19/23-6SS - HVACpartners
Contents
1. ONTYIM 01314 39V110A A138 710 havanoo3s 199923 Gi m 2 ong AINO 3801 f 83441 f um anns 110 4055344103 5 ANIL 6 on RE nna f anal 10 Lu KEY 105520403 9 s Vv wot gon 13538 84 210838 og eA dur u NOLLVUnLvS or unm zi 911011 3 9NIAY31 ONOJ ong END 80193802 Taino 902 04 KELI 4812 4918 1034 y NOSNIS 14801140 10011 OLAY NOTLdO 411918338 13 534 1140 LINIT OLNY 301A30 ONILYN3N39 1Y 50131 5 ONnOuD 22 APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical 19XRV Typical FU6 1021 1A FU7 1031 1A FU8 1041 1A 600V CLASS CC2. MODE x IN GND PE B JUMPER OUT LINE PE L Ji HARDWARE ENABLE CHASSIS SETTINGS AS SHIPPED Je SAFETY ENABLE MBEDDED ETHERNET 9 HUNDREDS 9 TENS 9 ONES EMBEDDED Dei ETHERNET ADAPTER ROTARY SWITCHES Ju AS SHIPPED gt SETTINGS CONTROL BREAKER CB2 1250 N 1251 1251 9197 gt TX POWER 1260 Shy 28 1261 gt JR 240 480 VAC 3000 VA PTL 120 VAC MR Hi 3 lt 240 480 1000 120 1300 FUL 120 1312 1310 1 CHASSIS 25 CNIB 600V VAPORIZER 120VAC H Fue 1320 CLASS CC HEATER m 1220 5 120 1300 CNIA OIL HEATER CLASS CC PUMP CONTROL POWER 120 1311 gt FU4 120VAC H 4 La 13505 1 600V CLASS CC FUS PER 13705 m METERING 38 40 CLASS CC 120 131 ENCLDSURE FANS 120VAC H FU3 FANI 1410 200 CFM 1 15 25 5 CHASSIS CHASSIS See Legend on page 26 25 1111 APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical cont 23XRV Typical cont 1 DRIVE CONTROL POD SLOT 4 CONTROL 1 0 DELUXE 1 0 SLOT 4 TB1 8 uul 24 JUMPER DEE SPARE
3. f ou f org orig e 134 Ss 40386 DAT 2802 NOILISOd 01 m9 018 11 u31vM AR 1 1 43 135 51 211 5 11 ZMS 033 1N3 QNOD AINO 1041002 811 4919 318 7 OPAG 1 IX3 440 MS dL GO IN PY jon LIHA 4 LHA vuQZ v 1X3 MS t DM s 59448 Svo 108 Bie Ree as Sd EE NOILISOd HOLIMS 018 HEV 31A 038 1 IN ete i a ee ge E i TNOTLVDIATGOW 9NTHIM 5i 5 zz 5 1 1 LHA oH a i 4 1002 OPAG 1 i vugg y TYNOI1d0 NOSN3S zeli 109 wn invazo rasa 2 gy 11 CWNO11d0 13938 et no 1Xj 3111 2 OLAY 710 m 140 m E vuoz y L 19 dune 1X3 LIMIT OLNY T4 EDT CQ 21 APPENDIX A WIRING SCHEMATICS cont 23XRV CHILLER CONTROL SCHEMATIC 8318302 10201084 011411 81110841802 TWASIA TVNOIIVNU3INI SSYdAg SVO LOH 31000 1081802 u311IH2 81 82 114 1 YIMVINE 1112812 9411511 NOI1VIA3U88V Noll40 554448 Svo 1040001
4. 4494 181 6 10 8 DIO TBI 16 8 pup 1 TEI TB4 41130 181 5 048 Q 5 DI 1 1 13 REMOTE START TBI 4 18 7 1 10 10 13 DIL INT LOCK T TBi H 1150 CRI 1151 His Ali O TB1 2 TB1 23 TB4 1 20 SHDtH am TB1 19 azo TB4 ANALOG PRESSURE one abs Bub f REFERENCE 1 20 1171 4 4 20mA AD0 L TBI 9 8 V CM 8110 DIG CUM bos TB1 18 TBI 21 DIL INT LDCK TBI 22 24 EVAP PUMP CRI OP tc SHD O ND 1 24 NC 2 6 182 3 1201 NC 1180 1 ROND TB4 9 2 1111 RDC TC 65 4 4 T 1212 TRIP ALARM 1 24 DRIVE CONTROL POD SLOT 5 NC CONTROL 1 0 PAVDC DELUXE 1 0 EAl SIppr si SLOT 5 1240 24V 1070 1241 1242 1243 1244 wang 1078548 1 L 1 i 1 0 1 0 4 TB4 TB4 TB1 5 TBI le 20 21 22 23 AA ine TBI 4 Tics EVAP PUMP TRIP ALARM TBI 19 TB1 3 A CDND PUMP 0113 1 11 Cod All 1280 1281 TBI 2 1 23 11014 SHD O TOWER FAN LOW TOWER FAN HIGH 1 32 CRS CR TB4 TB4 d 1290 1291 1292 1293 18 19 1 20 181 89 1 32 1 34 y cn TB4 TB4 TB4 TB4 COND PUMP 7 24 25 26 27 IG __ 27 1 18 0 TOWER FAN LOW TOWER FAN HIGH Bl 22 1 24 Gea 1 28 SH D ND res 1322 6 182 3 132
5. Fig 15 Drive Status Indicator Table 3 Drive Status Indicator Descriptions NAME COLOR STATE DESCRIPTION Green Flashing Drive ready but not running and no faults are present Steady Drive running no faults are present Yellow Flashing Drive is not running A type 2 non configurable alarm condition exists and the drive cannot be started Steady Drive is not running a type 1 alarm condition exists The drive can be started STS Status p Flashing A major fault has occurred Drive cannot be started until fault condition is cleared Steady A non resettable fault has occurred Red Yellow Flashing Alternately A minor fault has occurred When running the drive continues to run System is brought to a stop under system control Fault must be cleared to continue Use parameter 950 Minor Config to enable If not enabled acts like a major fault Green Red Flashing Alternately Drive is flash updating None Unlit Off Adapter and or network is not powered adapter is not properly connected to the network or adapter needs an IP address Flashing An Ethernet IP connection has timed out ENET Adapter failed the duplicate IP address detection test Red Green Flashing Alternately Adapter is performing a self test Green Flashing Adapter is properly connected but is not communicating with any devices on the network Steady Adapter is properly connected and communicating on the network None
6. 4 DIAGRAM S 5t j 1 16 2 50 7 12 00 CRANE POWER DISCONNECT HANDLE HANDLE FOR STANDARD FRONT VIEW CIRCUIT BREAKER SHOWN DETAIL A CIRCUIT BREAKER 15 SHIPPED SCALE 2 5 PACKAGED INSIDE VFD NOTE Dimensions shown in inches Fig 9 23XRV Enclosure Dimensions Frame 7 START UP A DANGER Internal components and circuit boards of the drive are live when the drive is connected to incoming power Coming into contact with this voltage is extremely dangerous and will result in severe personal injury or death The motor terminals U V W and the DC link brake resis tor terminals B R R are live when the drive is con nected to incoming power even if the motor is not running Do not make any connections when the drive is connected to the incoming power After having disconnected the drive wait until the indica tors on the keypad go out if no keypad is attached see the indicator through the keypad base Wait 5 more minutes before doing any work on drive connections Do not even open the cover before this time has expired Before connecting the drive to the incoming power make sure that the switchgear enclosure door is closed A WARNING The control I O terminals are isolated from the mains potential However the relay outputs and other I O termi nals may have a dangerous control voltage present even when the drive is disconnected from incoming power Coming into contact with this voltage could result
7. USED WITH METER OPTION USED WITH METER OPTION SEE METER OPTION POWERFLEX 755 POWER MODULE MAIN EAI COMPRESSOR CIRCUIT BREAKER MOTOR MOV AC JPR 1 1080 H R CHASSIS L2 s COMMON MODE CAP JPR N 24 SEE USER MANUAL 480V 3PH 60HZ po 5 L3 T MOV AC 1060 al 8 AC LINES d SETTINGS CAP_JUMPER AS SHIPPED COMMON MODE _ LINE PE L Ji HARDWARE ENABLE gt IN CHASSIS SETTINGS ENCLOSURE AS SHIPPED ENG OSURE J2 SAFETY ENABLE OUTI EMBEDDED ETHERNET 1 J12 LT 9 HUNDREDS 1062 1051 1040 5 9 ONES EMBEDDED ETHERNET ADAPTER ROTARY SWITCHES AS SHIPPED SETTINGS CONTROL BREAKER TB4 oN 2218 YELOW 48 2228 TB4 BLACK OIL PUMP 9 920 je gt F CONTACTORI x TB4 2238 o RED y 15 AMPS 600 VOLTS H3 gt lt He 240 480 3000 110 120 Ki 224 225 120 2268 5 20 OIL HEATER 600V CONTACTOR 120VAC N 38 4 CLASS CC 225 WHITE 5 4
8. PF750 Series Type 4X 12 Heatsink Fan Kit 4 PF750 Series Power Interface 5 PF750 Series Bus Cap Assembly 6 PF750 Series Power Interface Cable 7 PF750 Series Current Transducer Kit 8 PF750 Series Precharge Kit pu P Ow 9 Slot for 24V I O Module 24V I O Module Not Shown 5 j 6 10 PF755 Main Control Board ze NOTE When replacing the Main Control Board Item No 10 the r jumper marked J1 HARDWARE ENABLE must be removed and 3 the jumper marked J2 SAFETY ENABLE must be left in place Tu Fig 34 Frame 7 Parts 20 APPENDIX A WIRING SCHEMATICS 19XRV CHILLER CONTROL SCHEMATIC 8uutM uondo
9. 1 Xe AIM i 3 UUOD 1010 in m e H 3 18 Jewog Sle a9 lt 59384 dYAi jeuiuue V 18 W we H jeuiuJe 4015 dai pa 9 412 12 y 1 149 o1 80151534 IMI 11 489 MES 5 JO ONUOD 2 27 038 9 JeNsI 5 x Ok 2 GELALI 9 ssed g seb y T 21 80151538 001 Jeyesig 82 QN3931 Er H 4449 80151338 0001 9 NOILISOd 140 01 51 S QI Q 030 135 0 038 f ri 5 5 xr x 1 9038 S 80151534 0001 110 Mong m G3 uid 418 1018 dH 211 10 wig x 30v110 N221 41HM H 1001 re 55384 H2SIQ ae com 4 1 wae J 013188 013188 y 55384 SIHI 1Y SOTRIHS _ ___ __ f PD anns 110 HOX3 9 18 SSVdAB SVO 10H O0918 4 _ CIYNOLLdO NOILVIIJIGON ONIAIM W22 ul Z8 431 1 4
10. CONTENTS Page SAFETY CONSIDERATIONS 1 2 2 ABBREVIATIONS AND EXPLANATIONS 3 Required 3 Getting Assistance from Rockwell Automation 3 IDENTIFYING DRIVE COMPONENTS 3 6 Opening the VFD Access Door 3 Drive Assembly Catalog Number 4 Components and Physical Data 4 STARFUP stubs tes bun 7 9 Alternate Wire 605 7 Verify 7 Configure the 8 Commissioning the 8 Check Internal 8 SERVICE 10 20 Troubleshooting the 10 ICVC ALERT CODES ICVC ALARM CODES TEST EQUIPMENT NEEDED TO TROUBLESHOOT VERIFYING THAT DC BUS CAPACITORS ARE DIS CHARGED HIGH TEMPERATURE ALARMS MAIN CONTROL BOARD MCB COMPONENTS Checking Power Modules and Motor Input with Input Power Off 14 Servicing the 15 REMOVING THE DRIVE RIGGING THE ENCLOSURE REPLACING THE GATEWAY A B20 750 20COMM OPTION CARD CHILL PLATE AND INTERNAL FAN REPLACEMENT Part Identification and Location 18
11. T L3 V T2 W T3 PE Grounding Studs Terminating point to chassis ground for incoming motor shield DC Bus and Brake DC DC BR1 BR2 Terminals PE A and PE B MOV and CMC Jumper Wires DC and DC Bus Voltage Test Points Fig 7 Frame 7 Drive Components A g 0 33 f O y lt 36 00 REF __ gt lt 40 00 gt 22 00 FRONT VIEW SIDE VIEW NOTE Dimensions shown in inches Fig 8 19XRV Enclosure Dimensions Frames 6 and 7 15 00 X 7 50 REMOVABLE ACCESS COVER 1 50 le le 1 11500 4 TAPPED LIFT POINTS OPENING IN THE TOP OF CABINET 2 33 FOR REMOVABLE EYE BOLTS QUARTER TURN FASTENERS PI DOORS TOOL REQUIRED TO OPEN m o AIR EXHAUST AIR EXHAUST VENTS VENT 41 71 e o METER PACKAGE H n AC VOLTMETERS AND 0 WITH gee PHASE SELECTOR SWITCHCOPTIONAL L L 2 504 88 52 CA VFD WIRING 4 65
12. 805835 ALIGIWNH 5310830 ONTYIM 01140 5310830 80123 02 31VW31 31VW 801200802 5310830 321145 3UIM 5310830 TWNIWYGL LNINOdNOD AGLI 53108420 YOLIINNOD 13 1081802 OL G4A 5310830 w LZ pue og 1 20151591 xev 4110476 pue 19m07 pue O N f 01 YOUMS Jesuepuoo 12euuoo JOU 191009 y seues eq YMS Jesuepuoo 41104 2 t Jeduunf SB jeuondo Jelsu pinbr L SALON Q38IM 1401273 5310830 000 439388 1102412 5310830 401 TWNIWYIL ONTYIM 01313 5310830 4 13931 ADI x LJ 038 ong 038 ang 41815 TVNIWH3I WES 58 ONTYIM 01313 39V110A SnoQuvzvH anm 17 4 2 JUIN WAS LL VANE 24 YINYOISNVYL 1081802 VASLI 18 1081105 pem 110 13S 53 211 5 11V ar 301238809744
13. APPENDIX A WIRING SCHEMATICS 21 27 INTRODUCTION The Carrier VFD option Start Up and Service Manual is in tended for trained and qualified service personnel and is to be used during start up operation and maintenance of Rockwell Allen Bradley PF755L drive ABBREVIATIONS AND EXPLANATIONS Frequently used abbreviations in this manual include CCM Chiller Control Module DC Direct Current DPI Drive Peripheral Interface Ethernet International Chiller Visual Controller IGBT Insulated Gate Bipolar Transistor 1 0 Inputs Outputs IP Internet Protocol MCB Main Control Board MOV Metal Oxide Varistor PE Protective Earthing Conductor PIC Product Integrated Control PWM Pulse Width Modulation SIO Sensor Input Output STS Status VFD Variable Frequency Drive Required Publications The Carrier VFD option Start Up and Service Manual must be used with the following manuals Latest version of the PowerFlex 755 AC Drives manuals Latest revision of the Start Up Operation and Mainte nance Instructions for the 19XRV or 23XRV with PIC III Controls Getting Assistance from Rockwell Automa tion Contact the local Rockwell Automation sales office with any questions or problems relating to the products de scribed in this manual For technical support on drives call the HVAC Hotline at 1 888 926 6786 Option 1 Before calling have the
14. Hz 60 Hz Continuous Amps ND 477 367 477 361 60 Sec Ovid Amps 5247 5505 8247 841 5 3 Sec Ovid Amps ND HD 7155 684 718 8 649 8 COOLANT Treated Water R134A RATED s 185 PSIG Mfd on 20 Firmware 1 018 Aiion Bradioy WANUN PRODUCT OF USA FAC 1100 jumber 13865 Fig 11 Drive Module Label Configure the VFD All configurations required by the VFD are supplied by the ICVC through the VFD Gateway 19XRV 23XRV Std Tier can operate with PIC III ICVC and above Any configuration changes necessary and possible are made on the ICVC screens A complete set of configura tions is transmitted to the VFD each time the controls are pow ered up Table 2 lists parameters displayed on the 19XRV 23XRV PIC ICVC screen Parameters in ifalics are to be entered or confirmed at start up Parameters in bold are to be changed only after consulting with Carrier service engineering Table 2 VFD Configurations DEFAULT PARAMETER VALUE MOTOR NAMEPLATE VOLTAGE 460 COMPRESSOR 100 SPEED LINE FREQ 60 HZ NO 50 YES RATED LINE VOLTAGE t 460 RATED LINE AMPS t 200 RATED LINE KILOWATTS t 100 MOTOR RATED LOAD KW 100 MOTOR RATED LOAD AMPS 200 MOTOR NAMEPLATE AMPS 100 MOTOR NAMEPLATE RPM 3456 MOTOR NAMEPLATE KW 100 INVERTER PWM FREQUENCY 0 4 KHZ 1 1 2 KHZ SKIP FREQUENCY 1 HZ 20 0 SKIP FREQUENCY 2 HZ 20 0 SKIP FREQUENCY 3 HZ 20 0 SKIP FREQUENCY BAND LINE HZ 0 0 VOLTA
15. TB4 em 5A CHILLER 600V CONTROL 1352 CLASS CC 754 POWER FU3 751 2250 4 3 71352 1352 45 46 31 32 5A LE 145 CFM 145 CFM 00 2 THERMOSTAT 15 15 ENCLOSURE FANS FUA 1361 gt 1A 600 224 CLASS CC USED WITH T METERING 600 See Legend on page 24 225 CLASS CO 23 1010 APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical cont 19XRV Typical cont EAI DRIVE CONTROL POD SLOT 4 DRIVE CONTROL POD SLOT 6 CONTROL 1 0 COMMUNICATION DELUXE 1 0 RECOMM CARRIER RS485 EAT pPi s SLOT 4 DPI SI SLOT 6 EA1 6 Hear SEEE B8 781 14 JUMPER CARRIER GATEWAY CARD Tid jadi 181 6 COME 5 N DIO TBI 16 8 ice Buin CHASSIS GND TB4 TB4 1070 a 5 9 12 TB1 13 SHIELD REMOTE START 4 TBA 181 4 ADU s 88 RED pos 10 13 RIG SIGNAL COM OIL INT LOCK 003 2 256 BLACKS 241 240 B TB1 2 TB4 1 17 TB4 LIDI4 O e 7 E91 WHITE NEG 33 34 TB1 19 TB4l Ne SENADA SHLD ORANGE TB1 1 1 605 00 2 REFERENCE UW 181 20 20 18 20 130 TB4 OIL I
16. bodily injury NOTE Digital meters require a special diode check function or loss of life because the current sourced by the meter during a normal resis tance Ohms test is too low to accurately test a diode Make sure the meter is set to the diode test function Voltage readings may not be exact as shown in above table but look for consistency during each of the 4 tests When performing a test that should return infinity OL as shown in above table you may see a value slowly climbing toward infinity This is a result of the meter charging a capacitor and is normal 14 Servicing the Drive A WARNING To guard against possible personal injury and or equipment damage 1 Inspect all lifting hardware for proper attachment be fore lifting drive 2 Do not allow any part of the drive or lifting mecha nism to make contact with electrically charged con ductors or components Do not subject the drive to high rates of acceleration or deceleration while transporting to the mounting lo cation or when lifting Do not allow personnel or their limbs directly underneath the drive when it is being lifted and mounted A WARNING DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touch ing any internal co
17. following information available from the Allen Bradley data nameplate located inside the en closure on the right wall See Fig 1 Allen Bradley ID or CAT NO Carrier VFD Code Carrier Part Number e Allen Bradley serial number a Allen Bradley ID No 21P 104773 40 Input Rating 480VAC 454A 60Hz 3PH Output Rating 0 460VAC 477A 0 325Hz 3PH Short Circuit Rating 65kA 480V Max Max Ambient Temperature 40 C Interrupt Capacity Rating 100kAIC Enclosure Type TYPE 1 Coolant Type Refrigerant R134a Design Pressure 185 PSIG Carrier Part Number 19XVR0445335A1F Serial Number XXXXXXXXX Carrier Dwg Number 19XV04021001 Mfd On 08 13 10 FAC LOC 1100 ORDER NO 0001772838 00001 Made in USA for Carrier Corporation Syracuse NY 13221 4808 Fig 1 Allen Bradley Data Nameplate IDENTIFYING DRIVE COMPONENTS Chiller control schematics and VFD schematics are includ ed in Appendix A A WARNING DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter rated for the DC bus voltage to ensure the DC bus capacitors are discharged before touching any internal components Fail ure to observe this precaution could result in severe bodily injury or loss of life An isolated multimeter will be needed to measure DC bus voltage and to m
18. line voltage Line to line voltages should be balanced within 3 as calculated by Rockwell s procedure below Measure voltages phase to phase and phase to ground gt Vmax Maximum measured phase to phase voltage A to B B to C C to A Vmin Minimum measured phase to phase voltage Imbalance Calculation Formula VAB VBC VCA Vavg Imbalance Vmax Vmin x 100 Vavg 8 Take a final thermal measurement of the capacitor bank and power after finalizing the installation to ensure all connections are good 9 Ifa ground fault occurs then do the following a Check for a ground in the motor or motor wiring b Check for damage to wiring insulation and that wiring is dry c Verify the motor wiring is separated from ground and there is no connection between phases d Check for failed IGBTs 10 Ifan overcurrent fault occurs then do the following a Check for excessive load and verify load limit set tings on the ICVC Check motor and wiring insulation Check parameter settings on CONF screen in ICVC Check Internal Jumpers On the Main VFD Con trol board there are two jumpers labeled JI HARDWARE EN ABLE and J2 SAFETY ENABLE should be removed and J2 should be in place See Fig 12 Two jumper wires connect a particular terminal to chassis ground The MOV and AC EMI jumper should be connected to the PE A terminal The COMMON MODE CAPACITORS to GROUND jumper should be connec
19. 04 amp 05 E ETHERNET IP ADDRESS SWITCHES cy mE LE DIGITAL OUTPUT TERMINAL BLOCKS SLOTS 04 amp 05 C4 CI EMBEDDED ETHERNET IP PORT MCB I O TERMINALS AUX FAULT HIGH PRESSURE FAULT ENABLE INPUT Fig 17 MCB Main Control Board Components POWERFLEX 755 MAIN CONTROL BOARD HIGH 4 PRESSURE O 24 1 L124V COMMON Located outside of starter connected by field wiring Fig 18 High Pressure Switch Wiring VFD FAULT CODE ON VFD HIST SCREEN NONE 0 12 13 gt 15 17 20 21 24 33 36 Table 4 755 Fault Code Descriptions and Corrective Actions FAULT TYPE DESCRIPTION CORRECTIVE ACTION 200 Processor memory fault Consult VFD manual to resolve generic fault No Entry Check Compressor Discharge High Pressure switch wiring and accuracy Check for high condenser water temperatures low water flow fouled tubes Check for division plate gasket bypass Check for noncondensables in refrigerant Temporary loss of voltage Disable Single Cycle 210 Line voltage dropout Dropout in VFD_CONF sceen Verify phase to phase and phase to ground line 215 Undervoltage Low DC bus voltage voltage VFD Circuit Board malfunction Contact Carrier Service Verify phase to phase and phase to ground line 166 Overvoltage High DC bus voltage
20. 1 NC TB4 TB2 ROND T 1240 1240 rBe 4f RUNC n TDWER FAN HIGH CR6 1 29 NC 1302 26 EAL DRIVE CONTROL POD SLOT 6 COMMUNICATION i RECOMM CARRIER RS485 DF DPI SI SLOT 6 1 6 CARRIER GATEWAY CARD 6 Q CHASSIS GND 5 SHD SHIELD 4 1152 CAT 20 750 20 n gt PDS SIGNAL CUM 3 1162 CN3 D gt COM SIGNAL B COMM 2 SIGNAL MEG SHLD TERM Jt J3 20 COMM CARRIER ADAPTER 6 EAL POWERFLEX 755 MAIN CONTROL BOARD TB1 2 1270 O 24V POWER CAP CB COM COMM COND CR FU GND JMPR NC NO PE POD REM RO ROC SHLD TB HIGH TB4 PRESSURE 1 5 ODIO 120 1 4 1303 opr COMMON 1841313 36 LEGEND Capacitor Circuit Breaker Common Communication Condenser Control Relay Internal Communication Protocols Connections Electrical Assembly Electro Magnetic Interference Evaporator Fuse Ground Jumper Motor Normally Closed Normally Open Potential Earth Ground Card Mounting Board Slot Remote Relay Output Relay Output Common Shield Terminal Block APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical cont 19XRV 23XRV METER OPTION EA2 PowerMonitor 1000 PanelView 1408
21. 100 in Ib 43 5 mm 1 71 in 11 3 Nem 100 in Ib RIGGING THE ENCLOSURE Where overhead room and or clearance in front of the drive enclosure is insufficient to allow the drive to be safely removed from the enclosure the entire enclosure may have to be removed from the chiller The dimensions and weights specified must be taken into consideration when removing the enclosure For 19XRV chill ers the total weight for Frames 6 and 7 including drive weight and enclosure is 720 Ib The 23XRV chiller enclosure includ ing all components weighs 975 Ib All lifting equipment and lifting components hooks bolts lifts slings chains etc must be properly sized and rated to safely lift and hold the weight of the enclosure and drive while removing See Fig 24 and Fig 25 DRIVE RIGGING ACCESS DRIVE WIDTH 4 IN Y NG FRONT VIEW DRIVE RIGGING 4 pm A DRIVE POSITIONED FOR VERTICAL LIFT DRIVE EXTENDS BEHIND MAIN ENCLOSURE E mick SUPPORT FROM BELOW rr 7 SIDE VIEW Fig 22 19XRV Enclosure Access for Removing Drive 16 ENCLOSURE TOP 15 REMOVABLE FRONT CORNER OF DRIVE COMPARTMENT IS REMOVABLE DRIVE POSITIONED FOR VERTICAL LIFT DRIVE EXTENDS BEHIND lt MAIN ENCLOSURE SUPPORT FROM BELOW i fi SIDE VIEW Fig 23 23XRV Enclosure Access for Re
22. 19XRV 23XRV with PIC Controls Rockwell PowerFlex 755 VFD Option United Technologies Start Up and Service Instructions SAFETY CONSIDERATIONS Centrifugal and screw compressor liquid chillers are designed to provide safe and reliable service when oper ated within design specifications When operating this equipment use good judgment and safety precautions or to equipment and property or injury to ture and the design pressures on the equipment nameplate Be sure you understand and follow the procedures DO NOT USE air for leak testing Use only refrigerant or and safety precautions contained in the chiller instruc dry nitrogen A DANGER NEVER EXCEED specified test pressures VERIFY the allowable test pressure by checking the instruction litera tions as well as those listed in this guide A DANGER Failure to follow these procedures will result in severe per sonal injury or death ONLY QUALIFIED electrical personnel familiar with the construction and operation of this equipment and the haz ards involved should install adjust operate or service this equipment READ AND UNDERSTAND this manual and other appli cable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life DO NOT install modification kits with power applied to the drive Disconnect and lock out incoming power before attempting such installation or removal Failure to obse
23. 2711C T3M 2 9 3 J e o e 2112 2131 11 am Y SHIELD 2171 2191 PS1 AB Power Supply 1606 XLP15E 1350 FROM 1 36 1311 12 1370 FROM 1 38 1311 2091 1050 5 e a FROM m 1 6 v2 1070 6066 i 27 Carrier Corporation 2015 a ae Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53190033 01 Printed in U S A Form 19 23 6SS Pg 28 8 15 Replaces 19 23 4SS
24. 479 4 4imo 1 dil 3844 1034 0 1 44 198 5 3045 ASION dr e 3UnlVU3dN3l HOIH ONIQNIM 38 vz 34 4 1 8010 HOLON 110 A d 180 1 e ehano myn 49102 LHM H NUE n i 2 Bur iM m 1 4691 Or i o E M 18 dil 4 O8 257 09 0381 110 8 En 2 5 089 NRI Tu 2510 YOLYALOY INVA 30109 2 1 489 038 489 038 alo 074438410415 LVAD on Haa 8 4 02 onm M A 1 OND N3lNVIS 01 a ai 1 n 10 310 4134 e 4 1 1 TPP OR SE OL m 51 i e HET Y T 140 d 0118 0 E 020 13538 NEB NHB NHB NAO 2i WORROD MB o ms To oam L o ee 11 681 01 4 z amie 038 6 pvarz 013188 wave n OB ay og Er 4 581 OL 1 FA FATA lt 18 06 065 681 01 01 ANY S 12v80131 l LEER 15 038 16 681 01 3 nol soa P Kaga
25. E OFF any safety device BE SURE that all pressure relief devices are properly installed and functioning before operating any chiller THERE IS A RISK OF INJURY OR DEATH by electro cution High voltage may be present on the motor leads even though the motor is not running Open the power sup ply disconnect before touching motor leads or terminals A WARNING Failure to follow these procedures may result in personal injury or death DO NOT USE TORCH to remove any component System contains oil and refrigerant under pressure To remove a component wear protective gloves and gog gles and proceed as follows a Shut off electrical power to unit b Recover refrigerant to relieve all pressure from sys tem using both high pressure and low pressure ports Traces of vapor should be displaced with nitrogen and the work area should be well ventilated Refrig erant in contact with an open flame produces toxic gases Cut component connection tubing with tubing cutter and remove component from unit Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to the system e Carefully unsweat remaining tubing stubs when nec essary Oil can ignite when exposed to torch flame DO NOT work on high voltage equipment unless you are a qualified electrician DO NOT WORK ON electrical components including control panels switches VFD or oil heater until you are sure ALL POWER IS OFF and no r
26. GE IMBALANCE 10 LINE VOLT IMBALANCE TIME SEC t 10 LINE CURRENT IMBALANCET 40 LINE CURRENT IMBAL TIME SEC t 10 MOTOR CURRENT IMBALANCE 40 MOTOR CURRENT IMBAL TIME 10 INCREASE RAMP TIME SEC 30 DECREASE RAMP TIME SEC 30 SINGLE CYCLE DROPOUT DSABLE ENABLE DSABLE Parameters marked with an are not downloadable to the VFD but are used in other calculations and algorithms in the ICVC 1 Parameters marked with a 1 may not be available with PIC IV ICVC NOTES 1 Parameters in italics are to be entered or confirmed at start up 2 Parameters in bold are to be changed only after consultation with ser vice engineering Commissioning the Unit The commission proce dure is as follows 1 If the chiller has been stored outdoors allow at least 24 hours room temperature stabilization prior to commis sioning Ensure any condensation that occurs as a result of the ambient temperature is allowed to evaporate 2 Enter parameters in the VFD CONF screen Install surge suppression devices if required 4 Review the power wiring and grounding to ensure that it has been properly connected 5 Visually examine the inside of the drive enclosure to a Look for signs of corrosion or moisture residue b Remove any dirt or debris c Make sure all vents are clear 6 Apply power to the drive and take thermal measurements of the capacitor bank and power connections Do this again before start up 7 Measure and record the incoming
27. IPTION CORRECTIVE ACTION U to Gnd Check wiring between drive and motor SS Phase Vto Gnd to Gnd GROUND FAULT Check motor for grounded phase Check motor terminals Phase W to Gnd Replace drive Phase UV Short UV Phase UV Short Check wiring between drive and motor Phase VW Short GROUND FAULT Check motor terminals Phase WU Short WU Phase WU Short Replace drive 206 Phase UNot Check wiring between drive and motor Phase VNot GROUND FAULT no LF2 equivalent Check motor terminals Replace drive 206 PhaseWNot WNot 2a o temperature sensor on the main control Check that VFD refrigerant isolation valves are board detected excessive heat open Check VFD refrigerant strainer 206 Shear Pin 1 See VFD Fault Code 15 See VFD Fault Code 15 Shear Pin 2 See VFD Fault Code 15 See VFD Fault Code 15 Check for high entering water temperature or low 206 Drive Overload Drive is overloaded condenser water flow Check current settings in VFD_CONF screen OW TrqLviTimeout See VFD Fault Code 15 See VFD Fault Code 15 IR Volts Range See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 Check that guide vanes are closed completely 206 Excessive Load did not come up to speed the allotted Check for nigh entering water temperature or low Repeat Autotune ME a 1 See VFD Fault Code 15 See VFD Fault Code 15 See VFD F
28. NT LOCK 3 7 5810 y DIG COM TB1 18 TB1 21 m 4 SB DIL INT LDCK 181 22 TB1 24 EVAP PUMP NO 1 11 JPtc SHO NO 1 22 NC 170 182 6 182 5 NC 1011 gt 1 I 9 TB4 800 TO x52 2 gt m J3 RONG 1182 1 190 20 CARRIER ADAPTER TRIP ALARM 20 750 20 0 1 6 DRIVE CONTROL POD SLOT 5 NC CONTROL 1 0 24 0 DELUXE 1 0 5 lt SLOT 5 EVAP PUMP TRIP ALARM PE EE d al TB 1220 1221 1222 1223 EAI Tol 15 1 7 1550 POWERFLEX 755 1 6 eui TB4 TB4 TB4 TB4 MAIN CONTROL BOARD 320 ___ 10 0 21 22 23 2m 81 2 1 TB1 5 BERI 2 2 0 24V POWER Aon EVAP PUMP TRIP ALARM TB1 13 1 4 AIO C TBI 5 002 TB1 10 000 120 TB1 3 1 COND RUMP 003 RU 1280 181 4 1281 1282 ODI COMMON TB1 2 781 23 1 34 0014 SHOT TOWER FAN LOW TOWER FAN HIGH ar 4 Bizi 181 15 129 1291 1292 1293 TB4 TB4 243 m 5 ne i 18 19 005 SS d hae 781 20 1 34 1 37 COND BUMD T cou TB4 TB4 TB4 TB4 giAck BROWN MES 7 Rie es 26 27 124V COMMON JDG _ V y 7 1 4 181 21 181 18 TOWER FAN LOW TOWER FAN HIGH OPtc COND PUMP 181 22 TB1 24 TOWER FAN LOW CR4 NO 1 28 DPtc SHD D CRS ND 1 29 NC 1340 ipm 46 17 RONC n S TOWER FAN HIGHI LEGEND 1182 1360 ND 1 29 Capaci
29. OWARD DOOR FRONT VIEW LEFT SIDEWALL DOOR REMOVED VIEW FROM INSIDE LEGEND 80 Power Module Input Circuit Breaker 15 Amp Control Circuit Breaker Control Transformer Control Fuses Control Relays CR1 CR6 Fig 31 19XRV Assembly Parts 18 ONOOBRWN eoooco 88288 2859 6908S oooo oooco ooooo 66686 ooooo LINE4PE 6 EAL 5 FRONT VIEW DOORS REMOVED LEGEND Input Circuit Breaker Power Module Control Relays CR1 CR6 Control Fuses 120V Control Transformer 120V Vaporizer Heater Transformer 15 Amp Control Circuit Breaker Cooling Fan Fig 32 23XRV Assembly Parts 19 RIGHT SIDEWALL INSIDE VIEW NOTE When replacing the Main Control Board Item No 5 the jumper LEGEND marked J1 HARDWARE ENABLE must be removed and the jumper PF750 Series Precharge Kit marked J2 SAFETY ENABLE must be left in place PF750 Series Gate Interface PF750 Series Power Interface PowerFlex 750 Series Flange Gasket PF755 Main Control Board PF750 Series Backplane Interface PF750 Series Type 4X 12 Chill Plate Heatsink Fan Kit Chill Plate Fan ONOORWON Fig 33 Frame 6 Parts LEGEND 1 Slot for Gateway Gateway Not Shown 2 PF750 Series Backplane Interface 3
30. See VFD Fault Code 15 315 See VFD Fault Code 15 See VFD Fault Code 15 Checking Power Modules and Motor Input Table 5 Diode Checks with Input Power Off Use the following procedure toch d Nur check the drive s power module circuitry with power off METER LEAD METER READING 1 Turn off and lock out input power Wait five minutes 2 Verify there is no voltage at the drive s input power termi R 220 nals Infinite OL 3 Using a voltmeter check the DC bus potential as de 5 Det DSN scribed in the section Verifying That Bus Capacitors Infinite Are Discharged on page 11 to ensure the DC bus capaci DC 95V tors are discharged Infinite OL 4 Disconnect the motor from the drive U L 05 e i infinit 5 Check all AC line and DC bus fuses m 2 6 Use a multimeter to check the input diodes and output V Infinite OL IGBTs ifa fuse is open See Table 5 w DC 0 5 V 7 Check motor impedance Infinite OL 8 Reconnect the motor to the drive ____ Reapply input power 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 Bs EV discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touch ing any internal components Confirm that the DC bus has discharged before performing diode checks Failure to observe this precaution could result in severe
31. Unlit Adapter is not powered or is not transmitting on the network LINK Green Flashing Adapter is properly connected and transmitting data packets on the network Steady Adapter is properly connected but is not transmitting on the network NOTES 2 A Type 2 alarm indicates that a configuration error exists and 1 A Type 1 alarm indicates that a condition exists Type 1 alarms the drive cannot be started Type 2 alarms are not configurable are user configurable 10 VERIFYING THAT DC BUS CAPACITORS ARE DIS CHARGED The drive s DC bus capacitors retain hazard ous voltages after input power has been disconnected Perform the following steps before touching any internal components 1 Turn off and lock out input power Wait five minutes 2 Verify that there is no voltage at the drive s input power terminals 3 Measure the DC bus potential with a voltmeter while standing on a non conductive surface and wearing insu lated gloves 1000 V Measure the DC bus potential See Fig 6 for the 248 amp drive and Fig 7 for the 361 and 477 amp drives The voltage between DC and DC and from each DC terminal to the chassis must be zero before proceeding 4 Once the drive has been serviced reapply input power HIGH TEMPERATURE ALARMS Coolant flow through the cold plate is controlled by an orifice in the refriger ant line leaving the cold plate The orifice looks like one of the O ring face seal connectors and in fact is used as o
32. ake resistance checks The drive s DC bus capacitors retain hazardous voltages after input power has been disconnected Opening the VFD Access Door ANWARNING Before removing the drive enclosure open access door and verify that the DC bus voltage has dropped to zero by checking the terminals behind the access door Failure to observe this precaution could result in severe bodily injury or loss of life 1 Using recommended screwdriver 6 4 mm 0 25 in flat or T20 star open access door See Fig 2 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis is zero before proceeding See Fig 3 Fig 2 Opening Access Door 2 AN DC BUS TEST TERMINALS LOCATED INSIDE ACCESS DOOR MULTIMETER Fig 3 Check DC Bus Terminals 21 1 0248 5 Drive Assembly Catalog Number See Fig 4 and 5 for examples of the Rockwell Automation Drive Assem bly Catalog Number Components and Physical Data The 19XRV chillers use the Allen Bradley PF755 Frame 6 drive for the 230 amp rated application Carrier Part 19 0230 See Fig 6 The Allen Bradley PF755 Frame 7 drive is used for the 335 amp and 445 amp rated application Carrier Part No 19 0335 and 19 445 See Fig 7 See Fig 8 for the dimensions of Frames 6 and 7 for 19XRV chillers The 23XRV chiller uses the Frame 7 drive for 335 amp and 455 amp rated applicatio
33. ault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 Press ICVC reset Parameter Chk The checksum read from the board does not 206 Check VFD_CONF parameters ES match the checksum calculated Cycle power to the drive Press ICVC reset The main control board was moved to a different NONE Replaced MCB PB power structure Data set to default values 2 Verify application version See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 13 VFD FAULT CODE Table 4 Powerflex 755 Fault Code Descriptions and Corrective Actions cont ON VFD HIST FAULT TYPE DESCRIPTION CORRECTIVE ACTION SCREEN 5 Heatsink temperature sensor is reporting a value 168 below 18 7 1 66 or the sensor feedback sink temperature sensor Check heat circuit is open 210 ES HW Jumper See VFD Fault Code 15 See VFD Fault Code 15 211 Safety Brd Fault See VFD Fault Code 15 See VFD Fault Code 15 213 Safety Jumper In See VFD Fault Code 15 See VFD Fault Code 15 291 HSFan Lifwe See VFD Fault Code 15 See VFD Fault Code 15 292 InFan Life See VFD Fault Code 15 See VFD Fault Code 15 293 MtrBrg Life See VFD Fault Code 15 See VFD Fault Code 15 294 MtrBrg Lube See VFD Fault Code 15 See VFD Fault Code 15 295 MachBrg life See VFD Fault Code 15 See VFD Fault Code 15 296 MachBrg Lube See VFD Fault Code 15
34. e a Model or Cat Number b Serial Number 4 From the ICVC control panel screen a Carrier Part Number and Revision b ICVC Software Number Rockwell PowerFlex 755 drive start up must be regis tered on the Rockwell website ro moe ao http www automation rockwell com warp default asp MODEL NUMBER SERIAL NUMBER MACHINE NAMEPLATE SUPPLY DATA VOLTS PHASE HERTZ LOCKED ROTOR AMPS OVERLOAD TRIP AMPS MAX FUSE CIRCUIT BREAKER SIZE MIN SUPPLY CIRCUIT AMPACITY MACHINE ELECTRICAL DATA MOTOR NAMEPLATE VOLTAGE COMPRESSOR 1001 SPEED RATED LINE VOLTAGE RATED LINE AMPS RATED LINE KILOWATTS MOTOR RATED LOAD KW MOTOR RATED LOAD AMPS MOTOR NAMEPLATE AMPS MOTOR NAMEPLATE RPM MOTOR NAMEPLATE KW INVERTER PWM FREQUENCY SAFETY CODE CERTIFICATION THE COMPRESSOR MOTOR CONTROLLER AND OVERLOAD PROTECTION MUS Im ACCORQABCE WITE CARRICR SPECIFICATION 2 420 19105008101 3 Fig 10 Machine Nameplate Nameplate 1 Specifications and Custom Catalog Number representing options installed at factory See Nameplate 2 Located behind HIM for equivalent base catalog number and separate options Cat No 20GYA N D 477 ANONNNNNQBQ UL Open Type IP00 Series A 4 Power ND HD 270KW 200kW 400 300 HP Input 3 Phase 47 63Hz AC Voltage Range 342 440 432 628 Amps ND HD 467 3 3505 447 8 338 9 Output 3 Phase 0 400 Hz AC Voltage Range 0 400 0 460 Base Frequency default 50
35. esidual voltage can leak from capacitors or solid state components LOCK OPEN AND TAG electrical circuits during servic ing IF WORK IS INTERRUPTED confirm that all cir cuits are de energized before resuming work AVOID SPILLING liquid refrigerant on skin or getting it into the eyes USE SAFETY GOGGLES Wash any spills from the skin with soap and water If liquid refrigerant enters the eyes IMMEDIATELY FLUSH EYES with water and consult a physician Warnings continued on next page Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53190033 01 Printed in U S A Form 19 23 6SS Pg 1 8 15 Replaces 19 23 4SS A WARNING DO NOT ATTEMPT TO REMOVE fittings covers etc while chiller is under pressure or while chiller is running Be sure pressure is at 0 psig 0 kPa before breaking any refrigerant connection A CAUTION Failure to follow these procedures may result in personal injury or damage to equipment TO AVOID an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before ser vicing Check the DC bus voltage at the power terminal block by measuring between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements THE USER is responsible to conform with al
36. esulting in a shutdown is seen as an ALARM on the ICVC and as a VFD FAULT when viewed with Drive Explorer CONDITION CODES ICVC ALERT VFD ALARM ICVC ALARM FAULT See Tables 3 4 and Fig 15 ICVC ALERT CODES An alert condition is indicated by a message at the top of the ICVC default screen In addition an exclamation point will appear next to any affected point on an ICVC display screen The drive will continue to operate during the alert condition Investigate the cause of the alert to ensure it does not lead to a fault condition The alert code will automatically be cleared from the ICVC when the condition causing the alert no longer exists See the 19XRV or 23XRV Start Up Operation and Maintenance Instructions for ICVC alert codes ICVC ALARM CODES An alarm condition is also indi cated by a message at the top of the ICVC default screen If an alarm occurs the drive coasts to stop The STS status light on the drive will turn from Green to Red or Yellow see Table 3 The detected fault message is maintained on the display until it is cleared by pressing the RESET softkey See the 19XRV or 23XRV Start Up Operation and Maintenance Instructions for ICVC alarm codes TEST EQUIPMENT NEEDED TO TROUBLESHOOT An isolated multimeter adequately rated for the DC bus volt age will be needed to measure DC bus voltage and to make resistance checks Note that dedicated troubleshooting test points are not provided
37. his fault appears there may be a problem with check CONF settings and save set software configuration tings when exiting VFD_CONF screen The DC bus ripple Check phase to phase and phase to ground dis 216 has exceeded a Line Voltage imbalance tribution bus voltage Increase Line Voltage preset level Imbalance in VFD_CONF screen TorgPrv Spd Band See VFD Fault Code 15 See Fault Code 15 Verify input voltage is within drive specified limits Verify system ground impedance follows proper 204 Decelinhbit 490878 grounding techniques pung Disable bus regulation P186 and or add dynamic brake resistor and or extend deceleration time P537 and P538 AuRsts Exhausted See VFD Fault Code 15 See VFD Fault Code 15 To reset the processor cycle power to chiller 206 Load Loss Check VFD parameters with Drive Explorer The current in one or more phases has been lost Check Motor Current Imbalance in Output PhaseLoss or remains below preset level screen drive output current has exceeded the 1 ms Check excess load improper DC boost set 12 VFD FAULT CODE ON VFD HIST SCREEN 38 39 40 41 42 43 44 45 46 5 61 62 64 65 77 78 79 80 87 91 93 94 95 96 97 100 107 113 124 141 142 143 144 145 Table 4 Powerflex 755 Fault Code Descriptions and Corrective Actions cont FAULT TYPE DESCR
38. in severe personal injury A CAUTION If other than refrigerant cooling is used before connecting the drive to the incoming power make sure that the coolant is circulating and has no leaks A CAUTION When working with the Drive Explorer never use the Rotate function as the motor will immediately start and severe compressor damage could result Alternate Wire Lugs If the incoming power wire size does not fit the standard lug alternate lugs may be used See Table 1 Note that lugs rated for a higher current than the circuit breaker may be used Table 1 Wire Lugs CIRCUIT STANDARD Luc CABLE ALTERNATE BREAKER ABBLUG RANGE ABB LUG RANGE 65 KAIC STANDARD 3 2 0 400 2 250 500 K6TH 100 KAIC x MCM 5 MCM OPTIONAL Verify Installation Record the following job information 1 Job Name Job Number City State Zip Code Or oua Record the following nameplate information 1 From the Allen Bradley nameplate Fig 1 located inside the VFD enclosure a Allen Bradley ID or CAT NO b Allen Bradley Serial Number c Carrier Part Number 2 From the machine nameplete Fig 10 located inside the enclosure a Chiller Serial Number Chiller Model Motor rated load amps Motor nameplate rpm Motor nameplate kW Motor nameplate voltage Inverter PWM pulse width modulation frequency Voltage 3 From the drive module label Fig 11 located on the drive modul
39. l applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment THIS DRIVE contains ESD electrostatic discharge sensi tive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed For static control procedures reference Rockwell publication Guarding Against Electro static Damage or any other applicable ESD protection handbook DO NOT alter the setting of any jumper Failure to observe this precaution could result in damage to or destruction of the equipment USE OF power correction capacitors on the output of the drive can result in erratic operation of the motor nuisance tripping and or permanent damage to the drive Remove power correction capacitors before proceeding Failure to observe this precaution could result in damage to or destruction of the equipment MOST CODES require that upstream branch circuit pro tection be provided to protect input power wiring If fuses are chosen as the protection method refer to the PowerFlex 750 user manual Failure to observe this precaution could result in damage to or destruction of the equipment DO NOT route signal and control wiring with power wir ing in the same conduit This can cause interference with drive operation Failure to observe this precau
40. moving Drive Fig 24 Rigging the Enclosure Frame 6 Fig 25 Rigging the Enclosure Frame 7 REPLACING THE GATEWAY A B20 750 20COMM OPTION CARD Follow these steps for removing and re placing the existing gateway 1 Disconnect power to the drive Before removing the en closure open the access door on the front of the drive See Fig 19 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis is zero before proceeding See Fig 20 3 Remove the enclosure See Fig 21 4 Remove the 2 screws securing the mounting plate and re move the mounting plate and COMM card See Fig 26 5 Mount the new COMM card and mounting plate and at tach with the 2 screws removed in Step 4 See Fig 27 6 Use the shorter ribbon cable to connect the plug on the COMM card to the connector on the mounting plate See Fig 26 7 Install the enclosure See Fig 21 EAT Fig 27 Mount COMM Card Plate to Drive CHILL PLATE FAN AND INTERNAL FAN REPLACE Luise MENT Follow these steps to replace the chill plate fan and 2 internal fan in Frames 6 and 7 0 45 0 67 N m 4 0 6 0 Ib in 3 PLACES Frame 6 chill plate fan kit ZI P FAN A6 A 1 Disconnect power to the drive Before removing the en closure open the access door on the front of the drive See Fig 19 2 Check to be sure that the voltage bet
41. mponents Failure to observe this pre caution could result in severe bodily injury or loss of life 1 Using recommended screwdriver 6 4 mm 0 25 in flat or T20 star open access door See Fig 19 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis is zero before proceeding See Fig 20 3 Remove the enclosure See Fig 21 REMOVING THE DRIVE The dimensions and weights specified must be taken into consideration when removing the drive All lifting equipment and lifting components hooks bolts lifts slings chains etc must be properly sized and rated to safely lift and hold the weight of the drive while removing it For 19XRV chillers see Fig 22 For 23XRV chillers see Fig 23 The drive weights are as follows Drive weight for Frame 6 85 Ib Drive weight for Frame 7 160 249 Ib Fig 19 Open Access Door 15 LOCKOUT TAGOUT Z AN DC BUS TEST TERMINALS 9 LOCATED INSIDE ACCESS DOOR MULTIMETER ENCLOSURE LOOSEN FORWARD ENCLOSURE FASTENERS G Z 27 Fig 21 Removing Enclosure When replacing the drive reverse the procedures and tight en to the torques for Frames 6 and 7 power terminal block list ed in Table 6 Table 6 Frames 6 and 7 Power Terminal Block MAXIMUM LUG RECOMMENDED TERMINAL WIDTH TORQUE BOLT SIZE 8 x 1 25 8 x 1 25 34 6 mm 1 36 in 11 3 Nem
42. ne of the connections on the coolant tubing If the orifice is present and condenser liquid flow is present the liquid will flash to cooler temperature at the orifice This temperature difference is great enough to be easily felt MAIN CONTROL BOARD MCB COMPONENTS Figure 16 shows the drive module with the cover removed To access the control boards loosen the screw on the face of the keypad mount and swing the keypad mount upward The components on the main control board MCB are shown in Fig 17 Note the location of the terminals labeled MCB I O The high pressure switch is wired to these terminals as shown in Fig 18 In the event of a high condenser pressure alarm the connections at these terminals should be checked and tightened if necessary Typical wiring schematics are shown in Appendix A 8 SWING UP KEY PAD o pg MOUNT TO ACCESS C EE CONTROL BOARDS Bis AME 25 n Ni Fig 16 Drive Module with Cover Removed 11 DPI PORT 02 COMPUTER PORT 142 DIGITAL INPUT TERMINAL BLOCKS 29259 SLOTS
43. ns Carrier Part No 2 5 and 23 0445 Frame 6 is not used See Fig 9 for the dimensions of Frame 7 for 23XRV chillers 0 21P 19XRV Std Tier Voltage Code 1 480 vac 60 Hz 2 380 vac 50 Hz 3 380 vac 60 Hz 4 400 vac 50 Hz 5 400 vac 60 Hz 6 415 vac 50 Hz 7 415 vac 60 Hz Full Load Amp Rating Maximum Continuous Amps 0248 248 0361 361 0477 477 For Carrier applications maximum continuous amp ratings are 230 335 an d 445 Meter Option 0 No Meters 2 Digital Meter Input Device 3 65 Capacity Breaker 4 100 KAIC Capacity Breaker Enclosure 4 Unit Mount Type 1 IP23 Liquid Cooled 5 Unit Mount Type 1 IP23 Liquid Cooled Air Filter Fig 4 Rockwell Automation Drive Assembly Catalog Number Nomenclature 19XRV Units For Carrier appl 21PB 1 0248 4 0 0 21PB 23XRV Std Tier Voltage Code 1 480 vac 60 Hz 2 380 vac 50 Hz 3 380 vac 60 Hz 4 400 vac 50 Hz 6 415 vac 50 Hz 7 415 vac 60 Hz Full Load Amp Rating Maximum Continuous Amps 0248 248 0361 361 0477 477 ications maximum continuous amp ratings are 230 335 and 445 CE Conformit Europ enne 0 1 Yes Control Power 0 Standard 1 High Meter Option 0 No Meters 2 Digital Meter Input Device 3 65 Capacity Breaker 4 100 KAIC Capacity B
44. reaker Enclosure 1 Unit Mount Type 1 IP23 Air Cooled Filter 4 Unit Mount Type 1 IP23 Liquid Cooled Fig 5 Rockwell Automation Drive Assembly Catalog Number Nomenclature 23XRV Units 20000000000 N y 5 LEGEND DESCRIPTION R L1 S L2 T L3 U T1 V T2 W T3 PE Grounding Studs Terminating point to chassis ground for incoming motor shield DC Bus and Brake DC DC BR1 BR2 Terminals PE A and PE B MOV and CMC Jumper Wires DC and DC Bus Voltage Test Points Fig 6 Frame 6 Drive Components 00000800000000000000000000000000000600000 I lt 4 f OF X NS 49 Cai uu 5 m e oo 00 88 m oo wo Veet 0 Qu oP e G6 5 4 I oo eas 0 0 9 46 MI 9 9 A 812 T L3 WT2 WT3 LEGEND DESCRIPTION R L1 5 12
45. rve this precaution could result in severe bodily injury or loss of life UNUSED WIRES in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages Also drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled to eliminate the possible shock hazard from cross coupled motor leads Failure to observe these precautions could result in bodily injury DO NOT VENT refrigerant relief valves within a building Outlet from rupture disc or relief valve must be vented out doors in accordance with the latest edition of ANSI ASHRAE 15 American National Standards Institute American Society of Heating Refrigerating and Air Con ditioning Engineers The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxia tion PROVIDE adequate ventilation in accordance with ANSI ASHRAE 15 especially for enclosed and low overhead spaces Inhalation of high concentrations of vapor is harm ful and may cause heart irregularities unconsciousness or death Misuse can be fatal Vapor is heavier than air and reduces the amount of oxygen available for breathing Product causes eye and skin irritation Decomposition products are hazardous DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose Oxygen gas reacts violently with oil grease and other common substances Dangers continued in next column DO NOT VALV
46. supply Digital input common Connections for DC power supply Connections for drive supplied 24V power IMPORTANT Wiring to pluggable terminal block connectors should be supported by wire ties or other means to help pre loi a loi od 24v vent unintentional disconnection Fig 12 PF755 Main Control Board CONNECTED DISCONNECTED COMMON MOD CONNECTED DISCONNECTED COMMON MODE _ Fig 13 Jumper Wire Locations Frame 6 Fig 14 Jumper Wire Locations Frame 7 SERVICE A WARNING DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touch ing any internal components Failure to observe this pre caution could result in severe bodily injury or loss of life Troubleshooting the Drive The drive can display two kinds of error codes on the ICVC called Alert and Alarm codes These codes signal a problem detected during self tun ing or drive operation Note the following differences between Carrier and Allen Bradley terminology A warning message on the ICVC is an ALERT The same warning viewed with Rockwell Drive Explorer isa VFD ALARM failure r
47. ted to a standoff rather than the PE B terminal Use the recommended tools as follows when connecting jumper wires in Frame 6 and in Frame 7 Recommended torque screws and nuts 120 0 Ib in Recommended hex socket 7 mm Recommended screwdriver T20 star type 1 36 Nm See Fig 13 and Fig 14 for the correct positions of the jumpers LEGEND NAME DESCRIPTION 1 HIM Human DPI Port 1 HIM Cradle connection Interface Module Connector 2 Fan Connector Power supply for internal cooling fan Frames 2 and 3 Battery User installed CR1220 lithium coin Receptacle cell battery provides power to the Real Time Clock Optional not 3 048 supplied 4 DPI Port 2 Cable connection for handheld and remote HIM options Embedded Ethernet Rotary switches for setting lowest IP Address Selectors octet of Ethernet address forces address to 192 168 1 xxx Embedded Ethernet Network cable connection IP Connector Jumper J2 SAFETY Safety enable jumper Removed ENABLE when safety option is installed For additional information refer to the Check Internal Jumpers section on page 8 Jumper J1 HARD Hardware enable jumper Removed WARE ENABLE when a hardware enable configura tion is utilized For additional infor mation refer to the Check Internal Jumpers section on page 8 terminal block TB1 TERMINAL DESIGNATIONS FIXEDI O NAME DESCRIPTION i Connections for AC power
48. tion could result in damage to or destruction of the equipment DISTRIBUTION SYSTEM short circuit capacity shall not exceed the rating of the drive Failure to observe this pre caution could result in damage to or destruction of the equipment DO NOT STEP on refrigerant lines Broken lines can whip about and release refrigerant causing personal injury DO NOT climb over a chiller Use platform catwalk or staging Follow safe practices when using ladders USE MECHANICAL EQUIPMENT crane hoist etc to lift or move inspection covers or other heavy components Even if components are light use mechanical equipment when there is a risk of slipping or losing your balance BE AWARE that certain automatic start arrangements CAN ENGAGE THE VFD TOWER FAN OR PUMPS Open the disconnect ahead of the VFD tower fans or pumps Cautions continued in next column A CAUTION USE only repair or replacement parts that meet the code requirements ofthe original equipment PERIODICALLY INSPECT all valves fittings and piping for corrosion rust leaks or damage DO NOT re use compressor oil or any oil that has been exposed to the atmosphere Dispose of oil per local codes and regulations DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment Seal circuits being serviced and charge with dry nitrogen to pre vent oil contamination when timely repairs cannot be com pleted
49. tor m CB Circuit Breaker COM Common COMM Communication COND Condenser CR Control Relay Internal Communication Protocols Connections EA Electrical Assembly EMI Electro Magnetic Interference Evaporator FU Fuse GND Ground Jumper M Motor NC Normally Closed NO Normally Open PE Potential Earth Ground POD Card Mounting Board Slot REM Remote RO Relay Output ROC Relay Output Common SHLD Shield TB Terminal Block 24 APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical cont 23XRV Typical FU6 1050 gt FU7 FUB 1070 1A gt 600V CLASS CC USED WITH METER USED WITH METER OPTION POWERFLEX 755 POWER MODULE CIRCUIT BREAKER f 2 m a 592 MOV AC EMI CAP JPR 1100 8 8 EN FEA ae 2 D 7 CHASSIS COMMON MODE CAP JPR 12 110 TEIN 70 922 SEE USER MANUAL 480V N 3PH 60Hz L3 T MOV7AC N ac Lines 3 6 vox 220 z 1 JUMPER DUT CT2 AS
50. voltage Monitor AC line for high transient volt age conditions Any phase current gt 106 RLA Can result from significant load side current imbalance when running at full load 217 Motor Overload An internal electronic overload trip has occurred Check entering condenser water temperature and water flow rate Check Motor Rated Load Amps in VFD_CONF screen Check that VFD refrigerant isolation valves are 207 Auxiliary Input Input is open Heat Sink Over temp open Heat sink temperature has exceeded maximum Check VFD refrigerant cooling orifice and refrig operating temperature erant strainer Check for proper VFD cooling fan operation and air flow blockage Check that VFD refrigerant isolation valves are open The output transistors have exceeded maximum Check VFD refrigerant cooling orifice and refrig operating temperature erant strainer Check for proper VFD cooling fan operation and air flow blockage Check for high entering water temperature or low 286 HW Overcurrent The drive output current has exceeded hardware condenser water flow Check current settings in 219 Transistor Over 219 VFD_CONF screen Check the motor motor terminals and external 220 Ground Fault A current path to earth ground greater than 25 wiring to the drive output terminals for a 9 grounded condition 206 Ground Warning groung current has exceeded the level in If t
51. ween DC and DC and from each DC terminal to the chassis is zero before proceeding See Fig 20 Remove the enclosure See Fig 21 Remove and replace the chill plate fan See Fig 28 Remove and replace the internal fan See Fig 29 Install the enclosure See Fig 21 Nn amp UC CHILL PLATE FAN POWER CONNECTION Fig 26 COMM Card CHILL PLATE FAN 2 6 Nem 23 Ib in Fig 28 Chill Plate Fan Frame 6 17 4 Remove and replace the chill plate and internal fans See Fig 30 5 Install the enclosure See Fig 21 0 5 20 n 46 Ib in em 4 m Q3lbin 2 6 23 INTERNAL FAN E 23 Fig 29 Internal Fan Frame 6 2 6 Nem 23 Fig 30 Chill Plate and Internal Fans Removal 1 Disconnect power to the drive Before removing the en and Replacement Frame 7 closure open the access door on the front of the drive See Fig 19 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis is zero before Part Identification and Location See Fig 31 34 proceeding See Fig 20 for parts descriptions and locations 3 Remove the enclosure See Fig 21 _ TENE f 2 2 TB1 TB2 3 SECONDARY SIDE 4 T
Download Pdf Manuals
Related Search