5 the VFD EE EP um There is no feedback signal required from the variable frequency drive to the MicroTech II controller to indicate the speed of the motor The actual percent motor
28. selection 3 Disable bus regulation parameters 161 amp 162 and add a dynamic brake 4 Correct AC input line instability or add an isolation transformer 5 Reset drive IOMM VFD 2 Diagnostics Menu When a fault trips the drive use this menu to access detailed data about the drive Table 43 Fault menu Option Description Faults View fault queue or fault information clear faults or reset drive Status Info View parameters that display status information about the drive Device Version View the firmware version and hardware series of components HIM Version View the firmware version and hardware series of the HIM Parameter Menu Refer to Viewing and Editing Parameters Device Select Menu Use this menu to access parameters in connected peripheral devices Memory Storage Menu Drive data can be saved to or recalled from User and HIM sets User sets are files stored in permanent nonvolatile drive memory HIM sets are files stored in permanent nonvolatile HIM memory Table 44 Memory Storage HIM Copycat Device gt HIM Device lt HIM Save data to a HIM set load data from a HIM set to active drive memory or delete a HIM set Save data to a User set load data from a User set to active drive memory or name a User set Reset To Defaults Restore the drive to its factory default settings Device User Sets Preferences Menu The HIM and drive have features that you can customize
29. speed is within 196 of the analog output signal from the MicroTech II controller Digital Input ID9 terminal J7 on the compressor controller is wired to the Vane Open switch VO switch that indicates when the vanes are 10096 open If the switch is open the status of the vanes is Not Open If the switch is closed the status of the vanes is Open Or If the compressor controller pulses a load output for the vanes to load for a cumulative time of 300 seconds user adjustable the MicroTech II controller will assume the compressor is fully loaded the same as if the V O switch closed one unload pulse will reset the timer Sequence of Operation Compressor Off The VFD is turned off the speed output is 0 and the vanes are closed If the chiller is turned on and if there is a load the chiller will go through its start sequence The MCR will be energized the speed signal will be set to minimum speed and the VFD will start the compressor When the compressor starts it will be in the VFD Running hold speed adjust vanes mode Figure 24 MicroTech Il Operator Interface Panel 2 IOMM VFD 2 IOMM VFD 2 VFD Running Hold Minimum Speed Adjust Vanes The remains on the command speed is held at Minimum Speed and the vanes are modulated to maintain the Active LEWT Setpoint As the load increases if the vane open switch closes or the MicroTech II controller pulses the vanes open for a cumulative 300 seconds default a
30. the Leaving Evaporator Water Temperature LEWT is less than the active setpoint minus one half the control band the mode switches to VFD Running Hold Minimum Speed amp Adjust Vanes Otherwise the controller stays in this mode If any capacity override exists the VFD mode changes to the Override Capacity Control mode see Capacity Overrides on page 48 IOMM VFD 2 IOMM VFD 2 VFD Running Hold Minimum Speed amp Adjust Vanes The VED remains on the command speed is held at Minimum Speed and the vanes are modulated to maintain the Active Setpoint As the load increases if the vane open switch closes and the LEWT is greater than the active setpoint plus the control band the mode switches to Running Adjust Speed amp Open Vanes Otherwise the controller stays in this mode with the speed at Minimum Speed and the vanes being controlled to satisfy the Active Setpoint If any capacity override exists the VFD mode changes to the Override Capacity Control mode VFD Routine Shutdown The VFD remains on the speed output remains constant and the vanes are driven closed This state is used during a routine shutdown of the chiller If there is a rapid shutdown cause by a fault alarm the state switches to WFD Rapid Shutdown 1f there is a fault alarm the mode immediately switches to OFF Rapid Shutdown also occurs by changing the front panel Stop Auto switch on the MicroTech to
31. the motor terminal box and wired directly to the motor This arrangement is only available on WSC WDC 063 079 or 087 units and with LF On models WSC WDC 048 050 the VFD LF only is factory mounted on the front of the chiller unit and connected to the motor with conduit and cable Free standing standard Floor mounted separate from the chiller unit and field wired to the compressor motor This is available on all VFDs and is the only VFD arrangement available for WDC WCC 100 and 126 dual compressor units Brackets and cable extra cost option VFDs LF only for WSC 100 to 126 single compressor units may be shipped separately from the chiller unit and furnished with mounting brackets and interconnecting cables for field mounting and connection by others This option must be clearly specified when chillers are ordered since brackets are welded onto the evaporator during its construction Table 3 VFD Mounting Arrangements Chiller Air Cooled LiquiFlo LiquiFlo 2 0 Size Factory Mounted Free Standing Brackets amp Cables Free Standing WSC WDC 050 X X WSC WDC 063 WSC WDC 079 WSC WDC 087 y WSC 100 126 WDC 100 126 WCC 100 126 Receiving Since factory mounted VFDs are mounted and wired at the factory this section will only apply to free standing units The unit should be inspected immediately after receipt for possible damage All McQuay centrifugal VFDs are shipped FOB factory and all claims for han
32. top of the module and slide the module upwards and out One function of the module is to program the various parameters that control the VFD chiller operation Programming is to be done only by service technicians who factory trained and authorized to work on VFDs The module is used by the operator to troubleshoot the drive by viewing faults and to clear faults after corrective action has been taken as explained later in this section 77 78 Figure 38 LCD Display Main Menu Display Description F gt PowerLoss Direction Drive Status Alarm Auto Man Information Hz Commanded or Output Frequency Main Menu Diagnostics Parameter Device Select LEDs Programming Monitoring Troubleshooting Illumination of a yellow LED indicates the presence of an alarm a red LED indicated a fault Viewing Faults and Alarms The primary area of interest to the operator is viewing drive alarms and faults Alarms are problems that do not shut down the drive compressor They may eventually turn into faults which do stop the compressor From the main menu use the Up or Down arrows lt or gt to select Diagnostics See Figure 38 Press the Enter key to select this menu Then use these navigating keys to reach a desired menu as shown in Figure 39 IOMM VFD 2 IOMM VFD 2 Figure 39 HIM Menu Structure User Display e e e View Alarm Queue Al
33. up to 1 Uncouple load from motor Load speed in the allotted time 2 Repeat Autotune 61 Continued next page IOMM VFD 2 FluxAmpsRe f Rang Ground Fault High AC Line Description The value for flux amps determined by the autotune procedure exceeds the programmed Motor NP FLA 42 A current path to earth ground in excess of 7 of drive rated amps has been detected at one or more of the drive output terminals Input line voltage is too high Action Reprogram Motor NP FLA 42 with the correct motor nameplate value Repeat Autotune 61 Check the motor and external wiring to the drive output terminals for a grounded condition Reduce input voltage to meet specification of 480 10 HW OverCurrent I O Board Comm Loss The drive output current has exceeded the hardware current limit Loss of communication to I O board Check programming Check for excess load improper DC boost setting DC brake volts set too high or other causes of excess current Cycle power I O Board Fail I O Board Mismatch Incompat MCB PB Input Amp Imbalance Input Volt Imbalance Inverter Dsat U V W Inverter OverCurrent U VW Board failure Incorrect I O board identified Drive rating information stored on the power board is incompatible with the Main Control board Input phase current imbalance exceeded limits Input voltage imbalance exceeded limits Hig
34. used by McQuay AutoT Rs Stat Autotune static not used by McQuay CAN Bus Fit Controlled area network bus fit Command Speed The speed command issued by the MicroTech controller to the VFD Dynamic breaking not used on McQuay units Decel Inhibit Deceleration 2 not used by McQuay Deceleration inhibited Demand Limit The maximum amp draw as established by the Demand Limit setpoint Dig in Conflict Digital input conflict contradictory instructions Drive OL Esc Prog Flux Amps Full Load Drive overload Exit a menu cancel a change to a parameter or toggle between program and process user display screens Amount of current out of phase with the fundamental voltage component The vane open switch closes and the speed output 100 Or Load pulses exceed the full load setpoint timer default 300 cumulative seconds and the speed output 100 Or RLA is above or equal to Max Amp Limit or Demand Limit Or The evaporator pressure is below the low evap pressure inhibit setpoint FVC Flux vector control HIM Human interface module IGBT Insulated Gate Bi polar Transistors IntDBResOvrHeat Dynamic breaking resistor temp exceeded setpoint not used on McQuay units Lift Temperature Saturated condenser refrigerant temperature minus saturated evaporator temperature Lift Temperature Control Speed Low evap pressure inhibit se
35. voltage more than 15 above nominal Check actual line voltage against U 018 or H 021 High Dc bus voltage Continued on next page DC bus voltage too high capacitor protection Deceleration time too short Check input line voltage if necessary add transformer Increase deceleration time P 002 P 018 P 023 versus Maximum Speed Hz P 004 Install DB option with resistors 97 Alarm Description Input phase loss Low DC bus voltage Fault Cause Voltage ripple on DC bus due to missing input phase or an imbalance between phases DC bus voltage too low Line dip too long P 042 Input rectifier diodes defective Correction Action Verify that proper voltage is being applied to the drive Check all phases Check input voltage line fuses If necessary add transformer Check value of Ride Through Time R042 Line Voltage H 021 U 018 Check DC bus voltage If incorrect replace diode set Check network cabling from network master to network option board Check that network master is operating properly Reset fault Perform Identification Request Restart drive Network comm loss Communications with the AutoMax network have been lost Identification request not yet performed V Hz only Drive started but Identification Result Zero Overcurrent steady state Trips between 185 and 200 load based on inverter type current check power module rating
36. 15 on Panel 2 sets the lift in degrees F at the 100 speed point point B in Figure 26 Figure 27 Operating Envelope Setpoints 11 and 12 Settings 120 110 Typical Variable Frequency Drive Operating Envelope Saturated Temperature Difference F Condenser Saturation Temperature Minus Evaporator Saturation Temperature Figure 28 View I O Screen The MicroTech II controller View I O Screen shown to the right displays the compressor motor speed as controlled by the at the bottom of the screen This is information only and no settings are made on this screen COMPR I O Digital Inputs Manual Switch Mech High Press Motor High Temp Vanes Closed Starter Transition Starter Fault Evap Water Flow Cond Water Flow Vanes Open Digital Outputs Motor Control Relay Hot Gas Bypass Liquid Injection Oil Pump Oil Sump Heater Oil Cooler Unload Vanes Load Vanes Starter Latch Analog Outputs VFD Speed 100 IOMM VFD 2 IOMM VFD 2 Table 14 MicroTech II Settings and Ranges Single Compressor MicroTech Il VFD Default Setpoint Keypad OITS Location Locations N A Motor Current Threshold 1 5 1 to 20 UC SA 4 ae Motor Current Comp Nameplate RLA N A UC SC 4 Minimum Amp Setpoint 2 10 5 to 100 UC SC 1 Set Motor 2 Maximum Amp Setpoint 100 0 to 100 UC SC 1 Set Motor 3 VFD Yes yes no UC SU 10 Set Motor 9 Minim
37. 2080 2110 Free Standing sess eene ener nre 40 Figure 20 MicroTech 200 Control Panel eene eene nete nene 41 Figure 21 MicroTech 200 VFD Speed Control State Diagram sene 47 Figure 22 MicroTech II Operator Interface Panel 1 50 Figure 24 MOTOR VFD Setpoint Screen Panel 1 eese 52 Figure 25 MOTOR VED Setpoint Screen Panel 2 53 Figure 26 Operating Envelope Setpoints 11 and 12 Settings 54 Figure 27 View l O SCIeen s ceo eret Dee RE UR ERU geri o Eee 54 Figure 28 MicroTech VFD Speed Control State Diagram seen 56 Figure 29 Operator Interface Module essere nennen ener eret 57 Figure 30 Display Description eene nennen nennen nennen een rennen treten trennen tren 58 Figure 31 Location of Precharge Status LED seseeseseeeeeeeeeenneeee nennen nennen eene 59 Figure 32 Location of the Ready LED seseseesssseeeeeeeeen nennen ener tnnt nen 59 Figure 33 Sample Fault Screen on the LCD OIM eene eene 65 Figure 34 Accessing the Fault erinnere 76 Figure 55 Saniple Fault Queue Entry s n ose rte eget 76 Figure 36 Human Interface Module HIM enne nennen nennen entente ene TT Figure 3
38. 4 Et 0 56 SLOT 2 PLC S 14 63 NOTE Incoming cable entrance is top left Outgoing wiring is factory installed 34 IOMM VFD 2 LiquiFlo Figure 15 VFD 047LW Water Cooled Free Standing med 8500 a 8 00 1 60016 6 00 2 00 2 00 21 06 ENTRY PANEL 16 00 POWER WIRING ENT PANEL POWER WIRING P 16 00 e 99 6 i gt 36 00 12 20 NOTES Power entry for unit mounted VFD is on top left hand Unit Weights Operating Weight Ib kg 982 446 Shipping Weight Ib kg 1070 486 IOMM VFD 2 35 Figure 16 VFD 060LW 072LW Water Cooled Free Standing 6 0 120 _ a 120 Io 15 0 zl 152 4 304 8 304 8 381 3 0 76 2 3 0 76 2 m diene T POWI WIRING Note Remove before drilling to prevent metal particles from 12 0 ay ESS PANEL ACCESS PANEL 12 0 falling into drive components 304 8 lt 304 8 60 0 9 0 1 1524 228 6 OUTLET VALVE 3 4 19 1 NPT INLET VALVE 3 4 19 1 NPT 72 0 1828 8 88 9 et 7 5 190 5 NOTES Power entry for unit mounted VFD
39. 44 45 47 48 50 54 Decel Inhibit OverSpd Limit 1 VHz Neg Slope SpdRef Cnfict BrakResMissing 2 Anlg In Loss 1 MicroWatchdog 2 Fan Cooling 3 AutoReset Lim 2 CAN Bus Fit 1 HeatsinkUndTp 1 Device Change 2 Device Add 2 NvsReadChksum 2 ParamsDefault 2 MotorCalcData 2 Zero Divide 2 Continued on next page Description Drive cannot follow commanded due to bus limiting Functions such as Slip Compensation or Bus Regulation have attempted to add an output frequency adjustment greater than that programmed in Overspeed Limit Motor Cntl Sel Custom V Hz Action if appropriate 1 Verify that input voltage is within specified limits 2 Verify that system ground impedance follows proper grounding techniques 3 Disable bus regulation and or add dynamic brake resistor and or extend deceleration time Remove excessive load or overhauling conditions or increase Overspeed Limit amp the V Hz slope is negative Speed Ref x Sel or Reference Sel is set to Reserved No brake resistor detected An analog input is configured to fault on signal loss A signal loss has occurred Configure with Anlg In 1 2 Loss Microprocessor watchdog timeout Fan is not energized at start command Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of FIt RstRun Tries Enable Disable with Fault
40. 7 LCD Display Mai Menu diese ed tte He REG e PRU EH 78 Figure 38 HIM Menu Structure esses nennen eene e enne trne tenerent 79 Figure 39 Front Panel LED nennen enne 80 Figure 40 Keypad Display eese enne nennen nennen een rennen ener 90 Figure 41 Example of a Monitor Mode Display sese 91 Index of Tables Table 1 Model Sizes Air Cooled LiquiFlo eese enne nennen enne 4 T ble 2 Model Sizes Agua Flo 2 ise ctore cre e peste ree beet eee ote mie 4 Table 3 VFD Mounting eene nennen eene eene ener tenerent nen 11 Table 4 Cooling Reqiuremehnts n reete trei e Pt eius 15 Table 5 Chiller Cooling Water Connection Sizes eene nre 15 Table 6 Chiller Compressor Motor Terminal Sizes essere 23 Table 7 LiquiFlo 2 0 Terminal Size ener tenerent 24 Table 8 Air Cooled LiquiFlo Outgoing Incoming Power Block Terminal Size Range 24 Table 9 Incoming Terminal Size Range Disconnects amp Circuit Breakers esses 24 Table T0 Lane Reactor D ta z eee a cao ect ceti eite au ee ele dee EUR 27 IOMM VFD 2 103 104 Table 11 MicroTech 200 VED Setpoint essen enne nennen enne een nnne enne nene 45
41. 7 Monitor Mode LEDS 94 Table 48 Tast of Alarm Codes i kc 96 Table 49 List of Fault 97 Table 50 Fatal Fault Codes That Can Be Reset esses eene eene enne 102 IOMM VFD 2 McQuay International Post Office Box 2510 Staunton Virginia 24402 2510 USA e 800 432 1342 e www mcquay com IOMM VFD 2 9 05
42. B resistor Resistance is out of range 1 Check parameters 2 Check for broken loose connections at inputs Anlg Cal Chksum Auto Rstrt Tries Correct the cause of the fault and manually clear Restart procedure Replace resistor 1 Verify input voltage is within drive specified limits 2 Verify The drive is not following a System ground impedance follows Decel Inhibit commanded deceleration because itis proper grounding techniques 3 attempting to limit bus voltage Disable bus regulation and or add dynamic brake resistor and or extend deceleration time Drive rating of 11096 for 1 minute or Drive Reduce load or extend Accel Time OverLoad 64 150 for 3 seconds has been 140 exceeded Excessive 79 Motor did not come up to speed in the 1 Uncouple load from motor 2 Load allotted time Repeat Autotune 61 FluxAmpsRef The value for flux amps determined by 1 Reprogram Motor NP FLA 42 Rang 78 the autotune procedure exceeds the with the correct motor nameplate programmed Motor NP FLA 42 value 2 Repeat Autotune 61 Continued next page Faut No Type Description Action IOMM VFD 2 Function Loss 2 Function loss input is open Check remote wiring Check the motor and external Ground 13 A current path to earth ground wiring to the drive output Fault greater than 25 of drive rating terminals for a grounded condition 1 Check for blocked or d
43. CE SERVICING 22 000 FILL TUBE SUPPLY INLET TO CHILLER T 1 ie SUPPLY OUTLET IT FROM CHILLER 1 2 9 DRIVE OUTLET N 104 CHILLER im gt 8 DRIVE INLET TO CHILLER Weights Shipping weight 300 165 136 kg Dry weight 250 Ibs 114 kg Operating weight 270 Ibs 123 kg IOMM VFD 2 17 Figure 6 LF 2 0 Remote Cooling Module Interconnecting Wiring 1 nus SEES gt 52 B paag aga g 2 M om mn Da COOLANT LOOP PUMP lt DODR MOUNTED Mitea mai ha idis i RR y 1 LEGEND TB1 McQLAY CONTROL CONNECTION JUMPER REMOVE TO ADO x INTERLOCK AS NEEDED EXTERNAL VFD POWER MODULE RON T82 ODOLANT LOOP CONNECTION TB2 is the terminal board located in the remote module TBI is a terminal board located in the Field Wiring 18 TB1 10 DO NO2 to TB2 4 OP Open TB1 13 DO NO3 to TB2 5 CL Close Wire 42 Aux Relay to TB2 3 Neutral Wire 42 Aux Relay to TB2 2 LPN Loop Pump Neutral Aux Relay Terminal 7 to TB2 1 LP Loop Pump GRD PE to Ground IOMM VFD 2 IOMM VFD 2 Maximum Static Pressure 300 psi nominal limited by ball valve and piping pressure ratings Requirements for proper operation of the drive cooling module cooling loop Cooling Loop Liquid 25 inhibited corrosion protected propylene glycol DOWFROST or equivalent concentration by volume with distilled water Non inhibited or silica
44. Compressor Menus U Unit Menus Example Setpoint location for VFD Minimum speed UC SU 10 The location would be the Unit Controller Set Unit Setpoints Menu Screen 10 OITS locations are S Setpoint screen Alarms or Motor and the number of the setpoint on the screen Additional Setpoints the following two setpoints are at Technician level and are located at UC SC 8 and not on the OITS They are for exclusive use of factory trained service technicians 55 56 Mode Auto auto manual this allows the speed output signal to be manually controlled for testing or to be automatic for normal operation The MicroTech II controller will not allow the speed signal to go below the calculated lift control speed VFD Speed Manual Setpoint 100 when the unit is started for the first time and set up for design or to check the operation and performance of the unit it is necessary to run the unit at a constant fixed speed of 100 To accomplish this set the VFD Minimum Speed to 10096 UC SU 10 or OITS S Motor 10 then set up and adjust the unit When testing is complete set the minimum speed back to the original setpoint Do not set the drive minimum speed to 100 to set up or test the unit at full speed as the controller will not know that the drive will not respond to it s speed signal The controller will try to control the LEWT setpoint with speed and a control conflict will result Figure 29
45. Config 1 Sent message not acknowledged Ambient temperature is too low New power unit or option board installed of different type New option board added Error reading Elapsed MWh and Elapsed Run Time from EEPROM The drive was commanded to write default values to EEPROM Incorrect motor nameplate data This event called from arithmetical functions if divider is zero 1 Program Bus Reg Mode x to not use brake 2 Install brake resistor 1 Check parameters 2 Check for broken loose connections at inputs 1 Cycle Power 2 Replace control Correct the cause of the fault and manually clear 1 Cycle Power 2 Replace control Raise ambient temperature Clear fault and reset drive to factory defaults Clear fault 1 Clear the fault or cycle power to the drive 2 Program the drive parameters as needed Check motor nameplate data 1 Cycle Power 2 Replace control 83 Description Action if appropriate Programmed Current Lmt Val has been exceeded Check load requirements and Enable Disable with Fault Current Lmt Val setting Config 1 Removed Option board removed Shear Pin One or more of the output transistors were operating in the active region instead of Power Unit desaturation This can be 1 Clear fault caused by excessive transistor current or insufficient base drive voltage 1 Check DPI device event queue and corresponding fault info
46. E STRAINER MAX 40 MESH DRAIN STOP i OR PLUG VALVE VFD HEAT Y Field Supplied Piping Components EXCHANGER Field Piping m A Connection Point Factory Mounted E DL 14 VALVE Factory Mounted IOMM VFD 2 IOMM VFD 2 NOTE In some cases the VFD HEAT EXCHANGER may be a separate mounted cooling module that is in turn connected to the VFD Table 4 Cooling Requirements Combined s VFD Cooling Max Min Max Neko t P Only Copper Coolant Flow Entering Entering Pressure Number Tube Size Method gpm Coolant Coolant feel Water Pa or L Temp F Temp F Side psi Air Cooled LF VFD 009 028 in Water 1 300 in 300 Ai VFD 047 _ 10 78i Water 1 10 W 40 30 2 10 300 40 40 40 40 A 1 0 2 0 90 VED 060 1 0 7 8in Water t 20 9 VFD 072 1 0 7 8in Water 25 90 114 1Oin Water 1 3 70 90 300 120 114 1Oin 1 3 70 90 LF 2 0 vr203 SANPT jWeate t 3 70 90 40 VF 2055 NA SA4NPT jWater 3 70 90 40 VF 2080 NA SANPT Water 1 3 150 90 40 VF 2110 NA S3A4NPT jWater 1 3 150 90 40 Notes 1 Cooling water must be from the closed chilled water circuit with corrosion inhibitors for steel and copper and must be piped across t
47. From OM x eoe esr coit cto buie tese biete 74 Table 29 No Response to Changes in Speed Command sese 74 Table 30 Motor Will Not Accelerate to Commanded Speed sse 75 Table 31 Motor Operation is Unstable essere 75 Table 32 Stopping the Drive Results in a Decel Inhibit Fault eee esee 75 Table 33 Fault Types ea pU ttt RR REUS 80 Table 34 Alarm Types eee 80 Table 35 Fault Alarm Types Description and Actions sesenta 81 Table 36 Fault Alarm Cross Reference esses 86 37 onmi BRUN 87 Table 38 No eee rre ese tree ERU 87 Table 39 No Speed Change 4 ente te ttg re ERE RO Fd P p p 87 Table 40 No Acceleration cee a etna oe ride d tae et d aires teorie Es 87 Table 41 Unstable Operation sics 4 oic eee nre Dot ee DURO pe rre ES EEEE Eeee 88 Table 42 Stopping Gives Decel Fault nennen nennen nennen nennen 88 Table 43 EBault Tenue iro trahe T HE 89 Table 44 Memory Storage tee aite tti qe etre tte e ide 89 Table 45 Display Range Examples eene tee pom e tinte er dete 92 Table 46 Drive Status EBEDS senate etre re e ir ee iat iere re a be nter NN P 94 Table 4
48. MicroTech Il VFD Speed Control State Diagram OFF Manual Switch AUTO Remote Switch Shutdown Manual Switch Compressor OFF Compressor Motor Relays CR amp LR are off and VFD Speed 0 Vanes closed COMPRESSOR STATE BOX OFF Unit State or OFF Manual Switch OFF Evap Flow Recirculate 30 sec OFF Low Oil Sump Temp OFF Staging Next ON OFF Awaiting Load PRELUBE Vanes Open m M PRELUBE Timer 30 30 Startup Transition v PRELUBE Ones Fd Loads Vanes to LEWT control and N reduces speed at a fixed rate to Min N Speed Line x Motor Relay is closed amp VFD X Speed Min j _ Vanes Open v Gooed Switch Closed or s Loading The starting and running continuously Full compressor are bumped VFDSpeed Vanes Load timer to 100 speed expired 5min and MinSpeed Vane Closed reached Min Switch is Speed Line Startup Unloading Closed OR Speed is locked the vanes are unloaded UnitStatus to the Unload timer is Rapid Shutdown L3 jp ELI Full load flag set and over Full load flag set and Stage Delta over Stage Delta T c Likely Capcity override limited and More than Compressor set Compr set La Vanes Open Speed Modulating to chilled water Full Vanes Vanes Loaded continuously Capacity Overrides Correcti
49. Off Off Oil Pump Off VFD Off Oil Pump On Pre Lubrication VFD Off Condenser Pump On Waiting for Flow VFD Off Evaporator Pump On Waiting for Flow VFD Off Startup Unloading VFD Off MCR Started Running OK Or Running Capacity Override Can have either VFD status shown to the right VFD Start VFD Start Then VFD Running Hold Minimum Speed amp Adjust Vanes VFD Running Capacity Override Or VFD Running Adjust Speed amp Open Vane MCR Off Rapid Shutdown VFD Off Shutdown Unloading VFD Routine Shutdown Or VFD Off MCR Off Routine Shutdown VFD Off Condenser Pump Off Shutdown VFD Off Evaporator Pump Off Shutdown VFD Off Post Lubrication VFD Off Shutdown Oil Pump Off VFD Off IOMM VFD 2 Figure 22 MicroTech 200 VFD Speed Control State Diagram VFD Off Command Speed is held at 096 Vanes closed Motor Relay is closed VFD Start Command Speed starts at 70 full speed and increases with Minimum Speed Vanes modulating to chilled water Capacity Overrides effect Vane modulations Vane Closed Switch is VFDCapOverrides cm Motor Relay Vanes are Command Speed and vane position held constant UnitStatus is closed AND Full Open except if override becomes critical then modualte is Rapid Locked Speed Command Speed amp Vane position Shutdown is ON ommand S
50. RIC IOMM VFD 2 IOMM VFD 2 Step 4 Press the A and the W key The display steps through the error log entries which are numbered 0 through 9 maximum Step 5 Press the ENTER key HC em The display shows the day stamp which can range Reverse MEME sreco RUNNING Co 0075 C from 0 to 248 days C aurs C soc CI nz CI auto C kw ronwano E3 TORQUE C reverse Password PROGRAM ENTER STOP start RELIANCE NESET ELECTRIC Step 6 Press the Wkey The display shows the time stamp which is based 22 11 4 24 hour clock Use the arrow keys to move SPEED RUNNING Rever m ptt NOTE oe between the day and time data Co aurs Coe auro EH Forwaap Ea C Tonave C REVERSE Password PROGRAM RESET RELIANCE ELECTRIC Step 7 Press the PROGRAM key which displays the error log entries again The display shows the error log entry viewed prior to or associated with the time stamp Step 8 Repeat steps 4 through 7 for each additional error log entry to view the time and date for each error log entry Step 9 When you have viewed all the entries you should clear the error log Press the W key while you are viewing any entry in the log until the display shows CLr Press ENTER to clear the error log All entries will be cleared ED Cir jas sreco vots C Remote CI wrs E i
51. Table 12 MicroTech Unit Status vs Status eeessssssseseseseeeeee eene ener 45 Table 13 MOTOR Setpoint Settings emet nee ee tete eerte rer eR dnte 53 Table 14 MicroTech IL Settings and Ranges Single Compressor eese 55 Table 15 MicroTech Settings and Ranges Multiple Compressor Includes Duals 55 Table 16 Key Desctiptions nte qi tee decade ete ket ete b be geste e uice eed 58 Table 17 Precharge Board LED Indicators nennen eene eene 59 Table 18 Ready LED Status Functions seseesseeeeeeeeeneenne eene nennen 60 Table 19 Status LED Definitions eren entente nent nhan nsns 60 Table 20 Types of Alarms o nece aee ene e tete tet eerte Gor tena tule iter cube detect 61 Table 21 Alarm Descriptions 5 600 nennen nnne nentes enne nene 62 Table 22 Alarm Descriptions LF 2 0 essere enne ene 63 Table 23 Fault Types Ren ra RE HERR OH P p ipe 64 Table 24 SP600 Fault Descriptions and Corrective Actions seen 66 Table 25 LF 2 0 Fault Descriptions and Corrective Actions esee 69 Table 26 No Start From Terminal Block Logic eeeeeeeeeeeeeeenen nennen neen eene 73 Table 27 No Start From Terminal Block Logic Continued eee 74 Table 28 No Start
52. The keypad display is in program mode The keypad display is in monitor mode Parameters cannot be modified from the keypad without entering the correct password into P 051 Programming Disable Note that disabling program changes by means of P 051 does not prevent parameter changes being made from the serial port or the network Parameters can be modified from the keypad Table 47 describes the values that will be displayed when the corresponding monitor mode LED is on Table 47 Monitor Mode LEDs Monitor Mode LED Corresponding Display When LED Is On Actual Values Motor speed is displayed Drive output volts are displayed This value is not DC bus volts Drive output amps are displayed Drive output frequency in hertz is displayed Output power of the drive in kilowatts is displayed Note that this is intended for display purposes as a general indication of kilowatt output and should not be used for control or exact metering purposes TORQUE Motor output torque is displayed in percent Valid only for vector regulation ALL LEDs Selected speed reference or torque reference in is displayed IOMM VFD 2 IOMM VFD 2 Troubleshooting N DANGER 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 voltmete
53. There is no visual indication that there are faults in the log You must access the error log to view the faults The error log holds the 10 most recent faults that have occurred The last fault to occur is the first one to appear on the display when you access the error log The faults in the log are numbered sequentially The most recent fault is identified with the highest number up to 9 Once the log is full older faults are discarded from the log as new faults occur For each entry in the error log the system also displays the day and time that the fault occurred The day data is based on a relative 247 day counter rolls over after 247 55 Scrolling through the error screens will give the day for example 117 which would be 117 days from the 0 day The time is based on a 24 hour clock The first digits of the clock data represent hours The last two digits represent minutes For example 10 17 PM would be 22 17 The clock can be reset using R030 Elapsed Time Meter Reset See page 46 for details on adjusting the time stamp All entries in the error log and the day and time data are retained if power is lost 95 Identifying Alarm Codes and Corrections VFD drive alarm codes are shown in Table 48 Note that the alarm code will only be displayed for as long as the problem exists Once the problem has been corrected the alarm code will disappear from the display Table 48 List of Alarm Codes Alarm Description Alarm Caus
54. a value or toggle a bit Exit a menu cancel a change to a parameter or toggle between ESC PROG program and process user display screens Enter a menu select an option or save changes to parameter value HAND Enable Hand manual reference control Release Hand manual reference control 5 Stop the drive Clear a fault if the OIM is the control source CNi Start the drive if the OIM is the control source F1 though F4 Predefined or user configured functions The definition F1 of each key is shown directly above the key on the display See item in figure B 3 From the main menu use the 4 or gt keys to scroll through the sub menus The Diagnostics menu is if primary interest to the operator When selected press the Enter key IOMM VFD 2 to select it Then use the scroll keys up down right or left to select the item of interest Using the LEDs Determining Precharge Board Status Using the LED Indicators Frames 5 amp 6 Only Precharge is an internal function that is used automatically when powering up the control There is no operator function required Precharge LEDs give the status of the board They are located above the Line Type jumper shown in Figure 32 In addition to the LED signal a fault in the precharge function will also show on the display Figure 32 Location of Precharge Status LED o n 3 E S sig D IGTOP Line Type OO Spare
55. arms gt Clr Alarm Queue gt Fault into Status Info Drive Status 1 View Fault Queue wes Device Items Drive Status 2 Clear Faults Device Version PowerFlex 700H Drive Alarm 1 Clr Fault Queue HIM Version Product Data Drive Alarm 2 Reset Device Control Board Speed Ref Source Power Board Slot A E Start Inhibits M Last Stop Source LCD HIM Product Data Dig In Status LCD HIM Control Board Dig Out Status Keyboard Numeric Drive Temp Motor OL Count View selected through ED ED EAE eda Y Param Access Li Basic File Group Par FGP File Advanced Numbered List Changed Params File2 Group 1 Name FGP Parameter File 3 Name Group2Name Parameter Name Group3Name Parameter Name PowerFlex 700H Connected DPI Devices Parameter Name Him CopyCat Device gt HIM____ Memory Storage eo Device User Sets Drive User Set ___ Device HIM Save To User Set Delete HIM Set Reset To Defaults AY Load Frm Usr Set Active Name Set eo L Introduction Complete Steps __ 1 Input Voltage eo CODED Aly available if power 2 Motor Dat Ramp cycled during startup 3 Motor Tests 4 Speed Limits gt Make a selection 5 Speed Control Abort Device Identity B MES
56. ated nitus 57 Installation erret 11 Using the EEDS ah anes nes 59 Cooling Requirements for VEDs 13 About Alarms eee 61 Separate Cooling Module LF VFD 090 120 and About 64 15 Troubleshooting eeeeeen 73 Wiring General 21 Operation Large A C PF700H 77 Power Wiring eese 21 Using the Interface sse TI Terminal Sizes sese 23 Using the LEDS 80 Optional Line Reactor Installation Air Cooled LF Faults and Alarms seen 80 Only eii ned et eb reet Eee dy 25 Troubleshooting sssseeeeeenee 87 VAD Shiller Interconiecnon Winns Diagram Operation 90 VED Dimensions 32 Using the Interface see 90 Aur Cooled Ea RARI 32 Using the LEDS ssseseeeee 93 LiquiFlo Error Bookmark not defined Troubleshooting eene 95 Piu s 0 co PROF Bookmark nobdehncd Indices Figures amp Tables 103 Manufactured in an ISO Certified facility 2005 McQuay International Information and illustrations cover the McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice McQuay is a registered trademark of McQuay Inter
57. ation Note Local control is not allowed on McQuay Centrifugal Chillers Compressor may run without lubrication STOP RESET If the drive is running RUNNING LED is on the STOP RESET key stops the drive If the drive is not running RUNNING LED is off pressing this key resets drive faults Using the LEDs The keypad contains eight LEDs that show the present drive status The following table describes what each drive status LED means 93 Table 46 Drive Status LEDs LED RUNNING REMOTE LED Status On Meaning Output power is being applied to the motor Off On Output power is not being applied to the motor The drive is being controlled START RUN JOG FORWARD REVERSE speed reference from a source other than the keypad Off The drive is being controlled from the keypad Not Allowed e The network connection is lost _ Not Allowed FORWARD REVERSE PROGRAM PASSWORD The drive is receiving its speed reference from the terminal strip input or network option Flashing The drive is receiving its speed reference from the local keypad or serial port OIM or CS3000 i e using a manual reference Not Allowed The requested motor direction is forward the actual motor direction is reverse REVERSE LED is on The motor is running in the forward direction Flashing On Off The motor direction is not forward Not Allowed
58. ause the resistor temperature has exceeded a predetermined value The drive autotuning default is Calculate and the value calculated for IR Drop Volts is not in the range of acceptable values This alarm should clear when all motor nameplate data is properly entered The sum of Maximum Speed 82 and Overspeed Limit 83 exceeds Maximum Freq 55 Raise Maximum Freq 55 or lower Maximum Speed 82 and or Overspeed Limit 83 so that the sum is less than or equal to Maximum Freq 55 Motor Type 90 has been set to Sync Prm Mag or Sync Reluc and one or more DC functions for example DC Boost DC Brake etc have been activated DC injection functions are incompatible with synchronous motors and may demagnetize them Fan pump mode is selected in Torq Perf Mode 53 and the ratio of Motor NP Hertz 43 to Maximum Freq 55 is greater than 26 Drive has sensed a power line loss Drive is in the initial DC bus precharge state Speed Ref Cflct Speed Ref x Sel or PI Reference Sel is set to Reserved Under Voltage VHz Neg Slope 1 2 About Faults Faults indicate conditions within the drive that require immediate attention The drive responds to a fault by initiating a coast to stop sequence and turning off power to the motor The bus voltage has dropped below a predetermined value Custom V Hz mode has been selected in Torq Perf Mode 53 and the V Hz slope is negative A flashing red LED indicates a fault has occurred
59. away from oil coolants or other airborne contaminants Do not install the drive above 1000 meters 3300 feet without derating output power For every 91 4 meters 300 feet above 1000 meters 3300 feet derate the output current 1 Verify that the drive location meets the environmental conditions specified on page 5 Floor mounted units should be attached to the floor with the C channel rails provided IOMM VFD 2 IOMM VFD 2 Clearance The VFDs must be mounted on a level concrete or steel base and must be located to provide adequate service Local codes or the National Electric Code NEC can require more clearance in and around electrical components and must be checked Mounting Make sure that the floor or structural support is adequate to support the weight of the unit shown on the dimension drawing Standard NEMA 1 and NEMA 12 VFDs must be installed indoors in an area that is not exposed to direct water spray Do not install in areas where the ambient temperature falls below 32 F 0 or exceeds 104 F 40 C enclosed or 122 F 50 C open unless this was noted at the time of order placement and special precautions were taken to protect against these abnormal temperatures Heatsink temperatures can run as high as 158 F 70 C during normal operation Do not mount the starter in contact with any material that cannot accept this heat The VFD must be mounted with the heat sink fins oriented vertically in an area that wil
60. bled disable with Fault Config 1 238 The drive output current has Current Lmt Val 148 setting Check for excess load improper IOMM VFD 2 SW T UnderVoltage UserSet1 Chksum exceeded the software current DC at 400 480V input or Config 1 233 The checksum read from Troubleshooting DC bus voltage fell below the minimum value of 407V 204V DC at 200 240V input Enable disable with Fault the user set does not match the checksum calculated DC boost setting DC brake volts set too high Monitor the incoming AC line for Re save user set Common Symptoms and Corrective Actions Table 26 No Start From Terminal Block Logic Indication s Flashing red Ready LED Cause s Drive is faulted Corrective Action Clear fault Press OIM stop key if that OIM is control source Cycle power Set Fault Clear 240 to 1 Toggle terminal block stop or terminal block reset digital input if terminal block is the control source low voltage or power interruption Incorrect operation from the terminal block Incorrect input wiring 2 wire control requires Run Run Forward or Run Reverse input s e 3 wire control requires Start and Stop inputs Jumper from terminal 7 to 8 is required Wire inputs correctly and or install jumper Incorrect digital input programming Mutually exclusive choices have been made 2 wire and 3 wire programming may be
61. connect reactors supplied as a component part of a drive system or other power electronic system according to the system interconnection diagram supplied by the System Engineer will result in equipment damage injury or death N WARNING If a line reactor or a line reactor and a load reactor are used with a drive equipped with a bypass circuit the reactors must be removed from the motor circuit in the bypass mode Damage to the motor and other equipment will result if this warning is not observed Figure 10 Line Reactor Wiring Grounding A stud is provided in the reactor enclosure for grounding the enclosure The enclosure must be grounded The frame of line load reactors must be grounded at the designated grounding terminal or one of the reactor mounting holes if no designated grounding terminal is provided The enclosure of reactors supplied in enclosures must be grounded INJURY OR DEATH MAY RESULT IF SAFETY PRECAUTIONS ARE NOT OBSERVED 29 30 VFD Chiller Interconnection Wiring Diagram Figure 11 Control and Power Wiring Diagram MICROTECH CONTROL BOX TERMINALS
62. d Under Temperature Fault E4 Fluid Low Flow Fault To acknowledge the alarms hold the key for 3 seconds The alarm error code will be displayed and the reset led will light while the button is depressed After the key is released the process temperature will be displayed To view the alarm summary hold both the J keys for 3 seconds To exit the alarm summary screen press the key or the screen will automatically time out after 10 seconds 19 20 Figure 7 FX05 Display Panel o ALARM RESET PUMP ON O 9 Fx05 Operation The FX controller controls to a fixed loop water setpoint IOMM VFD 2 Wiring General Unit Mounted Unit mounted VFDs have factory wired control wiring plus power wiring from the VFD to the compressor motor terminals The VFDs only require a power supply Cable entrance is shown on the dimension drawings beginning on page 32 for LF and page Error Bookmark not defined for LF 2 0 models An exception is on models LF models 090 and 120 and all LF 2 0 models that require some interconnection control wiring from the VFD to the remote cooling module as described in the section beginning on page 15 Freestanding Freestanding units require both field control and power wiring from the to the chiller and some interconnection control wiring on models 090 and 120 Wiring Diagram The control and power wiring diagram is located on page 25 Power Wirin
63. ddress the condition that caused the fault The cause must be corrected before the fault can be cleared Step 3 After corrective action has been taken clear the fault using one of the following e Setting Fault Clear 240 to Clear Faults 1 e Press F1 Cflt from the fault queue screen e Issuing a Stop Clear Faults command from the control source Resetting faults will clear the faulted status indication If any fault condition still exists the fault will be latched and another entry made in the fault queue Note that performing a fault reset does not clear the fault queue Clearing the fault queue is a separate action See the Fault Clear 240 parameter description The table beginning on the following page describes drive faults and corrective actions It also indicates the fault type as Auto resettable 2 Non resettable 3 User configurable Table 24 SP600 Fault Descriptions and Corrective Actions Description An analog input is configured to fault Analog In on signal loss A signal loss has Loss occurred Configure with Anlg In 1 2 Loss 324 327 The checksum read from the analog calibration data does not match the Replace drive checksum calculated Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of Auto Rstrt Tries 174 Enable disable with Fault Config 1 238 AutoTune The autotune procedure was canceled Aborted by the user DB Resistance of the internal D
64. dling and shipping damage are the responsibility of the consignee Rigging Extreme care must be used when rigging the equipment to prevent damage See the certified dimension drawings included in the job submittal for the center of gravity of the unit Consult the local McQuay sales office for assistance if the drawings are not available 11 12 Air Cooled The unit can be lifted by fastening the rigging hooks to the two lifting eyes located on the top of the unit LiquiFlo The unit can be lifted by fastening the rigging hooks to the four lifting eyes located on the top of the unit LiquiFlo 2 0 Figure 2 LF 2 0 Lifting Points Lit Points Use the following procedure to lift and mount the LiquiFlo 2 0 drive Step 1 Using an overhead or portable hoist minimum 2 ton rated capacity attach a free fall chain to the chain secured to the drive Take up any vertical slack in the chain Step 2 Using the hoist lift the drive from the horizontal shipping pallet Step 3 Position the drive Step 4 Machine or floor mount the drive enclosure using 1 2 inch bolts grade 5 or better with compression washers Location and Mounting Location Consider the following guidelines Verify that NEMA 1 enclosure drives can be kept clean and dry The area chosen should allow the space required for proper air flow A minimum of 6 inch clearance is required wherever vents are located Be sure that the NEMA 1 enclosure is installed
65. downstream closer to the than the source from the PCC High voltage is used in the operation of line load reactors Use Extreme caution to avoid contact with high voltage when operating installing or repairing equipment containing line load reactors INJURY OR DEATH MAY RESULT IF SAFETY PRECAUTIONS ARE NOT OBSERVED A DANGER Even if the upstream disconnect protection device is open a drive or inverter down stream of the line load reactor may feed back high voltage to the reactor The inverter or drive safety instructions must be followed INJURY OR DEATH MAY RESULT IF THE SAFETY PRECAUTIONS ARE NOT OBSERVED A enmon An upstream disconnect protection device must be used as required by the National Electrical Code A enion The frame of line load reactors must be grounded at least at one of the reactor s mounting holes This section is intended for use by personnel experienced in the operation and maintenance of electronic drives inverters and similar types of power electronic equipment Because of the high voltages required by the equipment connected to line reactors and the potential dangers presented by rotating machinery it is essential that all personnel involved in the operation and maintenance of line load reactors know and practice the necessary safety precautions for this type of equipment Personnel should read and understand the instructions contained in this section before installing operati
66. e High DC bus The DC bus is charged voltage above the trip threshold If U 018 gt 415 DC bus is above 741 VDC If U 018 lt 415 DC bus is above 669 VDC Correction Action Increase the deceleration time in P 0002 P 018 Install optional snubber resistor braking kit Verify that the AC input is within specification Install an isolation transformer if required Check the actual line voltage against U 018 V Hz identification V Hz identification procedure active procedure is enabled and in progress V Hz identification H 020 On V Hz procedure identification procedure enabled has been enabled but not started Allow identification procedure to finish Press keypad STOP RESET to cancel identification procedure if desired Proceed with V Hz identification procedure start drive and allow procedure to begin Display will change to I Ac when drive is started Change H 020 to OFF to cancel identification and clear I En if desired Low AC input line AC input line is low For SVC indicates DC bus is being regulated No corrective action is required Vector self tuning Vector self tuning is active enabled and in progress Adjust line voltage parameter H 021 or U 018 to match actual Ac line voltage Allow vector self tuning procedure to finish Press keypad STOP RESET to cancel vector self tuning procedure if desired Vector self tuning U 008 On vector self enabl
67. e N Limits RLA to a value set by the Demand Limit Oil No Start Differential analog input where Lift 100 VFD Speed Fusion 20mA 100 RLA VFD Speed Zero Lift OFF The Demand Limit VFD Minimum Speed input is ignored Compressor VFD Maximum LWT Rate Minimum LWT Rate Soft Load Ramp Time Initial Soft Load Limit Soft Load Enable CANCEL Demand Limit Enable related settings are 9 through 12 Password T Technician Level Manager Level Operator Level Description No Default Range Password Comments 0 to 9999 Tons Oil No Start Diff 40 F 30 to 60 F Minimum Delta T between oil sump temperature above Evap Temp and saturated evaporator temperature i 0 Lift Max Speed 40 F 30 to 60 F RE lift at 100 speed cond sat evap sat Lift min speed as a of 100 lift SP 10 has priority over this setting Min VFD speed has priority over SPs 11 amp 12 VFD on unit or not Inhibits loading if LWT change exceed the setpoint value Additional compressor can start if LWT change is below setpoint Time period to go from initial load point RLA set in SP 5 to 100 RLA Initial amps as of RLA Used with SP 4 and SP 6 Soft load on using SP 5 and SP 6 or off RLA above which loading is inhibited Load Limit Unloading is forced at 596 above this value RLA below which unloading is inhibited ON sets RLA at 0 for 4 mA external signal and at 100 RLA for 20 mA si
68. e e 25 STARTER NOTE 1 1 Ar 2 2 3 4 4 11 6 11 11 e 11 12 e 12 22 e 22 JOAD 330387901 0 P D D OR 24VAC See notes on following page IOMM VFD 2 NOTES for Wiring Diagram IOMM VFD 2 Compressor motor VFDs are either factory mounted and wired or shipped separate for field mounting and wiring VFDs must be provided by McQuay All line and load side power conductors must be copper If VFDs are freestanding then field control wiring between the starter and the control panel is required Minimum wire size for 115 Vac is 12 GA for a maximum length of 50 feet If greater than 50 feet refer to McQuay for recommended wire size minimum Wire size for 24 Vac is 18 GA All wiring to be installed as NEC Class 1 wiring system and must be made with copper wire and copper lugs only All 24 Vac wiring must be run in separate conduit from 115 Vac wiring Main power wiring between VFD and motor terminals is factory installed when chillers are supplied with unit mounted VFDs Six conductors are used between the VFD and the motor as shown in the wiring diagram Wiring of free standing VFDs must be in accordance with the NEC and connection to the compressor motor terminals must be made with copper wire and copper lugs only LF models VFD 090 and 120 and all LF 2 0 models require field wiring between the VFD and the field mounted cooling module per instruction beginning
69. e drive IOMM VFD 2 LiquiFlo 2 0 LF 2 0 Standard Features NEMA 1 enclosure with hinged door Package includes a circuit breaker with shunt trip with AIC rating of 65 000 amps Full motor voltage is applied regardless of the input voltage Efficiency at rated load and 60 hertz is 97 Drive thermal overload is 110 for 60 seconds in volts per hertz mode and 150 for five seconds in sensorless vector mode Achieves IEEE519 using actively controlled IGBT front end maximum of 5 THD 0 99 power factor at full load and provides power factor correction at lighter loads IGBT switching 2kHz carrier frequency The entire drive package is UL CUL listed Optional multi language LCD keypad Power line dip ride through capability for up to 10 seconds Adjustable auto restart number of restarts and time delay between attempts are selectable Display indicates when controller is attempting to restart Control power transformer for chiller unit controls Codes Standards VFDs are UL 508 listed VFDs are designed to comply with the applicable requirements of the latest standards of ANSI NEMA National Electric Code NEC NEPU 70 IEEE 519 1992 FCC Part 15 Subpart J CE 96 Quality Assurance Every VFD is functionally tested under motor load During this test the VFD is monitored for correct phase current phase voltages and motor speed Correct current limit operation is verified by simulating a motor overload Scrolling through al
70. e x Check Drive Status 2 bit 10 to see if the drive is in Current Limit Remove excess load or reprogram Accel Time Acceleration time is excessive Excess load or short acceleration times force the drive into current limit slowing or stopping acceleration Speed command source or value is not as expected Programming is preventing the drive output from exceeding limiting values Table 41 Unstable Operation Motor operation is unstable x Check for the proper Speed Command using Steps 1 through 7 above Check Maximum Speed and Maximum Freq to assure that speed is not limited by programming Cause s Indication Corrective Action 1 Correctly enter motor nameplate data 2 Perform Static or Rotate Autotune procedure 3 Set gain parameters to default values Motor data was incorrectly entered or Autotune was not performed Table 42 Stopping Gives Decel Fault Stopping the drive results in a Decel Inhibit fault Cause s The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage Excess bus voltage is normally due to excessive regenerated energy or unstable AC line input voltages Internal timer has halted drive operation Indication Decel Inhibit fault screen LCD Status Line indicates Faulted Corrective Action 1 See Attention statement 2 Reprogram parameters 161 162 to eliminate any Adjust Freq
71. eck Drive Status 1 209 bits 12 15 for unexpected source selections 2 Check Dig In Status 216 to see if inputs are selecting an alternate source 3 Reprogram digital inputs to correct Speed Sel x option 1 Verify that common is properly connected to Anlgln terminal IOMM VFD 2 IOMM VFD 2 Table 30 Motor Will Not Accelerate to Commanded Speed Cause s Incorrect value in Accel Time x 140 141 Indication Acceleration time is excessive Corrective Action Reprogram Accel Time x 140 141 Drive is forced into current limit slowing or stopping acceleration Excess load or short acceleration time Check Drive Status 2 210 bit 10 to see if the drive is in current limit Remove excess load or reprogram Accel Time x 140 141 Speed command source or value is not as expected Improper speed command Check for the proper speed command using steps 1 through 7 in table 12 11 Programming is preventing the drive output from exceeding limiting values Incorrect programming Table 31 Motor Operation is Unstable None Motor data was incorrectly entered or autotune was not performed Check Maximum Speed 82 and Maximum Freq 55 to insure that speed is not limited by programming 1 Correctly enter motor nameplate data 2 Perform static or rotate autotune procedure 61 Table 32 Stopping the Drive Results in a Decel Inhibit Faul
72. ed tuning has been enabled but not started Proceed with vector self tuning start drive and allow self tuning procedure to begin Display will change to S Ac when drive is started Change U 008 to OFF to cancel self tuning and clear S En if desired Note Only properly trained and qualified service personnel should change the program or operating parameters 96 IOMM VFD 2 IOMM VFD 2 Identifying Fault Codes and Recovering N DANGER DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or death VFD drive fault codes are shown in Table 49 To clear a single fault that has occurred so that the drive can be started again correct any problems indicated by the fault code and press the STOP RESET key on the keypad or assert the fault reset from the selected control source P000 Because multiple faults can occur and the first will be displayed you must access the error log repeatedly in order to view all of the faults that have occurred and correct them Table 49 List of Fault Codes Alarm Description Analog input signal loss Fault Cause P 011 2 4 or 5 and 4 to 20 mA ana
73. eed and the vanes are modulated to maintain the evaporator leaving water setpoint This mode occurs when the load tons can be satisfied with the vanes not fully open while at minimum speed Decreasing speed can no longer reduce capacity so the vanes maintain temperature control When the load increases the vanes will pulse open until the vane open switch shows that the vanes are full open At this point the MicroTech controller changes the mode to VFD Running Adjust Speed and Open Vanes VFD Routine Shutdown The VFD remains on the speed output remains the same dependent on the prior state and the vanes are driven closed VFD Locked Speed The MicroTech has a VFD LOCKED Speed Setpoint that can be selected either ON or OFF from the MicroTech controller keypad When the VFD Locked Speed mode is set to ON the VFD speed will be locked at the locked speed setpoint keypad adjustable The purpose of this mode is to allow proper setup calibration testing etc of the chiller at a constant speed with constant conditions NOTE Do not set the drive minimum speed above the factory setpoint to limit reduced speed A control incompatibility will result between the MicroTech controller and the drive Override Capacity Control Any capacity override see Capacity Overrides on page 48 that forces the VFD out of normal speed control To return to normal speed control the capacity override condition is corrected First level capac
74. ent RLA is 5 greater than the Network setpoint reduce command speed by 1 every five seconds When the command speed is reduced to minimum speed close the vanes Max Pulldown Rate Max Pull Down Rate setpoint is an adjustable setpoint range 0 1 to 5 0 F minute in 0 1 F increments default is 1 0 F minute Pulldown rate leaving evap water temp one minute ago minus leaving evap water temp now If the Pulldown rate exceeds the setpoint hold command speed and vane position IOMM VFD 2 IOMM VFD 2 7 10 Demand Limit Establishes a demand limit between 10 and 100 RLA based on a 4 20 mA signal input If the motor current RLA is greater than the demand limit hold command speed and vane position If the motor current RLA is 5 greater than the demand limit reduce command speed by 1 every five seconds If the command speed is reduced to Minimum Speed close the vanes Softloading Establishes a soft load capacity limit between 10 and 100 RLA based on time from the first start of the day If the motor current RLA is greater than the soft load capacity limit hold command speed and vane position If the motor current RLA is 5 greater than the soft load capacity limit reduce command speed by 146 every five seconds If Command Speed is reduced to Minimum Speed close the vanes Low Evap Pressure If the evaporator refrigerant pressure is less than 38 0 psi default hold speed and vane position If the
75. ers Air Cooled LiquiFlo LF and LiquiFlo 2 0 LF 2 0 VFDs on centrifugal chillers with MicroTech 200 or the newer MicroTech II M controllers Many issues are the same for both and are treated in common Where differences occur information will be designated as being for a specific VFD or controller model The above three types of VFDs have four family designations as show in Table 1 and Table 2 Each of these VFD families has a separate section in this manual There is considerable overlap in programming methods and general operation of the drives but they are in separate sections to avoid confusion The beginning page number for each control section in the manual is noted in the tables IOMM VFD 2 3 Table 1 Model Sizes Air Cooled LiquiFlo L Shipped loose M Mounted A Air cooled W Water cooled VFD Model VED 009LA VED 009MA VED 012LA VED 012MA VED 015LA VED 015MA VED 017LA VED 017 VED 023LA VED 023MA VED 024LA VED 024MA VED 028LA VED 028MA VED 047LW VED 047MW VED O60LW VED 060MW VED 072LW VED 072MW VED 090LW VED120LW NOTES VFD Family Designation PF700H Page Location Cooling Air Air Air Air Air Air Air Air Air Air Air Air Water Water Water Water Water Water Water Water Air Air o Air Air Air Air Air Air Ar Air Air s Ar 7 Water Water Water Water Water Water Water Water Op
76. eue or by using a PC software tool IOMM VFD 2 61 62 Alarm Descriptions Table 21 Alarm Descriptions SP600 Analog In Loss Bipolar Conflict Description An analog input is configured for alarm on signal loss and signal loss has occurred Parameter 190 Direction Mode is set to Bipolar or Reverse Dis and one of more of the following digital input functions is configured Fwd Rev or Run Fwd Note that the default is Reverse Dis Decel Inhibit The drive is being inhibited from decelerating Digital input functions are in conflict Combinations marked with an X will cause an alarm Acc2 Dec2 Accel 2 Decel 2 Fwd Rev Acc2 Dec2 X X Accel 2 X Decel 2 X Fwd Rev Dig In ConflictB Digital input functions are in conflict Combinations marked with an X will cause an alarm Start Stop CF Run Fwd Fwd Rev Start Stop CF Run X Run Fwd X X X Fwd Rev X Dig In ConflictC More than one physical input has been configured to the same input function Multiple configurations are not allowed for the following input functions Forward Reverse Run Bus Regulation Mode B Speed Select 1 Stop Mode B Acc2 Dec2 Speed Select 2 OIM Control Accel 2 Speed Select 3 Stop Mode B Decel 2 Run Forward Digln Bad Value Unsupported function selected in Digital In x Sel parameters 361 366 Drive OL Level 1 The calc
77. fy connection between AC Line Sync and AC Line I O boards Verify proper input voltage Clear fault An excessive motor load exists Reduce load so drive output current does not exceed the current set by Motor NP FLA 42 IOMM VFD 2 IOMM VFD 2 OverSpeed Limit OverVoltage Functions such as slip compensation or bus regulation have attempted to add an output frequency adjustment greater than that programmed in Overspeed Limit 83 DC bus voltage exceeded maximum value Remove excessive load or overhauling conditions or increase Overspeed Limit 83 Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the ecal time or install dynamic brake option Parameter Chksum Params Defaulted Phase U to Grnd Phase W to Grnd Phase UV Short Phase VW Short Phase UW Short Port 1 5 DPI Loss Port 1 5 Net Loss The checksum read from the board does not match the checksum calculated The drive was commanded to write default values to EEPROM A phase to ground fault has been detected between the drive and motor in this phase Excessive current has been detected between these two output terminals DPI port stopped communicating An attached peripheral with control capabilities via Logic Source Sel 89 or OIM control was removed The fault code indicates the offending port number 81 port 1 e
78. g Wiring fuse and wire size must be in accordance with local codes and the National Electric Code NEC N CAUTION Voltage unbalance not to exceed 2 with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG 1 1998 Standard This is an important requirement to avoid excessive motor or drive heating N WARNING Qualified and licensed electricians must perform wiring Shock hazard exists Power wiring to compressors must be in proper phase sequence Motor rotation is set up for clockwise rotation facing the lead end with phase sequence of 1 2 3 Care must be taken that the proper phase sequence is carried through the VFD to the compressor With the phase sequence of 1 2 3 and L1 connected to T1 and T6 L2 connected to T2 and T4 and L3 connected to T3 and T5 rotation is proper See diagram in terminal box cover The McQuay start up technician will check the phase sequence N CAUTION Connections to terminals must be made with copper lugs and copper wire Care must be taken when attaching leads to compressor terminals Note Do not make final connections to motor terminals until wiring has been checked and approved by a McQuay technician Under no circumstances should a compressor be brought up to speed unless proper sequence and rotation have been established Serious damage can result if the compressor starts in the wrong direction Such damage is not covered by product warranty Compressor M
79. g RUNNING LED is on JOG LED is off Follow these steps to display the selected reference Step 1 If you are not already in monitor mode access it by pressing the PROGRAM key until the PROGRAM LED turns off Step2 Press the ENTER key repeatedly to advance through each of the monitor mode LEDs All of the monitor mode LEDs will then turn on at once and the reference will be displayed Note that the displayed speed reference value is scaled based on P 028 The torque reference value is displayed in percent If the selected reference is negative and its value is greater than 999 the SPEED LED will flash The Display The display portion of the keypad display is a four character seven segment LED At drive power up SELF is displayed as the drive performs power up self diagnostics During drive operation the display indicates parameter numbers parameter values fault or alarm codes and drive output values Display Range Normally a minus sign is used as one of the four characters in the display to indicate a negative value If a value including the minus sign exceeds four characters the display will drop the minus sign and display four digits In this case the SPEED LED will flash to indicate that the displayed value is a negative number Refer to the examples in the following table A decimal point to the right of the last digit in the display indicates there is further resolution examples A and E below unless a decimal
80. gain the problem is in the wiring between the drive and the encoder If the F3 error does occur again the problem is in the regulator board which should be replaced F 60 Option port identification errors The option board could not be identified by the regulator Check the ribbon cable between the regulator board and the option board Check the option board s jumper settings Refer to the appropriate option board instruction manual for more information about the option board F 61 Option board power up diagnostic failure Option board has failed one or more power up diagnostics Check the ribbon cable between the regulator board and the network option board Replace the option board if necessary Refer to the appropriate option board instruction manual for more information about the option board F 62 F 26 Option board runtime errors During operation the option board watchdog failed or handshaking with the drive failed If intermittent check for causes of noise for proper grounding and that outputs are not exceeding rated current capacities Replace the option board if necessary Refer to the appropriate option board instruction manual for more information about the option board 102 IOMM VFD 2 Indices Figures amp Tables Index of Figures Figure 1 LiquiFlo Internal Components Factory Mounted Water Cooled Model
81. gnal Nominal Capacity Design Determines when to shut off a compressor Speed 0 Lift 50 0 to 100 Minimum Speed 70 60 to 100 VFD No No Yes 0 1 to 5 0 F min 0 0 to 5 0 F min Maximum Rate 0 5 F min Minimum Rate 0 1 F min Soft Load Ramp 5 min 1 to 60 min Initial Soft Load Amp Limit 40 20 to 100 Soft Load Enable OFF OFF ON Maximum Amps 100 40 to 100 Minimum Amps 40 20 to 80 Demand Limit OFF OFF ON Enable NOTE Shaded settings are VFD related lt lt lt lt lt 44 A IOMM VFD 2 Figure 26 MOTOR VFD Setpoint Screen Panel 2 Unit Status Chiller A SETPOINTS Compressor Status 1 RUN Hold F m PSI 2 OFF Awaiting Load 2 STARTER Lift 100 VFD Speed Demand Limit Enable VFD Speed Zero Lift ON Limits RLA to a value set by the Demand Limit VFD Minimum Speed analog input where Compressor VFD 4mA 0 RLA Oil No Start Differential 20mA 100 RLA OFF The Demand Limit Nominal Capacity input is ignored Maximum LWT Rate Minimum LWT Rate MiimumAmps HISTORY Table 13 MOTOR Setpoint Settings related settings are 12 through 15 O Password T Technician Level Manager Level Operator Level Password Comments VED 30 to 60 F Temp lift at 100 speed cond sat evap sat temp Lift min speed as a of 100 lift SP 10 ha
82. h current was detected in an IGBT High current was detected in an IGBT 1 Cycle power 2 If fault repeats replace I O board Restore 1 board to original configuration or If new configuration is desired reset fault Load compatible version files into drive Check for loose connection in input power wiring Check for problem in input power distribution 1 Check for loose connection in IGBT wire harness 2 Check IGBTs 1 Verify proper motor data is entered 2 Reduce current limit Invtr Base Temp Invtr Gate Kill Invtr IGBT Temp IR Volts Range Line Frequency Low DC Bus Motor Imbalance Motor Overload 70 13 Base temperature exceeded limit Inverter gate kill contact is open Output transistors have exceeded their maximum operating temperature The drive autotuning default is Calculate and the value calculated for IR Drop Volts is not in the range of acceptable values Line frequency not in the range of 47 63 Hz The bus voltage is too low Phase current displayed in Imbalance Display 221 gt percentage set in Imbalance Limit 49 for time set in Imbalance Time 50 Internal electronic overload trip Enable disable with Fault Config 1 238 Check for proper temperature and flow rate of coolant Close gate kill contact Check for proper temperature and flow rate of coolant Re enter motor nameplate data Veri
83. he chilled water pump 2 The pressure drop is given for the maximum coolant temperature maximum flow The water regulating valve will reduce the flow when the coolant temperature is below the maximum in the table The pressure drop includes the drop across the solenoid valve heat exchanger and water regulating valve 3 Models VFD 090and 120 and all LF 2 0 models have a separate self contained cooling loop with a recirculating water pump and heat exchanger but have the same cooling source water piping as all water cooled VFDs ON 3 3 3 N A 300 180 180 NA 180 30 2 30 2 NA 180 O NA O NA NA 0 2 0 2 0 2 N A N A N A N A Table 5 Chiller Cooling Water Connection Sizes Chiller Unit Free Standing VFD LF and LF 2 0 Factory Mounted VFD LF Only To Oil Cooler To VFD WDC WCC 100 126 1 1 2 in FPT 54 in MPT 1 1 2 in FPT WSC WDC 050 Not Required Air Cooled Not Required All Others 1 in 3 4 in MPT 1 in Separate Cooling Module LF VFD 090 120 and all LF 2 0 The cooling module for the LF models VDF 090 and 120 has a self contained coolant temperature control system and no associated programming of the VDF is required All cooling modules used with LF 2 0 VFD models are controlled by the VFD and require VFD programming as shown on page 19 This is done by McQuay at startup Closed loop cooling system operation e A pump circulates a glycol water mixture coo
84. ininiaininia Diagnostics ii Ses i Monitor Lang Ii ECCA aJ v Highlight item Highlight Diagnostics icon Figure 36 Sample Fault Queue Entry Fita HF xxxxx Fault1 Text String Fault2 Text String Accum Accum hours min sec hours min sec For ora oe F1 F2 F3 F1 Clear fault F2 Clear fault queue F3 Drive Reset Appears only when fault is active The drive can be reset as if the power were cycled by pressing the F3 Dres function key while in the View Fault Queue screens The reset function is active only while the drive is stopped During a reset drive communication with peripheral devices will stop until the reset function completes A CAUTION Pressing F3 Dres will immediately cause the drive to be reset This may result in communication errors in other devices attached to the drive which could result in machine damage IOMM VFD 2 IOMM VFD 2 Operation Large A C PF700H The status of the drive can be viewed on the Human Interface Module HIM or on various LEDs Using the Interface Figure 37 Human Interface Module HIM O00 00000 OOOO 0 The interface module can be removed to provide security against tampering with the control To do so first press the ALT key release it and then press the left arrow REMOVE key This procedure allows the module to be removed without causing a fault Then press the tab on
85. ional hardware such as motor overload relays or motor thermostats are required e LED display that digitally indicates Frequency output Input kW DC bus voltage Voltage output Elapsed time Motor RPM Current output Time stamped fault indication e The VFD is capable of maintaining operation through power dips up to 10 seconds without a controller trip depending upon load and operating conditions In this extended ride through the drive uses the energy generated by the load inertia of the motor as a power source for electronic circuits e An isolated 0 20mA 4 20mA or 0 4 0 8 0 10 V analog speed input follower e An isolated 0 10V or 4 20mA output signal proportional to speed or load e Standard I O expansion interface card with the following features e Four isolated 24VDC programmable digital inputs e One frequency input 0 to 200Hz for digital control of speed or trim reference e Four programmable isolated digital outputs 24 VDC rated e One Form A output relay rated at 250 VAC or 24VDC Two NO NC programmable output relays rated at 250 VAC or 24 VDC e The VFD includes the following standard protective circuit features Output phase to phase short circuit condition Total ground fault under any operating condition High input line voltage Low input line voltage Loss of input or output phase External fault This protective circuit will permit wiring to a remote normally closed equipment protection contact to shut down th
86. irty heat sink fins Verify that ambient temperature has not Heatsink Heatsink temperature exceeds a A OvrTemp s predefined value of 90 C 195 F 9Xceeded 40 C 104 F NEMA HW Over Current Incompat MCB PB The drive output current has exceeded the hardware current limit Drive rating information stored on the power board is incompatible with the Main Control board Type 1 installations or 50 C 122 F for Open type installations 2 Check fan Check programming Check for excess load improper DC boost setting DC brake volts set too high or other causes of excess current Motor dynamics cannot be accommodated by autotuning Manual tuning of the current loop required Consult technical support Load compatible version files into drive Comm Loss Loss of communication to I O board Cycle power I O Board Fail Board failure 1 Cycle power 2 If fault repeats replace I O board I O Mismatch Incorrect I O board identified Restore 1 board to original configuration or If new configuration is desired reset fault IR Volts Range The drive autotuning default is Calculate and the value calculated for IR Drop Volts is not in the range of acceptable values Re enter motor nameplate data Motor Overload Internal electronic overload trip Enable disable with Fault Config 1 238 An excessive motor load exists Reduce load so drive output cur
87. is on top left hand Unit Weights Weight Ib kg 1272 577 1272 577 36 IOMM VFD 2 Figure 17 VFD 090LW 120LW Water Cooled Free Standing Only 3 38 M 858 10 5 243 119 m4 Note Remove nas oe TYP 266 7 617 3 to prevent metal particles from falling into drive components c DRIVE FAULT PUMP 4 MOTOR RUNNING B LINE LEAD ACCESS COVER PLATE MOTOR LEAD ACCESS COVER PLATE 24 2 614 7 NOTE The shipped loose field installed closed loop cooling module is shown installed adjacent to the VFD It can also be install separated from it See page 15 for installation instructions Unit Weights Weight Ib kg 1800 817 1800 817 IOMM VFD 2 37 Figure 18 VFD 047MW 072MW Water Cooled Unit Mounted 400 16 00 o e je 15 26 FA FA 72 00 38 00 amma 0010 YYYY Yyy 1711 0000 WG NN amma 000 WU ammam nana WW A 1111 1111 YYYY YYYY 1111 0000 WV 1111 1111 WU Y amama I N anna 1 o 1 o o Anal naan WAY gt f NUN TEIL 330 1 5 oc
88. ity overrides hold speed and vane position while waiting for the condition to correct If the override condition becomes critical second level capacity override speed and vane position will be modulated in an attempt to correct the critical condition Control Sequence MicroTech 200 VFD Off The VED is turned off the speed output is 0 and the vanes are closed If the chiller is turned on and if there is a load the chiller will go through its start sequence and when the unit status reaches Motor Control Relay MCR Started the VFD status MicroTech II controller Menu 1 Screen 2 will switch to Start VFD Start The VFD is turned on the speed output is minimum speed and the vanes are modulated to maintain the chilled water setpoint Active Setpoint on keypad display At the same time the minimum speed will continually be re calculated based on the lift temperature In the start mode capacity control is Hold Minimum Speed amp Adjust Vanes to satisfy the Active Setpoint leaving chilled water temperature When the vanes have been pulsed to the full open position the Vane Open switch closes the VFD mode changes to Running adjust speed open vanes VFD Running Adjust Speed amp Open Vanes The VFD remains on the speed output is modulated to maintain the Active Setpoint and the vanes are driven to the open position As the load decreases if the Speed equals the lift temperature control speed and
89. l 1 x CATEGORY MENU ITEM ACTION cu p El ES du Bez MicroTech Operation and adjustment of the VFD involves settings on both the VFD itself and also to the chiller controller either MicroTech 200 controller or MicroTech II controller This manual consists of a section relating to VFD operation common to both chiller controllers and also separate sections for the settings specific to either of the chiller MicroTech controllers NOTE VFDs are programmed differently in the factory for 50 and 60 hertz applications It is prudent to verify this by checking the settings sticker in the unit and the actual unit settings using the Reliance manual shipped with the VFD unit as a reference Environmental Conditions Operating Temperature inside NEMA 1 enclosure 32 to 131 F 0 C to 55 C Ambient Temperature outside NEMA 1 enclosure 32 to 104 F 0 C to 40 C Storage Temperature Ambient 32 to 131 F 0 C to 55 C Humidity 5 to 95 non condensing AC line distribution system capacity shall not exceed 85 000 amps symmetrical available fault current Harmonic Distortion Harmonic distortion the effect that any variable frequency drive has on the electrical system supplying it power is a consideration on most applications and is discussed in detail in Catalog Starter which can be obtained from the local McQuay sales office or on www mcquay com General Description The will
90. l not experience excessive shock or vibration Grounding the Drive Use the following steps to ground the drive Step 1 Open the door of the enclosure Step 2 Run a suitable equipment grounding conductor unbroken from the drive enclosure ground lug to earth ground See figure 2 2 Tighten these grounding connections to the proper torque Step 3 Close the door of the enclosure Safety Precautions Electrical codes require that all equipment VFD motor operator station etc be properly grounded An incoming disconnect must be locked open before wiring or servicing the starter motor or other related equipment The equipment must only be serviced by qualified personnel fully trained and familiar with the equipment The opening of the branch circuit protective device may be an indication that a fault current has been interrupted To reduce the risk of electrical shock current carrying parts and other components of the starter should be inspected and replaced if damaged Equipment is at line voltage when AC power is connected Pressing the Stop push button does not remove AC mains potential All phases must be disconnected before it is safe to work on machinery or touch motor terminals and control equipment parts Cooling Requirements for VFDs Air cooled VFDs all air cooled have self contained cooling systems and require no field work Water cooleed factory mounted VFDs VFD cooling water piping is factory connected to the chille
91. l parameters verifies proper factory presets The computer port also verifies that the proper factory settings are loaded into the drive Every VFD s heatsink is tested to verify proper embedding of the tubing for flow of coolant liquid Thermal tests are performed on the VFD to verify that the cooling occurs within the correct temperature range A C LiquiFlo Nomenclature VFD XXX M A EE Cooling Method Variable Frequency Drive A Air cooled W Water cooled Model Number 009 through 120 Mounting 2037 through 2110 LF 2 M Factory mounted L Shipped Loose for Field Mounting LiquiFlo 2 0 Nomenclature Since all LF 2 0 models are field mounted and water cooled there are no characters after the Model Number typically VFD 2037 IOMM VFD 2 Figure 1 LiquiFlo Internal Components Factory Mounted Water Cooled Model Motor Terminals Disconnect Switch Motor Control Relays MCR Control Transformer w Fuses Optional Meter Transformers 2 Terminal Board Fuses Drive Unit Keyboard Display Cooling Water Lines IOMM VFD 2 IOMM VFD 2 Definition of Terms Acceleration time 2 Acc2 Active LEWT Setpoint Analog in loss The current Leaving Evaporator Water Temperature Setpoint Analog input loss Anig Cal Chksum Analog input calculation check sum math function Autotune AutoT MagRot Set point adjustments made automatically not used by McQuay Autotune rotate not
92. lant through the VFD heat sink a coolant reservoir and a small plate heat exchanger Heat is removed from the VFD heat sink and rejected to the plate heat exchanger e The pump and control valve are controlled by the VFD control system on LF 2 0 VFD models and self contained on LF models e plate heat exchanger is cooled by water from the chilled water system Installation steps e Place cooling loop module in desired location e Attach coolant and chilled water piping Seven to nine gpm of coolant will be circulated A 40 mesh strainer is required at the drive inlet Include service isolation valves in the coolant and chilled water inlet and outlet piping 15 16 Wire according to the supplied wiring diagrams IOMM VFD 2 The following is required from the customer s chilled water supply for the McQuay cooling loop to perform properly Water Quality Water must be compatible with components supplied in the cooling loop brass copper stainless steel and neoprene rubber seals Supply water circulates through a copper brazed stainless steel plate type heat exchanger by way of a stainless steel and brass ball valve and associated stainless steel brass and copper piping Water Source Clean and non corrosive chilled water must be used as the coolant Figure 5 Cooling Module Dimensions LOW LEVEL WARNING FLOAT SWITCH BREATHER MANUAL FILL 20 000 REMOTE DISCONNECT CONTROL POWER BLE BEFORE ENTRAN
93. log input is below 1 mA Correction Action Verify that P 011 is set correctly Check that the analog input source supply 2 1 mA DC bus charging bypass contactor Charging bypass contactor did not close or contact closure was not sensed by the system Check operation of the bypass contactor Verify the contactor is closing when the proper bus voltage is applied Replace contactor Default parameter restore check sum error During drive operation Regulator board failure After Regulator board replacement Contact McQuay or replace regulator board Contact McQuay Earth current failure ground fault Non volatile memory write failure Encoder loss Unintentional grounding Failure to write on non volatile memory Drive is not detecting feedback from the encoder Check isolation between ground and output terminals Possible leakage current sensor defects replace sensor Connect CS3000 software to upload parameters or record by hand Then replace regulator board Parameter values will be lost when power is cycled Check the connection between the encoder and the drive Check the encoder motor coupling Function loss Function loss input on control terminal is opened Check external interlocks at terminals 16 20 High time identification aborted Identification process for B Hz has been aborted See H 019 for identification result High line voltage Input
94. lt TB Man Conflict Input Phase X S OK lt OK UnderVoltage IntDB OvrHeat UserSet Timer InverterFault Load Loss VHz Neg Slope Waking MaxFreqCnflct Zero Divide IOMM VFD 2 IOMM VFD 2 Troubleshooting Table 37 No Start Drive does not Start from Start or Run Inputs wired to the terminal block Cause s Drive is Faulted Incorrect input wiring See Installation Manual for wiring examples 2 wire control requires Run Run Forward Run Reverse or Jog input 3 wire control requires Start and Stop inputs Jumper from terminal 25 to 26 is required Incorrect digital input programming Mutually exclusive choices have been made i e Jog and Jog Forward 2 wire and 3 wire programming may be conflicting Exclusive functions i e direction control may have multiple inputs configured Stop is factory default and is not wired Table 38 No Start from HIM Indication Flashing red status light None Flashing yellow status light and Digln CflctB indication on LCD HIM Drive Status 2 shows type 2 alarm s Corrective Action Clear fault Press Stop Cycle power Set Fault Clear to 1 Clear Faults on the HIM Diagnostic menu Wire inputs correctly and or install jumper Program Digital Inx Sel for correct inputsStart or Run programming may be missing Program Digital Inx Sel to resolve conflicts Remove
95. ltage fell below the minimum value of 333V for 400 480V drives and 461V for 600 690V drives Enable Disable with Fault Config 1 Action if appropriate Monitor the incoming AC line for low voltage or power interruption OverVoltage Motor Stall MotorOverload HeatsinkOvrTp IGBT OverTemp System Fault OverCurrent Ground Fault InverterFault Load Loss Motor Therm DC bus voltage exceeded maximum value Motor is operating at high current and low frequency and is not accelerating Internal electronic overload trip Enable Disable with Fault Config 1 Heatsink temperature exceeds maximum allowable value 85 degrees C Alarm 90 degrees C Fault Output transistors have exceeded their maximum operating temperature due to excessive load Hardware problem exists in the power structure The drive output current has exceeded the hardware current limit A current path to earth ground greater than 2596 of drive rating Ground fault level is 5096 of the drive s heavy duty current rating The current must appear for 800ms before the drive will fault Hardware problem in the power structure Option board thermistor input is greater than limit Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option 1 Run Autotune 2 Reduce Load 1 Run Autotune 2 Verify set
96. lus user defined offset the user adjustable lag compressor shutdown timer same time as the lag start timer is activated When the timer times out and the above conditions still exist the lag compressor will be shut down MicroTech 200 Controller VFD Menu Screens The MicroTech controller screens are modified from standard when VFD software is loaded into the microprocessor in the factory VFDs require special software as described in this section The screens are grouped by menus that are further broken down to screen numbers Fields noted with an are only active when a VFD is used Arrows indicate that addition related screens are located above or below 43 44 Menu 1 Screen 2 Unit Status This entire screen only appears when a is used 1 Unit Status hh mm mon dd yy VFD Off etc Cmnd Speed XXX Vanes Not Open Open Lift Ctl Speed XXX Menu 2 Screen 2 Water Temps and Flows 2 Water Temps Flow hh mm mon dd yy PulldwnRate X X M EvapFlow XXXgpm Ent Ht RevyzN A F Cond Flow XXXgpm Lvg Ht Revy N A F Menu 3 Screen 2 Refrigerant Temps Press 3 Refrig Temps Press hh mm mon dd yy Lift Press XX Xpsi Lift Temp XX X F Cale Lift Speed XXX Menu 9 Screen 1 Network Status 9 Network Status hh mm mon dd yy Master Command Auto Compress Req One Slave Command Stop Status Lead amp Lag Off Lead Unit Slave LagShtdwnDT XX F Y
97. m read from the user set does not match the checksum calculated Re save user set Table 25 LF 2 0 Fault Descriptions and Corrective Actions Description Verify proper input voltage Check line sync board and fuse Check AC line I O board 4 Verify connection between boards AC Line Lost Input power Lost An analog input is configured to fault on signal loss A signal loss has occurred Configure with Anlg In 1 2 Loss 324 327 Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of Auto Rstrt Tries 174 Enable disable with Fault Config 1 238 The autotune procedure was canceled by the user Input is open Check parameters 2 Check for broken loose connections at inputs Analog In Loss Auto Rstrt Tries Correct the cause of the fault and manually clear AutoTune Aborted Auxiliary Input 2 Restart procedure Check remote wiring Verify input voltage is within drive specified limits Verify system ground impedance follows proper grounding techniques Disable bus regulation and or add dynamic brake resistor and or extend deceleration time The drive is not following a commanded deceleration because it is attempting to limit bus voltage Decel Inhibit 7 Drive rating of 110 for 1 Drive 64 minute or 150 for 3 Reduce load or extend Accel Time OverLoad seconds has been exceeded 140 Excessive 79 Motor did not come
98. me interface modules and their operation is the same except for some differences in parameters which are outside the purview of this manual and differences in some faults and alarms The faults and alarms are given separately later in this section N Warning Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this 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 The status of the drive can be viewed on the Operator Interface Module OIM or on various LEDs Using the Interface The LCD Operator Interface Module is a keypad display that enables programming monitoring and controlling the drive Figure 30 Operator Interface Module Refer to Figure 31 for display description CAUTION Stop and start keys are never used to start or stop the drive compressor These functions are controlled by the chiller MicroTech II only Refer to Table 16 for key descriptions Powering Up and Adjusting the LCD OIM The first time the LCD OIM is powered up you will be prompted to select a language for the display text If the Start Up routine has not been completed the Start Up menu is displayed immediately following the language selection screen Selecting the
99. mg ror 8 Cw Forward TORQUE C REVERSE Password MENS PROGRAM ENTER Em RELIANCE ELECTRIC Step 10 Err will be displayed again to indicate that the log is empty 101 Err Jaw sreco RUNNING Co volts C REMOTE C C oe C FORWaRD Co C Tonave C REVERSE COJ Password PROGRAM STOP RELIANCE ELECTRIC Step 11 Press the PROGRAM key to access monitor mode Fatal Faults Fatal fault codes are distinguished by the letter F preceding the code They normally indicate a malfunction of the microprocessor on the regulator board In some cases fatal fault codes can be reset and the drive can be re started Table 50 lists the fatal fault codes that can be reset If any other fault code appears on the display the regulator board will have to be replaced If the fault code FUE appears in error log entry 0 it indicates a fatal fault occurred as power was lost Contact McQuay International or observe the drive for subsequent fatal errors before turning off power Fatal fault codes are lost after power loss Table 50 Fatal Fault Codes That Can Be Reset Code Fault Description Fault Cause Corrective Action F3 Encoder power up diagnostic errors Encoder voltage is less than 10V Turn off power to the drive Disconnect the encoder wiring from the terminal strip Turn power to the drive back on If the F3 error does not occur a
100. n the keypad display can be used to stop the drive and reset drive faults See Table 46 for a description of the Drive status LEDs Note The STOP RESET key can be disabled by parameter R055 This must be done so that only the chiller MicroTech II controller can stop or start the drive compressor Monitor Mode Monitor mode is the keypad display s default mode during drive operation or it is entered by pressing the PROGRAM key until the PROGRAM LED turns off The following output data can be displayed in monitor mode e Speed e kW e Volts e Torque vector regulation only e Amps e Selected reference speed or torque e Hz IOMM VFD 2 IOMM VFD 2 To select a value to monitor press the ENTER key until the LED turns on next to the desired display item Pressing the ENTER key advances you through each of the displays Note All of the LEDs turn on to indicate the selected reference display Figure 42 Example of a Monitor Mode Display Displays value SPEED VOLTS etc based on selected monitor mode LED oes To enter monitor voirs Cojaewore mode press the Cames CI PROGRAM ke nee mew Kw NEM FORWARD JOG C C REVERSE PROGRAM LED C Password C PROGRAM turns off SIOP Displaying the Selected Reference In monitor mode you can display the speed reference speed and frequency or the torque reference the drive is using while it is runnin
101. n all irregularities The final result should be smooth and cylindrical Doing one terminal at a time brush the Scotchkote coating on the motor barrel to a distance of up to 2 around the terminal and on the wrapped terminal the rubber insulation next to the terminal and the lug and cable for approximately 10 Wrap additional Scotchfil insulation over the Scotchkote coating Tape the entire wrapped length with electrical tape to form a protective jacket Finally brush on one more coat of Scotchkote coating to provide an extra moisture barrier IOMM VFD 2 IOMM VFD 2 General Wiring Practice 1 Never connect input AC power to the motor output terminals T1 U T2 V or T3 W 2 Power wiring to the motor must have the maximum possible separation from all other wiring Do not run control wiring in the same conduit this separation reduces the possibility of coupling electrical noise between circuits Minimum spacing between metallic conduits containing different wiring groups should be three inches 76 mm 3 Minimum spacing between different wiring groups should be six inches 152 mm 4 Wire runs outside of an enclosure should be run in metallic conduit or have shielding armor with equivalent attenuation 5 Different wire groups should cross at 90 degrees whenever power and control wiring cross 6 Different wire groups should be run in separate conduits 7 Adhere to local electrical codes 8 The National Electrical Code
102. national LiquiFlo and Reliance are trademarks of Rockwell Automation IOMM VFD 2 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 DANGER DC bus capacitors retain hazardous voltages after power has been disconnected After disconnecting input power to the unit wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of life CAUTION The user is responsible for conforming to all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment N WARNING The drive contains printed circuit boards that are static sensitive Anyone who touches the drive components should wear an anti static wristband Erratic machine operation and damage to or destruction of equipment can result if this procedure is not followed Failure to observe this precaution can result in bodily injury Introduction This manual cov
103. nd runs as a single VFD compressor controlling speed and vane position based on LEWT Leaving Evaporator Water Temperature When the capacity of the first compressor reaches Full Load and LEWT is greater than stage delta and the slope pull down rate is less than the user adjustable minimum rate setpoint the next compressor will be enabled Dual Compressor Unit Stage Down When Compressor Capacity exceeds calculated system load internal algorithm the next off compressor will be disabled When the next off compressor is disabled the controller will unload the compressor by closing the vanes shutdown unload to unload the compressor The load balance function will make the other compressor follow When the shutdown unload timer expires or the vane close switch closes which ever occurs first the MCR will de energized and the controller will transition to the post lube sequence At the end of the post lube timer the oil pump will be turned off and the controller will transition to the off sequence 51 Interface Panel Screens MT Il NOTE This section contains the MicroTech II controller and Operator Interface Panel display screens Figure 25 is the setpoint screen on the initial production panel Panel 1 Figure 26 shows the screen used on the second issue panel Panel 2 that went into production mid 2005 Figure 25 MOTOR VFD Setpoint Screen Panel 1 Unit Status SETPOINTS fw Status o Demand Limit Enabl
104. nd the LEWT is greater than the active setpoint the mode switches to VFD Running Adjust Speed Open Vanes Otherwise the controller stays in this mode with the speed at Minimum Speed and the vanes being controlled to satisfy the Active LEWT Setpoint VFD Running Adjust Speed Open Vanes The VFD remains on the speed output is modulated to maintain the Active LEWT Setpoint and the vanes are driven to the open position As the load decreases if the speed equals the lift temperature control speed and the LEWT is less than the active LEWT setpoint the mode switches to Running Hold Minimum Speed Adjust Vanes Otherwise the controller stays in this mode Compressor Shutdown The VFD remains on the speed output remains constant and the vanes are driven closed shutdown unload state This state is used during a routine shutdown of the chiller If there is a rapid shutdown caused by a fault alarm the MCR will be immediately de energized the speed signal will go to zero and the compressor state will go directly to Postlube WDC Dual Compressor VFD Operation The MicroTech II controller has the capability to control a dual compressor VFD chiller or multiple stand alone VFD chillers with interconnecting network communications including all compressor staging and load balance functions See OMCentrifMicro II for set up of multiple compressor staging General Dual Compressor VFD Operation The first compressor starts a
105. nditions caused by improper Non programming and prevent the drive from starting until the problem is Configurable resolved These alarms are always enabled The status of these alarms is shown in Drive Alarm 2 212 The drive indicates alarm conditions in the following ways e Yellow LED visible from the front of the drive e Ready LED on the drive cover see Table 18 e Alarm name and bell graphic on the LCD OIM The alarm is displayed as long as the condition exists The drive automatically clears the alarm when the condition causing it is removed e Alarm status parameters Two 16 bit parameters Drive Alarm 1 211 and Drive Alarm 2 212 indicate the status of type 1 and type 2 alarms respectively e No external signal is available for alarms About the Alarm Queue The drive automatically retains a history of alarms that have occurred in the alarm queue The alarm queue is accessed using the OIM or PC software The alarm queue holds the eight most recent alarms The last alarm to occur is indicated in queue entry 1 As new alarms are logged into the queue existing alarm entries are shifted for example entry 1 will move to entry 2 Once the queue is full older alarms are discarded from the queue as new alarms occur All entries in the alarm queue are retained if power is lost Alarms are automatically cleared when the alarm condition goes away The alarm queue can be cleared using the OIM by selecting Clr Alarm Qu
106. ng or servicing line load reactors and the drive to which the reactor is connected AGENCY APPROVALS UL 508 File E180243 Component Recognized 1 amp 2400 amps UL 508 File E180243 UL Listed Nema 1 units 1 amp 2400 amps CSA C22 2 File LR29753 13 CSA Certified 1 amp 1200 amps Class H 200 C File E66214 Type 180 36 UL Recognized Insulation System CE IOMM VFD 2 IOMM VFD 2 Ambient Temperature Maximum ambient temperature is 45 C 113 F Figure 8 Line Reactor Dimensions Models VFD 009 017 Figure 9 Line Reactor Dimensions Models VFD 047 072 F 4 MTG HOLES Table 10 Line Reactor Data VFD Model 009 Width A in mm 13 2 335 Depth C in mm 13 2 335 Height B in mm 13 2 335 86 39 Torque In Ib 6 4 45 2 0 500 012MA 017MA 023MA 13 2 335 17 0 432 13 2 335 17 0 432 13 2 335 24 0 610 98 44 151 69 2 1 150 1 0 2 0 180 3 0 4 0 250 00 180 000 0000 250 250 350 325 500 375 024 028 See N ote 3 047MW 060MW 17 0 432 17 0 432 24 0 610 24 610 30 762 225 102 393 178 See Note 2 See Note 2 072MW 24 610 090LW 120LW NOTES Models 012MA through 023MA have box lugs one wire per lug 1 2 3 Models 047MW through 072MW have copper tabs with 1 0 656 hole See N ote 3 See Note 4 M
107. ng pads to reduce audible noise Standard vibration control pads made from neoprene or natural rubber and selected for the weight of the enclosed reactor are effective Reactor Power Wiring WARNING Input and output power wiring to the reactor must be performed by authorized personnel in accordance with the NEC and all local electrical codes and regulations Verify that the power source to which the reactor is to be connected is in agreement with the nameplate data on the reactor A fused disconnect switch or circuit breaker should be installed between the reactor and its source of power in accordance with the requirements of the NEC and all local electrical codes and regulations Refer to the drive inverter or other electrical equipment user manual for selection of the correct fuse rating and class The reactor is suitable for use on a circuit capable of delivering not more than 65 000 rms symmetrical amperes at 480 volts when protected by Bussman type JJS KTK KTK R PP or T class fuses Reactors are designed for use with copper conductors with a minimum temperature rating of 75 C Table 10 lists the wire range for the power input and output connections by VFD model Refer to Figure 10 for a typical electrical diagram of a reactor in its proper location upstream of a VFD Where desirable a flexible conduit connection to the reactor enclosure should be made to reduce audible noise IOMM VFD 2 IOMM VFD 2 Failure to
108. not generate damaging voltage pulses at the motor terminals when applied within 500 feet of each other The VFD drive complies with NEMA MGI section 30 40 4 2 which specifies these limits at a maximum peak voltage of 600 volts and a minimum rise time of 0 1 microseconds All VFDs require cooling Models 019 and 028 rated at 273 amps or less are air cooled All others are water cooled Factory mounted water cooled VFDs have VED cooling water combined in the factory with the compressor oil cooling system Freestanding water cooled VFDs require field installed chilled water supply and return piping for the VFD Models VFD 090 and 120 and all LF 2 0 models have an intermediate cooling module field installed between the cooling source and the Water cooled VFD s have a liquid cooled heatsink assembly enabling liquid cooling of the drive though a single inlet and outlet connection point There is a temperature regulating valve located in the drive It must be set to maintain 95 F 35 C leaving coolant temperature This is necessary to prevent condensation from forming in the heatsink Minimum entering coolent temperature is 40 F 4 4 C une LF Standard Features Electronic overload circuit designed to protect an AC motor operated by the VFD output from extended overload operation on an inverse time basis This electronic overload is UL and NEC recognized as adequate motor protection No addit
109. nt is greater than 105 RLA If Command Speed is 10 greater than Minimum Speed reduce Command Speed by 5 If Command Speed is within 10 of Minimum Speed reduce Command Speed by 2 Close the vanes by one two second pulse Wait 15 seconds to see the if motor current corrects before repeating the process Manual Loading Manual Load setpoint is adjustable from the keypad display If Manual Loading is Enabled Pulse vanes open OR closed to drive the motor current RLA to the Manual Load Setpoint Minimum Amp Limit Minimum Amp setpoint is adjustable from the keypad display Range 5 to 100 in 1 increments Default value is 10 If the motor current RLA is less than Minimum Amp Setpoint hold vane position and command speed If the motor current RLA is 5 below the Minimum Amp Setpoint open vanes and hold command speed Manual Amp Limit User defined capacity limit adjustable from the keypad display from 0 to 100 If the motor current RLA exceeds the Network setpoint hold Command Speed and vane position If the motor current RLA is 5 greater than the Network setpoint reduce command speed by 1 every five seconds If the command speed should be reduced to minimum speed close the vanes Network Capacity Limit Network provided capacity limit setpoint The setpoint is limited in the software from 0 to 100 If the motor current RLA exceeds the Network setpoint hold Command Speed and vane position If the motor curr
110. odels 024LA MA through 028LA MA have reactor as standard and it is mounted in VFD Wiring required to incoming reactor terminals Models 090LW through 120LW have 2 0 656 holes and are always shipped loose with reactors factory mounted in VFD Wiring required to incoming terminals 27 Mounting NEMA 1 enclosures designed for floor mounting must be mounted with the enclosure base horizontal for proper ventilation Wall mounting a floor mounted enclosure with the base against the wall will cause the reactor to over heat resulting in equipment damage Allow a minimum side front and back clearances of 12 inches 305 mm and vertical clearances of 18 inches 457 mm for proper heat dissipation and access Do not locate the enclosure next to resistors or any other component with operating surface temperatures above 260 F 125 C Allow a minimum side front and back clearances of 12 inches 305 mm and vertical clearances of 18 inches 457 mm for proper heat dissipation and access Do not locate the enclosure next to resistors or any other component with operating surface temperatures above 260 F 125 C Select a well ventilated dust free area away from direct sunlight rain or moisture where the ambient temperature does not exceed 45 C 113 F Do not install in or near a corrosive environment Avoid locations where the reactor will be subjected to excessive vibrations Where desirable enclosures may be mounted on vibration isolati
111. og Fwd Fwd Rev Rev x x A digital Start input has been configured without a Stop input or other functions are in conflict combinations that conflict are marked with a X and will cause an alarm Jog1 and Jog 2 Stop CF Start X Stop CF Run Start Run Run Fwd Run Rev Jog Jog Fwd Jog Rev Fwd Rev Run Fwd X X Run Rev X X More than one physical input has been configured to the same input function Multiple configurations are not allowed for the following inputs Forward Reverse Speed Select 1 Speed Select 2 Speed Select 3 Run Run Reverse Jog Forward Jog Reverse Bus Regulation Mode B Acc2 Dec2 Accel 2 Decel 2 Run Forward Stop Mode B 85 86 BipolarCnflct TB Man Conflict Start AtPwrUp IntDB OvrHeat Waking Sleep Config Description Action if appropriate Parameter 190 Direction Mode is set to Bipolar or Reverse Dis and one or more of the following digital input functions is configured Fwd Reverse Run Forward Run Reverse Jog Forward or Jog Reverse TB Man Ref Sel is using an analog input that is programmed for another function Start At PowerUp is enabled Drive may start at any time within 10 seconds of drive powerup The drive has temporarily disabled the DB regulator because the re
112. on page 15 31 VFD Dimensions Air Cooled Figure 12 VFD 009LA 023LA Air Cooled Free Standing 8 0 zi 6 0 __ 20 203 2 152 4 E 50 8 25 ji Note Remove before drilling 2 to prevent metal particles from S r 14 0 falling into drive components 5 5 355 6 Sc amp LLI o at d Removable ff lifting Eyes 2 2 j 1828 8 TRI ls T 36 0 914 4 485 1 Unit Weights Modei VFD009 VFD 012 VFD 015 VFD 017 VFD 023 Operating Weight Ib kg 725 329 725 329 796 361 796 361 796 361 Shipping Weight Ib kg 795 361 795 361 866 393 866 393 866 393 32 IOMM VFD 2 IOMM VFD 2 Figure 13 VFD 024LA 028LA Air Cooled Free Standing POWER WIRING ENTRY PANEL REMOTE OIM 551 SE 882 RE4ALCD Unit Weights Operating Weight Ib kg 1206 548 1206 548 Shipping Weight Ib kg 1326 602 1326 602 2 4 j 19 06 _ E 7 i OUT 5 H L eA 33 Figure 14 VFD 009MA 028MA Air Cooled Unit Mounted 0 56 42 00 SHOLES 0 50 LIFTING EYE y 1 95 i r Y x L OND To 68 00 5 n 1 95 38 10
113. onnections 3 User Set load or save not UserSet Timer Replace main control completed in less than 5 sec The checksum read from the Param Chksum board does not match the checksum calculated 1 Restore defaults 2 Cycle power 3 Reload User Set if used The checksum read from the EEPROM does not match the PwrBrd Chksum eale lated front the 1 Cycle power 2 Replace drive EEPROM data Continued next page IOMM VFD 2 IOMM VFD 2 106 MCB PB Config New IO Option AutoT Enable Fatal App Change 1 0 Comm Loss DigIn CnflctA Digln CnflctB DigIn CnflctC Continued on next page Description Drive rating information stored on the power board is incompatible with the main control board New option board added to control Fatal Application error Autotune enabled but not started Option board replaced l O Board lost communications with the Main Control Board Action if appropriate 1 Reset fault or cycle power 2 Replace control board 1 Restore defaults 2 Reprogram parameters 1 Replace control board Press the Start key within 20 seconds of enabing autotune Reset Fault Check connector Check for induced noise Replace I O board or Main Control Board Digital input functions are in conflict Combinations marked with a X will cause an alarm Jog 1 and Jog 2 Acc2 Dec2 Acc2 Dece2 Jog Jog J
114. oo short Check parameters H 006 H 007 See OC fault corrective actions Increase deceleration time P002 P018 P022 IOMM VFD 2 Alarm Description Overfrequency Fault Cause Drive has exceeded maximum allowable output frequency Regenerating energy is too high Stability or slip compensation circuit adds frequency reference If H 016 ON searching current is too high Motor is too small Correction Action Vector Check parameters Encoder PPR U 001 Motor Poles U 002 Base Frequency U 003 V Hz Check DC bus voltage increase decelerating time Check values Max Speed P004 Overfreq H 022 Check slip compensation H 004 If H 016 ON check motor size versus Power Module size recheck setting of P005 too high Drive overtemperature Motor overload Cooling fan failure Excess motor current V Hz Torque boost too high therm overload level too low Excess load on motor for example at too low speeds Loss of phase connection Check ambient temperature cooling fan minimum clearances around drive Vector Check actual Motor Rated Nameplate Amps U 004 V Hz Check actual current Torque Boost H 003 Check that Power Module is sized correctly Reduce load on motor for example at low frequency Check that Power Module is sized correctly Reduce load on motor e g at low frequency Check output lines to the motor Motor output phase loss Phase lost
115. otor Terminal Insulation It is the installing contractor s responsibility to insulate the compressor motor terminals as described below when the unit is installed in a high humidity location that could cause condensate to form on the motor terminals The terminals are cooled to 45 F to 50 F as a result of the motor cooling The required material can be ordered and shipped in as a kit 775123601 IOMM VFD 2 21 22 This is to be done after the McQuay start up technician has checked for proper phase sequence and motor rotation Following this verification by the McQuay technician the contractor should apply the following items Materials required 1 2 3 4 Loctite brand safety solvent 12 oz package available as McQuay part number 350A263H72 3M Co Scotchfil brand electrical insulation putty available in a 60 inch roll as McQuay part number 350A263H81 3M Co Scotchkote brand electrical coating available in a 15 oz can with brush as McQuay Part Number 350A263H16 Vinyl plastic electrical tape The above items are available at most electrical supply outlets Application procedure 1 2 Disconnect and lock out the power source to the compressor motor Using the safety solvent clean the motor terminals motor barrel adjacent to the terminals lead lugs and electrical cables within the terminal 4OX to remove all dirt grime moisture and oil Wrap the terminal with Scotchfil putty filling i
116. ounted in the VFD enclosure on free standing units and must be field mounted and wired when the VFD is factory mounted When the reactor is installed in the VFD enclosure a much larger enclosure is required and it is too large to mount on the chiller VFD Line Harmonics VFDs have many benefits but care must be taken when applying VFDs due to the effect of line harmonics on the building electric system VFDs cause distortion of the AC line because they are nonlinear loads that is they don t draw sinusoidal current from the line They draw their current from only the peaks of the AC line thereby flattening the top of the voltage waveform Some other nonlinear loads are electronic ballasts and uninterruptible power supplies Reflected harmonic levels are dependent on the source impedance and the KVA of the of the power system to which the drive is connected Generally if the connected power source has a capacity greater than twice the drive s rated amps see Table 1 or Table 2 for rated amps the installation will conform to IEEE Standard 519 with no additional attenuation Presumably the application on which this drive is applied has been checked for harmonic levels If not contact the local McQuay office The IEEE 519 1991 Standard The Institute of Electrical and Electronics Engineers IEEE has developed a standard that defines acceptable limits of system current and voltage distortion A simple form is available from McQuay that allo
117. peed Jr Use the ENTER key to ENTER Display a parameter or a selection value in program mode e Save a value e Move through each monitor display item when in monitor mode 92 IOMM VFD 2 IOMM VFD 2 FORWARD REVERSE Use the FORWARD REVERSE key to select the direction of motor rotation when the control source is local REMOTE LED is off This key is ignored if the control source is not local REMOTE LED is on See the FORWARD and REVERSE LED descriptions for more information Note Local control source is not allowed on McQuay Centrifugal Chillers PROGRAM Use the PROGRAM key to move between program and monitor modes The PROGRAM LED turns on when the keypad display is in program mode and turns off when the keypad display is in monitor mode RUN JOG Use the RUN JOG key to toggle between run and jog when in local control REMOTE LED is off When run is selected pressing the START key results in continuous drive operation When JOG is selected pressing the START key results in drive operation only until the START key is released Note Do not run in local control Do not JOG Compressor may run without lubrication This key is ignored if the control source is not local REMOTE LED is on See the RUN and JOG LED descriptions for more information START Use the START key to apply power to the motor in local control REMOTE LED is off See the RUNNING LED description for more inform
118. peed always gt MinimumSpeed Override Corrects Command Speed Override corrects equals Unit Status Command Speed gt Minimum Speed is any Minimum Speed Any Shutdown Override Any Override exists exists i FD Running Adj Speed vanes VFD Running Hold Min pen Vanes AND Speed Adj Vanes Speed Modulating to chilled water LEWT gt Command Speed equals Minimum Speed except when driven faster by MinSpeed Spt 5CB Vanes modulating to LEWT Vanes continuously pulsed Open Command Speed gt MinSpeed Unit 3 t Locked AND LEWT lt Spt 5CB nit Status Speed is IS any OFF Shutdown Unit Status is any Shutdown locked speed Routine Shutdown Command Speed equals Locked speed set point Command Speed held 0 except when driven faster by Minimum Speed Unit Status eo vanes continuosly pulsed closed Vanes modulating to LEWT CRUCE dsdny 9 Shutdown LEWT leaving evap water temperature Vane Closed Switch isOpen CB Control Band IOMM VFD 2 47 48 Capacity Overrides Override Types Listed by Priority The following explains certain control functions and setpoints of interest NOTE Stp Setpoint 1 Max Amp Limit If the motor current is greater than 100 RLA Hold Command Speed pulse vanes closed for two seconds once every two minutes If the motor curre
119. point already appears as part of the number displayed example G below In either case the system uses the full resolution of the number for drive control not the displayed value 91 Table 45 Display Range Examples It will appear on the a And the SPEED LED will display as Example If the actual number is Not Flash Not Flash Flash Not Flash Flash Not Flash Flash Flash This does not apply for the speed display For the speed display the FORWARD REVERSE LEDs indicate actual speed reference polarity The Keypad The drive s keypad has nine membrane keys that are used to monitor program and control the drive Use the AUTO MAN key to switch between the auto speed reference and AUTO the manual speed reference as shown below LA P MAN AUTO MAN Control Source P 000 Speed Reference Status Source Local keypad display P 000 LOCL Terminal Strip Terminal Strip Remote AUTO Selected Inputs 000 Terminal Strip Option Port 000 Network Serial Port P 000 SerL Terminal Strip Note Manual speed reference is not allowed on McQuay Centrifugal Chillers Use the A and V keys to e Step through the drive parameter menus and error log when the keypad display is in program mode e Increase or decrease a numeric value such as the reference or a parameter value Hold down these keys to increase the scroll s
120. r s oil cooling system See Figure 3 Cooling water piping is to the normal chiller oil cooling system connections Freestanding VFDs VFD cooling water piping must be field connected on freestanding units See Figure 4 Cooling water is connected directly to models 047LA through 072LW Models 090LW and 120LW and all LF 2 0 units are always freestanding and have a separate cooling module that must be field piped to the cooling water supply and also interconnected to the VFD See page 15 for detailed installation instructions 13 Figure 3 VFD 047 through 072 Cooling Water Piping for Factory Mounted VFD STOP CHILLED VALVE WATER PUMP gt GT BALANCING VALVE STOP VALVE E WATER REGULATING VALVE a Factory Mounted VFD HEAT EXCHANGER SOLENOID VALVE Factory Mounted STOP A VALVE STRAINER A MAX 40 MESH DRAIN VALVE OR PLUG COMPRESSOR Field Supplied Piping Components Field Piping Connection Point OIL COOLER CIRCUIT SOLENOID A VALVE WATER Factory Mounted REGULATING VALVE Factory Mounted Figure 4 VFD 047 120 and all LF 2 0 Cooling Water Piping for Free Standing VFD STOP CHILLED VALVE WATER PUMP P VALVE BALANCING WATER REGULATING VALVE gi m Factory Mounted COMPRESSOR OIL COOLER CIRCUIT SOLENOID LVE ae py en ossei STOP P VALV
121. r to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or death The drive can display two kinds of error codes alarms and faults to signal a problem detected during self tuning or drive operation Fault and alarm codes are shown in Table 48 and Table 49 A special type of fault code which occurs rarely is the fatal fault code Alarm Codes An alarm condition is signified by a two or three letter code flashing on the display The drive will continue to operate during the alarm condition The cause of the alarm should be investigated to check that it does not lead to a fault condition The alarm code remains on the display as long as the alarm condition exists and clears when the condition causing it is corrected Fault Codes A fault condition is also signified by a two or three letter code flashing on the display If a fault occurs the drive coasts to stop and the RUNNING LED turns off The first fault detected is maintained flashing on the display regardless of whether other faults occur after it The fault code remains on the display until it is cleared by the operator using the STOP RESET key or using the fault reset input from the selected control source Error Log The drive automatically stores all fault codes for faults that have occurred in the system error log The error log is accessible through the keypad or the OIM
122. re efficient than guide vanes by themselves In actual practice a combination of the two techniques is used The microprocessor slows the compressor to a programmed minimum percent of full load speed as much as possible IOMM VFD 2 IOMM VFD 2 considering the need for sufficient tip speed to make the required compressor lift Then the guide vanes take over for further capacity reduction This methodology provides the optimum efficiency under any operating condition Inlet guide vanes control compressor capacity based on a signal from the microprocessor which is sensing changes in the leaving chilled water temperature The guide vanes vary capacity by changing the angle and flow of the suction gas entering the impeller The impeller takes a smaller bite of the gas Reduced gas flow results in less capacity Compressors start unloaded guide vanes closed in order to reduce the starting effort A vane closed switch VC signals the microprocessor that the compressor vanes are closed VFDs can be found on centrifugal chillers with the older MicroTech 200 controller sometimes referred to as MicroTech I or just plain MicroTech or the newer MicroTech controller The two MicroTech controller versions are easily differentiated as shown below The MicroTech II panel shown below is the initial version known as Panel 1 Panel 2 shown on page 50 replaced it in mid 2005 MicroTech 200 Control Panel MicroTech II Operator Interface Pane
123. rent does not exceed the current set by Motor NP FLA 42 Functions such as slip compensation or bus regulation have attempted to add an output frequency adjustment greater than that programmed in Overspeed Limit 83 Remove excessive load or overhauling conditions or increase Overspeed Limit 83 Over Voltage DC bus voltage exceeded maximum value Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the ecal time or install dynamic brake option Parameter Chksum Continued next page IOMM VFD 2 The checksum read from the board does not match the checksum calculated 1 Restore defaults 2 Reload user set if used 67 68 Params Defaulted Phase Imbalance Description The drive was commanded to write default values to EEPROM Phase current displayed in Imbalance Display 221 gt percentage set in Imbalance Limit 49 for time set in Imbalance Time 50 Action 1 Clear the fault or cycle power to the drive 2 Program the drive parameters as needed Clear fault Phase U to Grnd Phase V to Grnd Phase W to Grnd A phase to ground fault has been detected between the drive and motor in this phase 1 Check the wiring between the drive and motor 2 Check motor for grounded phase 3 Replace drive Phase UV Short Phase VW Short Phase UW
124. rmation for the device The communications card has a Periph Loss fault on the network side 1 If adapter was not intentionally disconnected check wiring to the port Replace wiring port expander adapters Main Control Board or complete drive as required 2 Check HIM connection 3 If an adapter was intentionally disconnected and the Logic Mask bit for that adapter is set to 1 this fault will occur To disable this fault set the Logic Mask bit for the adapter to 0 DPI port stopped communicating A SCANport Port DPI Loss device was connected to a drive operating DPI devices at 500k baud 1 Check control wiring 2 Check Enable signal missing from position of hardware enable control terminal block jumper 3 Check digital input programming Hardware Enbl 1 Verify that motor is not rotating AutoT Rs Stat Autotune Rs Static Test failed when autotune is enabled 2 Check motor connections 1 Check motor nameplate data 2 Check motor connections 3 Verify that Accel Time lt Base Speed 40 x 33 sec Note 33 sec time limit to bring motor to 40 Hz AutoT Lm Rot Autotune Lm rotate test failed 1 Check motor nameplate data 2 Autotune magnetizing current Check motor connections 3 rotate test failed Verify that Accel Time lt Base Speed 40 x 33 sec see above AutoT MagRot Autotune saturation curve test 1 Check motor nameplate data 2 AutoT Saturat failed Check motor c
125. s VFD Speed 0 Lift 14 50 0 to 100 priority over this setting VFD Minimum Speed 70 60 to 100 Min VFD speed has priority over SPs 11 amp 12 VED on unit or not Oil No Start Diff 40 F 30 to 60 F Minimum Delta T between oil sump temperature and above Evap Temp saturated evaporator temperature 0 to 9999 Determines when to shut off a compressor factory Tons set 0 1 to 5 0 Inhibits loading if LWT change exceed the setpoint F min value 0 0 to 5 0 Additional compressor can start if LWT change is F min below setpoint Time period to go from initial load point RLA set in SP 5 to 100 RLA Initial amps as of RLA Used with SP 4 and SP 6 Soft load on using SP 5 and SP 6 or off Not used on these chillers RLA above which loading is inhibited Load Limit Unloading is forced at 5 above this value RLA below which unloading is inhibited ON sets RLA at 0 for 4 mA external signal and at 100 RLA for 20 mA signal Nominal Capacity Design Maximum LWT Rate 0 5 F min Minimum LWT Rate 0 1 F min Soft Load Ramp Time 5 min 1 to 60 min Initial Soft Load Amp Limit 20 to 100 Soft Load Enable OFF ON gt 40 100 20 to 80 a IOMM VFD 2 53 Percent Speed Setpoint 11 on Panel 1 setpoint 14 on Panel 2 sets the speed at 0 degrees F Lift point A in Figure 25 Setpoint 12 on Panel 1 setpoint
126. sistor temperature has exceeded a predetermined value Check parameter settings to avoid problem The Wake timer is counting toward a value that will start the drive Sleep Wake configuration error With Sleep Wake Mode Direct possible causes include drive is stopped and Wake Level lt Sleep Level Stop CF Run Run Forward or Run Reverse is not configured in Digital Inx Sel Table 36 Fault Alarm Cross Reference Name Anlg In Loss AutoReset Lim Name MCB PB Config MicroWatchdog AutoT Enable Motor Stall AutoT Lm Rot Motor Therm AutoT MagRot MotorCalcData AutoT Rs Stat MotorOverload AutoT Saturat gt lt X X gt lt lt x New IO Option Auxiliary In NP Hz Cnflct BipolarCnflct NvsReadChksum BrakResMissng CAN Bus Fit OutPhasMissng OverCurrent Decel Inhibit OverSpd Limit Device Add OverVoltage Device Change Param Chksum DigIn CnflctA DigIn CnflctB DigIn CnflctC ParamsDefault Periph Loss Port DPI Loss Fan Cooling x lt Power Loss Fatal App x lt X X X lt X X X X X X x Power Unit Ground Fault PrechargeActv Hardware Enbl PwrBrd Chksum HeatsinkOvrTp Shear Pin HeatsinkUndTp Sleep Config Change SpdRef Cnfict Comm Loss Start AtPwrUp Removed IGBT OverTemp System Fau
127. t Indication Decel Inhibit fault screen LCD status line indicates Faulted Cause s The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage Excess bus voltage is normally due to excessive regenerated energy or unstable AC line input voltages Internal timer has halted drive operation Corrective Action Reprogram bus regulation parameters161 and 162 to eliminate any Adjust Freq selection Disable bus regulation parameters 161 and162 and add a dynamic brake Correct AC input line instability or add an isolation transformer Reset drive Troubleshooting the Drive w the LCD OIM The LCD OIM provides immediate visual notification of alarm or fault conditions as well as the following diagnostic information e Entres in the fault queue e Fault parameters e Drive status parameters e Selected device version and status information OIM version information Accessing the Fault Queue The drive automatically retains a history of the last eight faults that have occurred in the fault queue To access the fault queue press the F4 key at the process display screen or see Figure 35 to access the fault queue from the Main Menu 75 Figure 35 Accessing the Fault Queue PO SP600 Stopped Auto Main Menu Diagnostics FitQ F xxxxx View Fault Queue Fault Text String it Device Version Accurre Version hours min sec ininia
128. tc The network card connected to DPI port stopped communicating The fault code indicates the offending port number 71 port 1 etc 1 Restore defaults 2 Reload user set if used 1 Clear the fault or cycle power to the drive 2 Program the drive parameters as needed 1 Check the wiring between the drive and motor 2 Check motor for grounded phase 3 Replace drive 1 Check the motor and drive output terminal wiring for a shorted condition 2 Replace drive 1 If module was not intentionally disconnected check wiring to the port Replace wiring port expander modules Main Control board or complete drive as required 2 Check OIM connection 1 Check communication board for proper connection to external network 2 Check external wiring to module on port 3 Verify external network fault Power Loss Precharge closed Precharge open DC bus voltage remained below 85 of nominal for longer than Power Loss Time 185 Enable disable with Fault Config Precharge was closed when it should be open Precharge was open when it should be closed Monitor the incoming AC line for low voltage or line power interruption 1 Check AUX contacts on precharge 2 Check input bit O in rectifier parameter 216 to view status of input 3 Check wiring 1 Check AUX contacts on precharge 2 Check input bit 0 in rectifier parameter 216 to view status of input
129. te containing glycols may cause equipment damage Coolant Volume Approx 1 gallon is required with side by side connection of cooling module to the drive cabinet More coolant volume will be required if coolant loop is located up to 20 feet away from drive Coolant Maintenance The coolant liquid should be checked and refreshed as needed on a yearly basis The pH should be maintained between 8 0 and 10 0 A 50 solution of sodium hydroxide or potassium hydroxide can be used to raise pH if falls below 8 0 Any time the coolant falls below a pH of 7 0 the loop should be flushed and coolant replaced Any time the coolant appears other than water white it should be replaced Remote Mounted Cooling Loop The maximum distance the cooling loop can be installed away from the drive cabinet connections is 20 feet Careful planning of remote mounting is required to minimize coolant flow restrictions introduced by piping connections Cooling Module Parameters Set in LF 2 0 VFD models LF 2 0 drives control the operation of the cooling module The parameters are set by McQuay at chiller commissioning How to Monitor Cooling Loop Operation FX 05 Screen Navigation see Figure 7 After power up the process temperature will be displayed Alarms When an alarm is present the alarm LED will blink fast and the error code will flash The following is a list of the error code E0 OK E1 Low Level Fault E2 Fluid Over Temperature Fault E3 Flui
130. the decel time or install dynamic brake option Load compatible version files into drive 1 Cycle power to the drive 2 If problem persists replace drive Check for proper temperature and flow rate of coolant 1 Check for loose connection in IGBT wire harness 2 Check IGBTs Check for grounded input wiring Check for proper temperature and flow rate of coolant 1 Verify proper motor data is entered 2 Reduce current limit 1 Restore defaults 2 Reload user set if used Reactor Temp Rectifier IT Overload Rectifier I2T Overload Replaced MCB PB Ride Thru Abort Continued next page Type Temperature switch in reactor opened Short term current rating of rectifier exceeded Long term current rating of rectifier exceeded Main Control board was replaced and parameters were not programmed Input power loss timed out Description Check for proper temperature and fan operation Low input voltage can result in increased current load Provide proper input voltage to the drive Low input voltage can result in increased current load Provide proper input voltage to the drive 1 Restore defaults 2 Reprogram parameters 1 Verify input power and connections 2 Check Line Sync board 3 Check AC Line I O board Action Fault No Shear Pin 63 3 Programmed Current Lmt Check load requirements and IOMM VFD 2 Val 148 has been exceeded Ena
131. tings of Motor Overload Factor and Motor Overload Frequency 3 Reduce load so drive output current does not exceed the current set by Motor NP FLA 1 Verify that maximum ambient temperature has not been exceeded 2 Check fan 3 Check for excess load 4 Check carrier frequency 1 Verify that maximum ambient temperature has not been exceeded 2 Check fan 3 Check for excess load 1 Cycle power 2 Replace drive Check programming Check for excess load improper DC boost setting DC brake volts set too high or other causes of excess current Check for shorted motor leads or shorted motor Check the motor and external wiring to the drive output terminals for a grounded condition 1 Cycle power 2 Replace drive Input Phase OutPhasMissng NP Hz Cnflct MaxFreqCnflct Continued on next page One input line phase missing Zero current in one output motor phase 1 Check user supplied fuses 2 Check AC input line voltage 1 Check motor wiring 2 Check motor for open phase Fan pump mode is selected in Motor Cntl Sel and the ratio of Motor NP Hertz to Maximum Freq is greater than 26 The sum of Maximum Speed and Overspeed Limit exceeds Maximum Freq Raise Maximum Freq or lower Maximum Speed and or Overspeed Limit so that the sum is less than or equal to Maximum Freq IOMM VFD 2 IOMM VFD 2 25 26 27 28 29 30 32 33 34 37
132. tional Line Reactor Note 1 Size Amp Rating 3 R R 7 C R R R2 R2 R A lt 1 Line reactors are optional on all sizes except Models VFD 024 and 028 where they are included as standard 2 Electrical characteristics 380 460 VAC 10 3 phase 50 60 Hertz 5 Hz 3 Optional line reactors are 3 impedance Table 2 Model Sizes LiquiFlo 2 0 VFD Model VED Family Page Cooling Designation Location VF 2037 9 1105 VE 2055 VE 2080 VE 2110 LF 2 0 Frame 4 WSC and WDC single and dual compressor and WCC dual compressor chillers can be equipped with Variable Frequency Drives A starts the compressor motor and then modulates the compressor speed in response to load evaporator pressure and condenser pressure as sensed by the chiller microprocessor Despite the small power penalty attributed to the VFD internal losses a chiller can achieve outstanding overall efficiency by using a VFD VFDs are effective when there is a reduced load combined with a low compressor lift lower condenser water temperatures dominating the operating hours The traditional method of controlling centrifugal compressor capacity is by inlet guide vanes Slowing down the compressor thereby reducing the impeller tip speed can also reduce capacity However sufficient impeller tip speed must always be maintained to meet the chiller s discharge pressure requirements The speed control method is mo
133. tpoint The minimum speed to maintain lift and avoid surge The controller continuously calculates the minimum operating speed in all modes based on the lift temperature The low evaporator pressure that inhibits any further compressor loading Manual Load Setpoint Maximum Pulldown Rate MCB MicroTech controller manual operation of the guide vanes for testing Maximum pulldown rate of chilled water in degrees per minute Main control board MCR Motor control relay Minimum Amp Setpoint MicroTech controller minimum unloading setpoint Minimum Rate Setpoint Minimum Speed Pulldown rate for MicroTech 200 controller The minimum speed allowed usually set at 70 Mod Module Net Network Setpoint Network Chilled water setpoint from an external source NP Hz OIM Operator interface module PCB Printed circuit board Continued next page Precharge capacitors PWM Pulse width modulated If there is a fault the MicroTech switches the state to VFD OFF This includes changing the Unit Control Panel switch to OFF RLA Rated Load Amps the maximum motor amps RMI Remote meter interface located in the VFD panel Softloading Extended ramp up in capacity set in the MicroTech controller Speed signal to the compressor motor from the variable frequency drive VFD based on analog output 0 10 VDC from the MicroTech controller Stage Delta Multi compressor or d
134. tual percent motor speed is within 1 of the analog output signal from the MicroTech controller Digital Input DI 10 is wired to a switch on the compressor that indicates when the vanes are 100 open VO switch If the switch is open the status of the vanes is Not Open If the switch is closed the status of the vanes is Open VFD Chiller Control States There are seven VFD chiller control states viewable as shown below They are based on the unit status See Table 12 on page 45 for relationships MicroTech Menu 1 Screen 2 States VED Off VED Start Running Adjust Speed amp Open Vanes VFD Running Hold Minimum Speed amp Adjust Vanes VED Routine Shutdown VED Locked Speed VED Override Capacity Control VFD Off The VFD is turned off the speed output is 0 and the vanes are closed VFD Start The VFD is turned on the speed output is minimum speed and the vanes are modulated to maintain the leaving evaporator setpoint VFD running hold minimum speed and adjust vanes mode VFD Running Adjust Speed amp Open Vanes The VFD remains on the speed output is modulated to maintain the leaving evaporator setpoint and the vanes are pulsed to the open position This mode drives the vanes open and uses the speed to control capacity based on the evaporator leaving water setpoint 41 42 VFD Running Hold Minimum Speed amp Adjust Vanes The VFD remains on the speed output is held at Minimum Sp
135. ual compressor unit on off cycling temperature delta T SVC Sensorless vector control Rapid Shutdown Speed Parameters Throughout this manual you will see references to parameter names and numbers that identify them for the drive This manual uses the same format that will be shown on the keypad display to refer to parameters P nnn H nnn R nnn Where nnn is a number P designates general parameters H designates Volts Hertz parameters R designates optional RMI parameters AN CAUTION The original parameters values set by the McQuay startup technician must never be changed by anyone not specifically trained and experienced with these VFDs Damage to the chiller or drive could occur IOMM VFD 2 IOMM VFD 2 Installation Mounting Arrangements Depending on size and type VFDs may be factory mounted with power and control wiring factory installed or free standing requiring field mounting remote from the unit and field wiring of power and control wiring Because of dimension restrictions for shipping some factory mounted VFDs for some large chillers are shipped separate from the unit Mounting supports are on the unit and preassembled cable kits are provided Mounting and wiring on site are the customer s responsibility and can be subcontracted to McQuay Factory Service if desired Factory Mounted extra cost option The VFD is mounted on the chiller unit with the back of the VFD against
136. ulated IGBT temperature requires a reduction in PWM carrier frequency If Drive OL Mode 150 is disabled and the load is not reduced an overload fault will eventually occur Drive OL Level 2 The calculated IGBT temperature requires a reduction in Current Limit If Drive OL Mode 150 is disabled and the load is not reduced an overload fault will eventually occur Flux Amps Ref Rang Result of autotune procedure 61 IntDBRes OvrHeat The drive has temporarily disabled the dynamic braking regulator because the resistor temperature has exceeded a predetermined value IR Volts Range Ixo VIt Rang The drive autotuning default is Calculate and the value calculated for IR Drop Volts is not in the range of acceptable values This alarm should clear when all motor nameplate data is properly entered Motor leakage inductance is out of range MaxFreq Conflict The sum of Maximum Speed 82 and Overspeed Limit 83 exceeds Maximum Freq 55 Raise Maximum Freq 55 or lower Maximum Speed 82 and or Overspeed Limit 83 so that the sum is less than or equal to Maximum Freq 55 Continued on next page IOMM VFD 2 IOMM VFD 2 Motor Type Cflct Description Motor Type 40 has been set to Sync Prm Mag or Sync Reluc and one or more DC functions for example DC Boost DC Brake etc have been activated DC injection functions are imcompatible with synchronous motors and may demagnetize them
137. um Speed 70 70to100 UC sU 0 8 Setpoint 11 Panel 1 setpoint 14 on Panel 2 Set Motor 50 0 F lift Y axis sets the speed UC SU 10 11 at 0 degrees F Lift point A in Figure 25 Setpoint 12 on Panel 1 setpoint 15 on Panel 2 40 F 100 speed X sets the lift in Set Motor axis degrees F at the Be Seg 12 100 speed point point B in Figure 26 NOTES 1 Motor Current Threshold current at which a low current fault occurs 2 Minimum Amp Setpoint Minimum unloading amp setpoint 3 The OITS is the preferred place to adjust setpoints The unit controller is the second choice and the compressor controller should never be used Table 15 MicroTech II Settings and Ranges Multiple Compressor Includes Duals MicroTech II VFD Default Setpoints Range Keypad OITS Locations Max Comp On 2 for Dual 1 to 16 UC SC 2 Modes 9 Stage Delta TF 0 5 to 5 0 F UC SC 3 Water 6 Motor 14 Timers 6 Nominal Capacity Unit Design Tons N A UC SC 5 10 to 240 Unload Timer 1 030 sec eee UC SC 6 Min LWT Rate 0 1 F 0 0 to 5 0 F UC SU 7 Motor 7 NOTE 1 This must be set longer than the mech vane speed to unload the compressor Code Unit Controller CC Compressor Controller OITS Operator Interface Touch Screen V View Menu Keypad or OITS Screen Alarm Menu Keypad Or OITS Screen S Set Menu Keypad or OITS Screen C
138. um read from the EEPROM does not match the checksum calculated from the EEPROM data Clear the fault or cycle power to the drive Pwr Brd Chksum2 The checksum read from the board does not match the checksum calculated 1 Cycle power to the drive 2 If problem persists replace drive Replaced MCB PB Main Control board was replaced and parameters were not programmed 1 Restore defaults 2 Reprogram parameters Shear Pin Programmed Current Lmt Val 148 has been exceeded Enabled disable with Fault Config 1 238 Check load requirements and Current Lmt Val 148 setting IOMM VFD 2 SW Over Current Description The drive output current has exceeded the software current Check for excess load improper DC boost setting DC brake volts set too high 1 Check for blocked or dirty heat sink fins Verify that ambient temperature has not exceeded 40 C 104 F for NEMA Type 1 installations or 50 C 122 F for Open type installations 2 Check fan Output transistors have exceeded their maximum operating temperature Trnsistr OvrTemp DC bus voltage fell below the minimum value of 160V DC at Under 200 240V input 300V DC at Voltage 400 480V input or 375V DC at 575V input Enable disable with Fault Config 1 233 Monitor the incoming AC line for low voltage or power interruption UserSet1 Chksum UserSet2 Chksum UserSet3 Chksum The checksu
139. us LEDs located TE front surface of 7 on the DPI Communications Interface board on the front of the power module The Ege Inverter Status LED LEDs indicate of the status amp of the inverter and the rectifier Note that if the LEDs are off it indicates it is not receiving power 4 Rectifier Status LED Table 19 Status LED Definitions Color State Description O IOMM VFD 2 Giaen Flashing Drive ready but not running and no faults are present Steady Drive running no faults are present Flashing The drive is not ready Check parameter 214 Start Inhibits Yellow Stead An alarm condition exists Check parameters 211 Drive Alarm 1 and 212 Drive Alarm 2 Flashing A fault has occurred Steady A non resettable fault has occurred Red About Alarms Alarms indicate conditions that may affect drive operation or application performance There are two alarm types as described in Table 20 Alarms do not shut down a unit but often lead to a fault that will Table 20 Types of Alarms Alarm Description These alarms alert the operator of conditions that if left untreated may User lead to a fault condition The drive continues to operate during the Configurable alarm condition The alarms are enabled or disabled using Alarm Config 1 259 The status of these alarms is shown in Drive Alarm 1 211 These alarms alert the operator of co
140. ve action RUN Hold Speed Pull down Rate RUN Unload Speed Max Amps Shutdown RUN Hold Speed Max Amps Im Compressor Shutdown Command Speed held 096 vanes continuosly pulsed closed LEWT leaving evap water temperature CB Control Band Vane Closed Switch isOpen Notes 1 The above pressures must be set at unit design conditions 2 Low evaporator pressure shutdown alarm setpoint is 26 0 psi default Switch RUN Load Vanes VFD Running Adj Speed Closed or Running Hold Min RUN Unload Vanes While holding Open Vanes Loading Speed Adj Vanes RUN tio anas continuously VFD Speed equals Minimum Speed RUN Hold Vanes Pull down Rate Vanes modulating to LEWT RUN Unload Vanes Max Amps Capacity Overrides Corrective action RUN Hold Vanes Max Amps RUN Unload Vanes Evap Press expired applies to Vanes applies to Speed 5min T RUN Hold Vanes Evap P COMPRESSOR STATE VFDSpeed RUN Load Speed T RUN Unload Speed aoe eat Unit Status RUN Hold Speed is any RUN Unload Speed Evap Press Shutdown RUN Hold Speed Evap Press Unit Status is any COMPRESSOR STATE SHUTDOWN Unload POSTLUBE Timer 30 30sec COMPRESSOR STATE 3 If the discharge temperature is higher than 170 F pulse the load solenoid if the vanes are not fully open IOMM VFD 2 IOMM VFD 2 Operation Small A C SP600 amp LF 2 0 The SP600 and LF 2 0 VFDs share the sa
141. will be reset and the drive will be restarted This type of fault normally requires drive or motor repair The cause of the fault must be corrected before the fault can be cleared The fault will be reset on power up after repair User These faults can be enabled disabled to annunciate or ignore a fault Configurable condition Auto Reset Run Non Resettable An alarm is a condition that if left untreated may stop the drive There are two alarm types Table 34 Alarm Types Type Alarm _ O User These alarms can be enabled or disabled through Alarm Config 1 It is Configurable recommended that factory setting not be changed Non Configurable Drive Status These alarms are always enabled The condition or state of the drive is constantly monitored Any changes will be indicated through the LEDs and or the Human Interface module HIM Clearing Alarms Alarms clear automatically when the condition that caused the alarm is no longer present 80 IOMM VFD 2 IOMM VFD 2 HIM Indication The LCD HIM also provides visual notification of a fault or alarm condition on the top line Drive is indicating a fault The LCD HIM immediately reports the fault condition by displaying the following Faulted appears in the status line Fault number Fault name Time that has passed since fault occurred Press Esc to regain HIM control F Faulted Auto
142. ws McQuay to determine compliance with IEEE 519 1991 Line harmonics and their associated distortion may be critical to AC drive users for three reasons 1 Current harmonics can cause additional heating to transformers conductors and switchgear 2 Voltage harmonics upset the smooth voltage sinusoidal waveform 3 High frequency components of voltage distortion can interfere with signals transmitted on the AC line for some control systems The harmonics of concern are the 5 7 11 and 13 Even harmonics harmonics divisible by three and high magnitude harmonics are usually not a problem Current Harmonics An increase in reactive impedance in front of the VFD helps reduce the harmonic currents Reactive impedance can be added in the following ways 1 Mounting the drive far from the source transformer 2 Adding line reactors 3 Using an isolation transformer Voltage Harmonics Voltage distortion is caused by the flow of harmonic currents through a source impedance A reduction in source impedance to the point of common coupling PCC will result in a reduction in voltage harmonics This may be done in the following ways 1 Keep the point of common coupling PCC as far from the drives close to the power source as possible 2 Increase the size decrease the impedance of the source transformer 25 3 Increase the capacity of the busway or cables from the source to the PCC 4 Make sure that added reactance is

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