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Start-Up and Service Instructions

1. m CONTINUED ON AUTO DEMAND LIMIT 12 RED FACING PAGE OPTIONAL veal j Y iun AUTO CHILLED WATER RESET OPTIONAL a CLR SHIELD BLK D J OUTPUT 1 loc 4 600600 321 43921 5 4 3 2 Li 5 J6 J8 EVAP ENT 75 9 uto 1 WATER TEMP 2 SWITCH POSITION EVAP LYG 3 RED 3 EXT 4 20mA WATER TEMP LAA AY uo 4 OFF EXT 1 5vde unm COND ENT REDI 5 1 corr 1BLU1 BLK WATER TEMP 3 uuu tS bd x 9 0ORN 71 COND LVG F ubi DE WATER TEMP 7 2 Llo EL G V POSITION nf 4 5 120 F K 1 9 DIFFUSER ACTUATOR ML K EVAP REFRIG gt 802 n alis al LIOUID TEMP P oy aun 12 3o mE Hr TEMP Es imn 13 z 1o m 63 OPTIONAL Vy tun 14 10 igo CY DECREASE 0 15 uo 16 120 REDD 17 GUIDE VANE ACTUATOR DISCH TEMP V 3 uuo 18 oa RED 19 THRUST 2 BRG TEMP 20 YEL tun NVV O SPARE 2
2. Denotes Component Terminal Wire Splice Denotes Conductor Male Female Connector Le 1 1 10 78 6 Eu o com a ii OIL HEATER O 3 OPEN 230v o1 cose 2 12 ae BLK I is um o4 115v o 1 RM di 23 CANCRO T RED SO en 1 reat un 4 x 5 1 d coe won urea L 230V WIRING MODIFICATION J n BLK N tBLU ir ini X m j cas Bypass FR 47 8 8 HT EXC BLK BLK 115v CONTROL ONLY BLK RED I EE TT unn BLK BLK I BLK 1 RENE m REDI RED RED Ip ORM 50 GLAD n 12 13 BRM 43 BLK 1 2AVAC i Bur 17 BLK GR TO VFD 4 Pu BRN BRN BRN BRW BRW BRM BLU 7 CLR DISCH REDI HIGH PRESS e BLU 1 BLK 4 2 4 4 RED HGBP lt REDI a I man SOLENOID RED GRY RED VEL 1 4 2
3. 3 BT485 TERMINATOR OPN UPC 24V ac gt Gnd UPC Open ES BACNET gt CONNECTION o BOE S 3 POWER LED BAS PORT 2 0 Zo ta eo 32 5 cr Loher E Kal Rx1 LED TO 20 N20 0011 20 3 Modbus 0100 i 90 IO Lon 1310 7 Uc BAS PORT Tx2 LED gt EIA485 MODE 4 R2 LET 3 Rx2 LED D Om oc T UD BACNET META On 7j BAUD RATE CEQ o pgg PP SwiTcHes EIA 485 T JumPERs 102 EX e NLE ADDRESS ib Cs om 4f ROTARY E SWITCHES 00 2 LISTED 002106 MadeinUSA Enclosed Energy Management Equipment RUN LED ERROR LED J Fig A UPC Open Controller Sponsored by ASHRAE American Society of Heating Refrigerating and Air Conditioning Engineers 35 APPENDIX B BACNET COMMUNICATION OPTION cont CONFIGURING THE BAS PORT FOR BACNET MS Use the same baud rate and communication settings for all controllers on the network segment The UPC Open con troller is fixed at 8 data bits No Parity and 1 Stop bit for this protocol s communications If the UPC Open controller has been wired for power pull the screw terminal connector from th
4. SUPPORT FROM BELOW i ge SIDE VIEW Fig 21 23XRV Enclosure Access for Removing Drive gt 1 2A ooooo ooooo ooooo oooo ooooo oooo ooooo O ooooo ooooo ooooo ooooo ooooo ooooo ooooo Fig 22B Rigging the Enclosure Frame 7 REPLACING THE GATEWAY A B20 750 20COMM OPTION CARD The following are the steps for remov ing and replacing the existing gateway 1 Disconnect power to the drive Before removing the en closure open the access door on the front of the drive See Fig 17 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 18 3 Remove the enclosure See Fig 19 4 Remove the 2 screws securing the mounting plate and re move the mounting plate and COMM card See Fig 23 5 Mount the new COMM card and mounting plate and at tach with the 2 screws removed in Step 4 See Fig 24 6 Use the shorter ribbon cable to connect the plug on the COMM card to the connector on the mounting plate See Fig 23 7 Install the enclosure See Fig 19 4 MOUNTING PLATE 0 45 0 67 N m 4 0 6 0 Ib in 3 PLACES Fig
5. 00 00 00 So000000 0 DOO 000 000 000 000 00 oo 900 008 000 e 000 0808 6 5 iO o g m 0 oe og 0 1 e D S o Mi 9 ya 512 UTI V T2 WT3 o o eee LEGEND DESCRIPTION R L1 S L2 T L3 U T1 V T2 W T3 PE Grounding Studs Terminating point to chassis ground for incoming motor shield DC Bus and Brake DC DC BR1 BR2 Terminals PE A and PE B MOV and CMC Jumper Wires DC and DC Bus Voltage Test Points Fig 6 Frame 7 Drive Components 54 00 50 00 REF 2 pu 6 36 00 REF 99 lt 40 00 FRONT VIEW NOTE Dimensions shown in inches 30 00 Fig 7 19XRV Enclosure Dimensions Frames 6 and 7 a dl xw 15 00 X 7 50 REMOVABLE ACCESS COVER OPENING IN THE TOP OF CABINET SEE DETAIL DETAIL SCALE 2 5 QUARTER TURN FASTENERS TOOL REQUIRED TO OPEN LIFT OFF HINGES ALL DOORS 4 TAP
6. Target Guide Vane Position GV TRG R 0010 wa gv trg 1 Target VFD Speed otio AV42 vid out 1 Tower Fan Relay High R NA OFF tfr high 1 Tower Fan Relay Low TFRLOW R NA OFF OFFON ffr low 1 User Defined Analog 1 NA NA NA AV2901 useranalog 11 User Defined Analog 2 NA NA NA AV2902 useranalog 2 1 User Defined Analog 3 NA NA NA AV2908 useranalog 3 1 User Defined Analog 4 NA NA NA AV2904 useranalog 4 1 User Defined Analog 5 NA R NA NA AV2905 useranalog 5 1 User Defined Binary 1 NA R NA NA user binary 1 1 User Defined Binary 2 NA NA NA BV2912 vser binary 2 1 User Defined Binary 3 NA R NA NA BV2913 _ user binary 3 1 User Defined Binary 4 NA NA NA BV2914 _ user binary 4 1 User Defined Binary 5 na R NA NA SBV2915 userbinary 5 1 LEGEND CHW Chilled Water R Read VFD Variable Frequency Drive Write NOTE Network Points List is subject to change Consult most recent service bulletins for latest information 41 Carrier Corporation 2013 EI porcos c x oper cux Manufacturer reserves the right to
7. 755 Fault Code Descriptions and Corrective Actions FAULT TYPE DESCRIPTION CORRECTIVE ACTION 206 Processor memory fault Consult VFD manual to resolve generic fault No Enty 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 voltage Monitor AC line for high transient voltage 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 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 o
8. Fig 9 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 UU DPA TWO TO Series A J 400V Cla 180 Clas Power ND HD 400 HP 300 HP Input 3 Phase 47 83Hz AC Voltage Range 342 440 432 628 Amps ND HD 4873 3595 447 8 338 9 Output 3 Phase 0 400 Hz AC Voltage Range 0 400 0 480 Base Frequency default 50 Hz 60 Hz Continuous Amps ND HD 477 367 477 361 60 Sec Ovid Amps ND HD 5247 550 5 524 7 541 5 3 Sec Ovid Amps ND HD 715 5 684 715 5 649 8 COOLANT Treated Water R134A RATED PRESSURE 1885 PSIG on 2010 08 09 Willi Firmware 1 018 Allen Bradtey PRODUCT USA FAC 1102 Serial Number 13865136 Fig 10 Drive Module Label Configure the VFD 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 The following is from the 19XRV 23XRV PIC ICVC screen Parameters in italics are to be entered or confirmed at start up Parameters in bold are to be changed only after con sulting with Carrier service engi
9. 0 to 110 AV 11 vid_act_1 Calc Evap Sat Temp EAT R F NA 40to245 AV 13 1 Chilled Water Deadband 10 051920 ChiledWaterDetap cHweD NA eroso chwpd ChiledWaterDetaT Dr R NA 40t245 chw_ot 1 Chilled Water Pump cHP B NA or ormon eva opi Chilled Water Temp CHWTMP B NA 400245 chwtmp i Chiller Start Stop cis si Comp Discharge Temp NA 40045 1 Comp Motor Winding Temp mew NA 40245 mwi CompThrustBrgTemp R F 4010245 mw mtb Cond Water Flow CDW_FLOW R NA NO YES cdw flow 1 Cond Water Pump cp R NA OFFO 1 Condenser Pressure cRP R 67to420 AV 21 crp 1 Condenser Refrig Temp R F 40 to 245 AV 22 crt 1 Condenser Water Delta P CDWPD 6 7 to 420 AV 23 cdwpd 1 Control Point LCW STPT 10 to 120 AV 24 Icw_stpt_1 Current CHW Setpoint CHWSTPT 0 00 to 99 9 AV 25 chwstpt_1 Demand Level 1 LR 0 to 100 dmv ML 1 1 Demand Level 2 0 to 100 2 perct 1 Demand Level 3 0 to 100 AV 3 dmv_lvl_3_perct_1 Element Comm Status No Comm Normal BV 2999 element_stat_1 N A N A N A N A A Emergency Stop EMSTOP oR ENABLE EM BV 8 emstop 1 NA 40to 245 AV 26 ecw_1 F NA 40to 245 AV 27 ecdw_1 Evaporator Pressure 6 7
10. 0230 See Fig 5 The Allen Bradley PF755 Frame 7 drive is used for the 335 amp and 445 amp rated application Carrier Part No 19 0335 and 19XVR0445 See Fig 6 See Fig 7 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 applications Carrier Part No 23XVR0335 and 23XVR0445 Frame 6 is not used See Fig 8 for the dimensions of Frame 7 for 23XRV chillers Meter Package 0 No Meter Package 2 Digital Meter Package Disconnect Breaker Options 3 65 KAIC Capacity Breaker 4 100 KAIC Capacity Breaker Drive Assembly 3 Unit Mount NEMA 1 Liquid Cooled 4 Unit Mount NEMA 1 IP 23 Liquid Cooled Fig 4 Rockwell Automation Drive Assembly Catalog Number Nomenclature 3000000000080 o 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 5 Frame 6 Drive Components 00000300000000000000000000000000000800000 VT SAAT 575752452 A 20 imn D 8
11. MOUNT TO ACCESS CONTROL BOARDS 9 cc coco Fig 14 Drive Module with Cover Removed 11 TB4 x TB4 5 1294 DPI PORT 02 COMPUTER PORT Lr 880 DIGITAL INPUT TERMINAL BLOCKS SLOTS 04 amp 05 LE Co EJ BRE ETHERNET IP ADDRESS SWITCHES o c3 DIGITAL OUTPUT TERMINAL cz 2 BLOCKS SLOTS 04 amp 05 L Tu L1 CI EMBEDDED ETHERNET IP PORT f MCB TERMINALS AUX FAULT HIGH PRESSURE FAULT ENABLE INPUT Fig 15 MCB Main Control Board Components EA1 POWERFLEX 755 MAIN CONTROL BOARD Sees 4 1 2 1241 24V POWER TB1 5 DDIO 120VAC TB1 4 DI COMMON HIGH PRESSURE 781 3 DI 24VDC e4 25 TB1 1 24V COMMON Located outside of starter connected by field wiring Fig 16 High Pressure Switch Wiring Table 4 ICVC Alert Codes PRE START ALERTS These alerts only delay start up When alert is corrected the start up will continue No reset is necessary ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 100 PRESTART STARTS LIMIT 100 gt compressor st
12. Before calling have the following information available from the Allen Bradley data nameplate located inside the en closure on the right wall See Fig 1 Allen Bradley ID or CAT NO Carrier VFD Code Allen Bradley serial number 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 VFD Serial Number Carrier Dwg Number 19XV04021001 Mfd On 08 13 10 ORDER NO 0001772838 00001 FAC LOC 1100 Made in USA for Carrier Corporation Syracuse NY 13221 4808 Fig 1 Allen Bradley Data Nameplate IDENTIFYING DRIVE COMPONENTS A chiller control schematic and a VFD schematic are in cluded in Appendix A ANWARNING DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter 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 volta
13. 210 Single Cycle Line Volt Temporary loss of voltage Disable Single Cycle age Dropout Dropout in VFD_CONF screen PROTECTIVE LIMIT HIGH LINE VOLTAGE 211 8High Percent Line Volt Check phase to phase and phase to ground dis age VALUE tribution bus voltage Consult power company PROTECTIVE LIMIT LOW LINE VOLTAGE 212Low Percent Line Volt phase to phase and phase to ground dis age VALUE tribution bus voltage Consult power company PROTECTIVE LIMIT VFD MODULE RESET 2185 VFD Module Power On Temporary loss of VFD control voltage Check Reset When Running VFD control power breaker transformer and fuses PROTECTIVE LIMIT POWER LOSS 214 Control Power Loss Check phase to phase and phase to ground dis When Running tribution bus voltage Check VFD fuses Check 24 vac power supply to ICVC Consult power company PROTECTIVE LIMIT LOW DC BUS VOLTAGE 215Low DC Bus Voltage Verify phase to phase and phase to ground line VALUE exceeded limit of voltage VFD Circuit Board malfunction LIMIT Contact Carrier Service PROTECTIVE LIMIT LINE VOLTAGE 216Line Voltage Imbal Check phase to phase and phase to ground IMBALANCE ance Check VFD Fault His distribution bus voltage Increase Line Voltage tory for Values Imbalance in VFD_CONF screen PROTECTIVE LIMIT MOTOR OVERLOAD TRIP 217 Overload Trip Any phase current gt 106 Rated Load Amps Check VFD configurations Can result from significant loa
14. 23 COMM Card Fig 24 Mount COMM Card Plate to Drive CHILL PLATE FAN AND INTERNAL FAN REPLACE MENT The following are the steps to replace the chill plate fan and internal fan in Frames 6 and 7 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 17 2 Check to be sure that the voltage between and DC and from each DC terminal to the chassis 1s zero before proceeding See Fig 18 Remove the enclosure See Fig 19 Remove and replace the chill plate fan See Fig 25 Remove and replace the internal fan See Fig 26 Install the enclosure See Fig 19 Nn RU CHILL PLATE FAN POWER 2 6 Nem 23 Ibsin Fig 25 Chill Plate Fan Frame 6 2 6 Nem 23 Ibin ran 1 INTERNAL FAN Fig 26 Internal Fan Frame 6 4 Remove and replace the heat sink and internal fans See Fig 27 Install the enclosure See Fig 19 5 20 Nem fs 46 Ib in 2 6 Nem 23 23 Ibin 2 6 Nem 23 Ibsin Frame 7 chill plate fan kit ZIP FAN A7 A Fig 27 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 17 2 Check to be sure that the voltage
15. APPENDIX A WIRING SCHEMATICS 31 34 APPENDIX B BACNET COMMUNICATION OPTION 35 41 INTRODUCTION The Carrier VFD option Start Up and Service Manual 1s in tended for trained and qualified service personnel and is to be used during start up operation and maintenance of Rockwell Allen Bradley PF755L drive ABBREVIATIONS AND EXPLANATIONS Frequently used abbreviations in this manual include CCM Chiller Control Module DC Direct Current DPI Drive Peripheral Interface Ethernet ICVC International Chiller Visual Controller IGBT Insulated Gate Bipolar Transistor 1 0 Inputs Outputs IP Internet Protocol IPWM Inverter Pulse Width Modulation MCB Main Control Board MOV Metal Oxide Varistor PE Protective Earthing Conductor SIO Sensor Input Output STS Status 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
16. Allen Bradley Serial Number c Carrier Part Number 2 From the machine nameplete Fig 9 located inside the VFD 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 h Voltage 3 From the drive module label Fig 10 located on the drive module a Model or Cat Number b Serial Number 4 From the ICVC control panel screen a Carrier Part Number and Revision b ICVC Software Number Rockwell PowerFlex 755 drive start up must be regis tered on the Rockwell website Rockwell Registration site URL 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 100 SPEED RATED LINE VOLTAGE RATED LINE AMPS RATED LINE KILOWATTS MOTOR RATED LOAD KW MOTOR RATED LOAD AMPS MOTOR NAMEPLATE AMPS MOTOR NAMEPLATE RPM MOTOR NAMEPLATE KW INTERTER PWM FREQUENCY SAFETY CODE CERTIFICATION THE COMPRESSOR MOTOR CONTROLLER AND OVERLOAD PROTECTION MUST BE IN ACCORDANCE WITH CARRIER SPECIFICATION 2 420 19XV05008701 REV 3
17. Reduce unit pressure if possible FAILURE TO STOP VFD SHUTDOWN FAULT 2049VFD Shutdown Fault VFD Circuit Board malfunction Check Inverter Power Unit Contact Carrier Service PROTECTIVE LIMIT HIGH DC BUS VOLTAGE 205 gt DC Bus Voltage Verify phase to phase and phase to ground line VALUE exceeded limit of voltage Monitor AC line for high transient volt LIMIT age conditions VFD Circuit Board malfunction Contact Carrier Service PROTECTIVE LIMIT VFD FAULT 2065 VFD Fault Code See VFD Fault Code description and corrective VALUE Check VFD Fault action Code List PROTECTIVE LIMIT HIGH CONDENSER 207 High Cond Pressure Check Compressor Discharge High Pressure PRESSURE trip VALUE exceeded Switch switch wiring and accuracy Trippoint Check for high condenser water temperatures low water flow fouled tubes Check for division plate gasket bypass Check for noncondensables in refrigerant PROTECTIVE LIMIT EXCESSIVE MOTOR 208 Percent Load Current Check Motor Rated Load Amps in CONF AMPS VALUE exceeded limit of screen Percent Load Current gt 110 LIMIT Check Motor Rated Load Amps setting PROTECTIVE LIMIT LINE CURRENT 209 gt Line Current Imbal Check phase to phase and phase to ground IMBALANCE ance Check VFD Fault His power distribution bus voltage tory for Values Check Line Current Imbalance in VFD_CONF screen Consult power company PROTECTIVE LIMIT LINE VOLTAGE DROPOUT
18. play Navigation BACview CCN Home Element Comm Stat Element 1 Bus 0 TROUBLESHOOTING If there are problems wiring or addressing the UPC Open controller contact Carrier Technical Support Fig F BACview Device Connection 38 APPENDIX B BACNET COMMUNICATION OPTION cont COMMUNICATION LEDS The LEDs indicate if the controller is communicating with the devices on the network See Tables E and F The LEDs should reflect communication traffic based on the baud rate set The higher the baud rate the more solid the LEDs become See Fig A for location of LEDs on UPC Open module REPLACING THE UPC OPEN BATTERY The UPC Open controller s 10 year lithium CR2032 battery provides a minimum of 10 000 hours of data retention during power outages IMPORTANT Power must be ON to the UPC Open con troller when replacing the battery or the date time and trend data will be lost Remove the battery from the controller making note of the battery s polarity Insert the new battery matching the battery s polarity with the polarity indicated on the UPC Open controller NETWORK POINTS LIST The points list for the control ler is shown in Table G Table E LED Status Indicators LED STATUS Lights when power is being supplied to the controller The UPC Open controller is protected by internal solid state polyswitches on Power the incoming power and network connections These p
19. Disconnect motor from VFD and megger motor Contact Carrier Service 221 PROTECTIVE LIMIT UNUSED 221 UNUSED 222 PROTECTIVE LIMIT LINE FREQUENCY TRIP 222 gt Line Frequency If operating from a generator check generator VALUE exceeded limit of size and speed LIMIT Check Power Supply Check utility power supply 223 WITH VFD GATEWAY 223 1055 of SIO Comm with Check VFD communication wiring and COMMUNICATION MODULE VFD Gateway Check VFG connectors on VFD Gateway and DPI board Module and Power Check for compatibility between ICVC and Gateway software 224 PROTECTIVE LIMIT VFD COMMUNICATIONS 224 Loss of DP Comm with Check VFD communication wiring and VFD Gateway Check VFG to connectors VFD Comm Check status lights on DPI Communications Interface Board Contact Carrier Service 225 PROTECTIVE LIMIT MOTOR CURRENT 225 Motor Current Imbal Check Motor Current Imbalance in IMBALANCE ance Check VFD Fault VFD CONF screen History for Values 226 PROTECTIVE LIMIT LINE PHASE REVERSAL 226 Line Phase Reversal Reverse connections of any two line conductors Check Line Phases to circuit breaker 227 PROTECTIVE LIMIT PRESS SENSOR 2270 Pressure Delta P Check transducer wiring and accuracy VALUE Pump Off Check Check power supply to pump Pump Transducers Check pump operation Check transducer calibration 228 PROTECTIVE LIMIT LOW OIL PRESSURE 228Low Operating Oil Check transducer wiring an
20. 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 7 Hardware enable jumper Removed when a hardware enable configura tion is utilized For additional infor mation refer to the Check Internal Jumpers section on page 7 1 O terminal block Receptacle Jumper J1 HARD WARE ENABLE TB1 I O Terminal Designations FIXED I O loi a loi od 24v vent unintentional disconnection TERMINAL IMPORTANT Wiring to pluggable terminal block connectors should be supported by wire ties or other means to help pre DESCRIPTION Connections for AC power supply Digital input common Connections for DC power supply Connections for drive supplied 24V power Fig 11 PF755 Main Control Board eA Fig 12A Jumper Wire Locations Frame 6 TEYA ANEN SW Fig 12B Jumper Wire Locations Frame 7 SERVICE ANWARNING DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touch ing any internal components Failure to observe this pre caution could
21. RED 1 I aam CLR SHOWN WIRED FOR 115V BLK 23 n GR tGRN WHT ZN ose ZA WHT wc 1 BLU COMP R OIL PUMP MOTOR RED e WINDING HIGH TEMPERATURE BLU RED e trEL1 SOLENOID RED ee 1 BLK GRY BLK BLK x 230V WIRING MODIFICATION HOT GAS BYPASS FR a1 6 HT EXCH EL 5 o N VOLTAGE 2 T 2 BLK 1 1 2 HP PER JOB BLK N M COMP R OIL REOM T x PUMP MOTOR 23 3 RED RED N x LEGEND CB Circuit Breater O D enotes Control Panel Terminal CCM Chiller Control Module HGBP Hot Gas Bypass Denotes Oil Pump Terminal ICVC International Chiller Visual Controller B Panel Terminal RHS Relative Humidity Sensor L enotes Fower Fane termina UPC Universal Protocol Controller Denotes Motor Starter Panel Conn VFD Variable Frequency Drive e Standard on LF2 drive optional on machines equipped with other VFDs Option Wiring 32 APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical POWERFLEX 755 POWER MODULE HP SEE TR CHARTA COMPRESSOR CIRCUIT BREAKER CBI MOV AC EMI CAP JPR PE A a aa 1030 CHASSIS COMMON MODE CAP JPR A2 ____ 1050 SEE USER MANUAL 480V 3PH 60HZ 5 L3 1060 AC LI
22. Sensor Fault Check Check humidity sensor wiring on CCM connec INPUT Humidity Sensor Input Sensor tors J3 and J5 CCM switch SW2 1 must be in OFF position Check Humidity Sensor Input in Controls Test LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 15 Table 5 ICVC Alarm Codes CHILLER PROTECTIVE LIMIT FAULTS ICVC FAULT STATE 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 PRIMARY SECONDARY MESSAGE M SSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY PROTECTIVE LIMIT RECTIFIER POWER 200 Rectifier Power Fault Malfunction within VFD Power Module FAULT Check VFD Status Contact Carrier Service PROTECTIVE LIMIT INVERTER POWER FAULT 201 gt Inverter Power Fault Malfunction within VFD Power Module Check VFD Status Contact Carrier Service PROTECTIVE LIMIT MOTOR AMPS 202 Motor Amps Not Check main circuit breaker for trip Increase SENSED Sensed Average Load Current Imbalance in VED CONF screen Current VALUE FAILURE TO START MOTOR ACCELERATION 203 Motor Acceleration Fault Check that inlet guide vanes are fully closed at Average Load Current start up VALUE Check Motor Rated Load Amps in VFED CONF screen
23. a voltmeter to ensure the DC bus capacitors are discharged before touch ing any internal components Failure to observe this pre caution could result in severe bodily injury or loss of life 1 Using recommended screwdriver 6 4 mm 0 25 in flat or T20 star open access door See Fig 17 2 Check to be sure that the voltage between DC and DC and from each DC terminal to the chassis 1s zero before proceeding See Fig 18 3 Remove the enclosure See Fig 19 MOVING 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 20 For 23XRV chillers see Fig 21 The drive weights are as follows Drive weight for Frame 6 85 lb Drive weight for Frame 7 160 249 Ib Fig 17 Open Access Door 2 A DC BUS TEST TERMINALS LOCATED INSIDE ACCESS DOOR SLIDE A ENCLOSURE vet FORWARD LOOSEN ENCLOSURE FASTENERS Fig 19 Removing Enclosure When replacing the drive reverse the procedures and tight en to the torques for the Frames 6 and 7 Power Terminal Block referred to in Table 8 Table 8 Frames 6 and 7 Power Terminal Block MAXIMUM LUG RE
24. and last controller on a network segment to add bias and prevent signal distortions due to echoing See Fig A D and E To wire the UPC Open controller to the BAS network 1 Pull the screw terminal connector from the controller s BAS Port 2 Check the communications wiring for shorts and grounds 3 Connect the communications wiring to the BAS port s screw terminals labeled Net Net and Shield NOTE Use the same polarity throughout the network segment 4 Insert the power screw terminal connector into the UPC Open controller s power terminals if they are not current ly connected 5 Verify communication with the network by viewing a module status report To perform a module status report using the BACview keypad display unit press and hold the FN key then press the key BT485 Terminator Fig D Network Wiring 36 APPENDIX B BACNET COMMUNICATION OPTION cont BACnet Shield 2 Port S1 ID BACnet MS TP EIA 485 4 2222 485 2wire Fig E BT485 Terminator Installation To install a BT485 terminator push the BT485 terminator on to the BT485 connector located near the BACnet connector NOTE The BT485 terminator has no polarity associated with it To order a BT485 terminator consult Commercial Products i Vu Open Control System Master Prices MS TP WIRING RECOMMENDATIONS Recommen dations are shown in Tables C and D The wire jacket and UL temperature rating specificat
25. for proper VFD cooling fan operation and blockage LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 13 Table 4 ICVC Alert Codes cont CHILLER ALERTS ICVC FAULT STATE 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 PRIMARY SECONDARY MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY SENSOR ALERT LEAVING COND WATER 140 Sensor Fault Check Check sensor resistance or voltage drop TEMP Leaving Cond Water Sensor for proper wiring SENSOR ALERT ENTERING COND WATER 141 gt Fault Check Check sensor resistance or voltage drop TEMP Entering Cond Water Sensor Check for proper wiring LOW OIL CHECK OIL FILTER PRESSURE ALERT 142 Oil Pressure Alert Check for partially or closed shut off valves Check Oil Filter Check oil filter Check oil pump and power supply Check oil level Check for foaming oil at start up Check transducer wiring and accuracy AUTORESTART LINE CURRENT 143 Line Current Imbal Power loss has been detected in any phase PENDING IMBALANCE ance Check VFD Fault His Chiller automatically restarting tory for Values AUTORESTART LINE VOLTAGE 144 Single Cycle Line A drop in line
26. result in severe bodily injury or loss of life Troubleshooting the Drive The drive can display two kinds of error codes on the ICVC called the Alert and Alarm codes These codes signal a problem detected during self tuning or drive operation Note the following differences between Carrier and Allen Bradley terminology A warning message on the ICVC is an ALERT Thesame warning viewed with Rockwell Drive Explorer is a VFD ALARM A failure resulting in a shutdown is seen as an ALARM on the ICVC and as a VFD FAULT when viewed with Drive Explorer CONDITION CODES ICVC ALERT VFD ALARM ICVC ALARM FAULT See Tables 3 6 and Fig 13 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 Table 4 ICVC ALARM CODES An alarm condition is also indi cated by a message at the top of the ICVC default screen If an alarm occurs the drive coasts to stop The STS status light on the drive will turn from Green to Red or Yellow see Table 3 The detected fault message is maintained on the display until it is c
27. temperature CONDENSER PUMP RELAY 151High Condenser Pres sensor wiring and accuracy PRESSURE ALERT ENERGIZED sure VALUE Pump Ener Check condenser flow and water temperature gized to Reduce Pressure Check for fouled tubes This alarm is not caused by the High Pressure Switch RECYCLE ALERT EXCESSIVE RECYCLE 152 Excessive recycle Chiller load is too low to keep compressor on STARTS starts line and there has been more than 5 starts in 4 hours Increase chiller load adjust hot gas bypass increase RECYCLE RESTART DELTA T from SETUP1 Screen no message no message ALERT only 153 Lead Lag Disabled Illegal chiller address configuration in Lead Lag ALERT Config Duplicate Chiller screen Both chillers require a different address only Address 154 Condenser freeze up The condenser pressure transducer is reading a prevention pressure that could freeze the condenser tubes Check for condenser refrigerant leaks Check fluid temperature Check sensor wiring and accuracy Place the chiller in PUMPDOWN mode if the vessel is evacuated OPTION SENSOR REMOTE RESET 155 Sensor Fault Option Check sensor resistance or voltage drop FAULT SENSOR Disabled Remote Reset Check for proper wiring to CCM connector J4 Sensor OPTION SENSOR AUTO CHILLED WATER 156 Sensor Fault Option Check sensor resistance or voltage drop FAULT RESET Disabled Auto Chilled Water for proper wiring to CCM connector J5 Reset O
28. voltage has been detected within PENDING DROP OUT Voltage Dropout 2 voltage cycles Chiller automatically restarting if Auto Restart is enabled in OPTIONS screen AUTORESTART HIGH LINE VOLTAGE 145 gt Percent Line Check phase to phase and phase to ground line PENDING Voltage VALUE power AUTORESTART LOW LINE VOLTAGE 146Low Percent Line Check phase to phase and phase to ground line PENDING Voltage VALUE power AUTORESTART VFD MODULE RESET 147 2 VFD Module Power On VFD Module has detected a hardware fault due PENDING Reset When Running to electrical noise power loss or software and has reset Chiller automatically restarting Check for power loss and sources of electro magnetic interference AUTORESTART POWER LOSS 148 Control Power Loss Check 24 vac control power supply to ICVC PENDING When Running SENSOR ALERT HIGH DISCHARGE TEMP 149 Comp Discharge Temp Check sensor resistance or voltage drop VALUE Exceeded Limit of Check for proper wiring LIMIT Check for proper inlet guide vane and optional diffuser actuator operation Check for proper condenser flow and temperature Check for high lift or low load Check for fouled tubes or noncondensables in the chiller SENSOR ALERT HIGH BEARING 150 Comp Thrust Brg Temp Check sensor resistance or voltage drop TEMPERATURE VALUE exceeded limit of Check for proper wiring LIMIT Check for partially closed service valves Check oil cooler TXV Check oil level and oil
29. 19XRV 23XRV with PIC Controls Rockwell PowerFlex 755 VFD Option Start Up and Service Instructions SAFETY CONSIDERATIONS A DANGER Centrifugal and screw compressor liquid chillers are designed to provide safe and reliable service when oper NEVER EXCEED specified test pressures VERIFY the allowable test pressure by checking the instruction litera ated within design specifications When operating this equipment use good judgment and safety precautions ture and the design pressures on the equipment nameplate to avoid damage to equipment and property or injury to personnel DO NOT USE air for leak testing Use only refrigerant or Be sure you understand and follow the procedures dry nitrogen and safety precautions contained in the chiller instruc 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 t
30. 1A 600A CARRIER 400HP 477A 600A 1310 FACTORY PANEL WIRING LEGEND CAP Capacitor CB Circuit Breaker COM Common COMM Communication COND Condenser CR Control Relay DPI SI Internal Communication Protocols Connections EA Electrical Assembly EMI Electro Magnetic Interference EVAP Evaporator FU Fuse GND Ground JMPR Jumper M Motor NC Normally Closed NO Normally Open PE Potential Earth Ground POD 1 Card Mounting Slot Board REM Remote ROC Relay Output Common SHLD Shield TB Terminal Block Located outside of starter connected by field wiring 34 APPENDIX B BACNET COMMUNICATION OPTION The following section is used to configure the UPC Open con troller which is used when the BACnet communication option is selected The UPC Open controller is mounted in v separate enclosure below the main control box 10 s TO ADDRESS THE UPC OPEN CONTROLLER 9g user must give the UPC Open controller an address that is unique on the BACnet network Perform the following proce QM Fe dure to assign an address 5 C 1 1 Ifthe UPC Open controller is powered pull the screw ter connector from the controller s power terminals la S beled Gnd and HOT The controller reads the address each time power is applied to it 2 Using the rotary switches see Fig A and B set the con tro
31. ARY SECONDARY mi MESSAGE MESSAGE PRIMARY PRIMARY CAUSE ADDITIONAL CAUSE REMEDY SENSOR FAULT LEAVING CHILLED WATER oe Fault Check Check sensor resistance or voltage drop Leaving Chilled Water Sensor Check for proper wiring Check for disconnected or shorted wiring 261 SENSOR FAULT ENTERING CHILLED 261 gt Fault Check Check sensor resistance or voltage drop WATER Entering Chilled Water Check for proper wiring Sensor Check for disconnected or shorted wiring 262 SENSOR FAULT CONDENSER PRESSURE 262 gt 5 Fault Check Check sensor wiring Condenser Pressure Sensor Check for disconnected or shorted wiring Check for condensation in transducer connector 263 SENSOR FAULT EVAPORATOR 263 gt Fault Check Check sensor wiring PRESSURE Evaporator Pressure Sensor Check for disconnected or shorted wiring Check for condensation in transducer connector 264 SENSOR FAULT COMPRESSOR BEARING 264 gt Fault Check Check sensor resistance or voltage drop TEMP Comp Thrust Brg Temp Sensor Check for proper wiring Check for disconnected or shorted wiring 265 SENSOR FAULT COMPRESSOR MOTOR 265 Sensor Fault Check Check sensor resistance or voltage drop TEMP Comp Motor Winding Temp Check for proper wiring Sensor Check for disconnected or shorted wiring 266 SENSOR FAULT COMP DISCHARGE TEMP 266 gt 5 Fault Check Check sensor resistance or voltage drop Comp Discharg
32. COMMENDED TERMINAL WIDTH TORQUE BOLT SIZE 34 6 mm 1 36 in 11 3 Nem 100 in Ib M8 x 1 25 43 5 mm 1 71 in 11 3 Nem 100 in Ib M8 x 1 25 RIGGING THE ENCLOSURE Where overhead room and or clearance in front of the drive enclosure is insufficient to allow the drive to be safely removed from the enclosure the entire enclosure may have to be removed from the chiller The dimensions and weights specified must be taken into consideration when removing the enclosure 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 AII 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 22A and Fig 22B DRIVE RIGGING ACCESS DRIVE WIDTH 4 IN E 21N DRIVE RIGGING ACCESS DRIVE POSITIONED FOR VERTICAL LIFT DRIVE EXTENDS BEHIND MAIN ENCLOSURE g mick SUPPORT FROM BELOW SIDE VIEW Fig 20 19XRV Enclosure Access for Removing Drive 25 ENCLOSURE TOP FRONT CORNER OF IS REMOVABLE DRIVE COMPARTMENT IS B 6 4 G DRIVE POSITIONED FOR VERTICAL LIFT _ DRIVE EXTENDS BEHIND x MAIN ENCLOSURE BW
33. ER screen must be VALUE Exceeded Configura maintained between 45 52 Hz if LINE tion Range FREQ 60Hz is set to NO 50 Hz LINE FRE QUENCY must be maintained between 55 62 Hz if LINE FREQ 60Hz is set to YES 60 Hz Check high pressure switch and connections to TB4 24 and TB4 25 283 Compressor 100 COMPRESSOR 10096 SPEED in VFD CONF Speed Config Ranges 50 Hz screen must be set between 45 52 Hz if LINE 45 52 60 Hz 55 62 60 2 is set to NO 50 Hz COMPRES SOR 100 SPEED must be set between 55 62 Hz if LINE FREQ 260HZ is set to YES 60 Hz 284 VFD GATEWAY COMPATIBILITY 284 VFD Gateway Compati VFD Gateway and VFD software versions CONFLICT bility Conflict Check VFG not compatible VFD Versions Contact Carrier Service 285 VFD GATEWAY COMPATIBILITY 2855 VFD Gateway Compati VFD Gateway and ICVC software versions are CONFLICT bility Conflict Check VFG not compatible ICVC Versions Contact Carrier Service 286 PROTECTIVE LIMIT INVERTER 286 gt Overcurrent Check for high entering water temperature or OVERCURRENT Fault Check VFD Status low condenser water flow Check current settings in VFD_CONF screen LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped OUT OF RANGE SENSOR ICVC FAULT PRIM
34. H VALUE Exceeded Limit of waterbox division plate gaskets are sealing LIMIT evaporator tubes are not fouled and that oil reclaim system is working Check sensor resistance or voltage drop Check for proper wiring Check Evap Approach Alert setting in SETUP1 Screen CONDENSER APPROACH 163 Condenser Approach Check sensors resistance or voltage drop VALUE Exceeded Limit of Check for proper wiring LIMIT Check Cond Approach Alert setting in SETUP1 Screen Check for noncondensable gas in the condenser Check that the condenser tubes are not fouled 164 VFD SPEED ALERT LOW VFD SPEED 164 Actual VFD Speed Actual VFD Speed on COMPRESS screen must exceeded limit of Target VFD be at least 90 of Target VFD Speed Speed 10 165 AUTORESTART LOW DC BUS VOLTAGE 165Low DC Bus Voltage Verify phase to phase and phase to ground line PENDING VALUE Exceeded Limit of voltage LIMIT 166 AUTORESTART HIGH DC BUS VOLTAGE 166 High DC Bus Voltage Verify phase to phase and phase to ground line PENDING VALUE Exceeded Limit of voltage Monitor AC line for high transient volt LIMIT age conditions 167 SYSTEM ALERT HIGH DISCHARGE TEMP 167 gt Discharge Temp Check sensor resistance or voltage drop VALUE exceeded limit of Check for proper wiring LIMIT Check for excessive starts Check Comp Discharge Alert setting in SETUP1 162 163 SENSOR ALERT Screen 168 SENSOR ALERT HUMIDITY SENSOR 168
35. HUMIDITY in POWER screen Check for moisture in VFD enclosure Check Humidity Sensor in CONTROLS TEST Check for contamination on CCM J3 7 and J3 9 Humidity Sensor Check that VFD refrigerant cooling modulating valve is closing PROTECTIVE LIMIT INDUCTOR OVERTEMP 256lnductor Overtemp Trip Check for cooling fan air flow obstructions Check Temp Switch and Cool ing Fans PROTECTIVE LIMIT VFD START INHIBIT 257 VFD Start Inhibit Check The VFD Start Inhibit is derived from the Alarm VFD Diagnostic Parameters bit being set in the VFD The conditions causing 212 214 the alarm must be corrected in the VFD to enable subsequent starts and operation See VFD parameters 212 214 UNUSED STATE UNUSED 258 Unused LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 19 Table 5 ICVC Alarm Codes cont CHILLER PROTECTIVE LIMIT FAULTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 259 PROTECTIVE LIMIT OVERRIDE STOP 259 gt Emergency has signaled the chiller to stop This fault Override Stop must be manually reset from the default screen of the ICVC 282 PROTECTIVE LIMIT INVALID VFD CONFIG 2825Line Frequency LINE FREQUENCY in POW
36. IMIT is shown on the ICVC as temperature pressure voltage etc predefined or selected by the operator as an override or an alert VALUE is the actual pressure temperature voltage etc at which the control tripped 12 NORMAL RUN WITH OVERRIDES ICVC FAULT STATE 120 121 122 123 124 125 126 127 128 PRIMARY MESSAGE RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED RUN CAPACITY LIMITED HIGH CONDENSER PRESSURE HIGH MOTOR TEMPERATURE LOW EVAP REFRIG TEMP HIGH COMPRESSOR LIFT MANUAL GUIDE VANE TARGET LOW DISCHARGE SUPERHEAT HIGH RECTIFIER TEMP MANUAL SPEED CONTROL HIGH INVERTER TEMP Table 4 ICVC Alert Codes cont PRIMARY CAUSE 120 Condenser Pressure VALUE exceeded limit of LIMIT SECONDARY MESSAGE 121 Comp Motor Winding Temp VALUE exceeded limit of LIMIT 122 Evaporator Refrig Temp VALUE exceeded limit of LIMIT 123 Surge Prevention Override Lift Too High For Compressor 124 Run Capacity Limited Manual Guide Vane Target No Alert message 126 Rectifier Temperature VALUE exceeded limit of LIMIT No Alert message 128 Inverter Temperature VALUE exceeded limit of LIMIT ADDITIONAL CAUSE REMEDY Check condenser water pump operation Check for hig
37. IST FAULT TYPE DESCRIPTION CORRECTIVE ACTION SCREEN Heatsink temperature sensor is reporting a value 168 206 below 18 7 1 66 F or the sensor feedback sensor Check heat p circuit is open p 210 HW En Jumper See VFD Fault Code 15 See VFD Fault Code 15 zn See VFD Fault Code 15 213 See VFD Fault Code 15 291 See VFD Fault Code 15 292 See VFD Fault Code 15 293 See VFD Fault Code 15 294 See VFD Fault Code 15 295 See VFD Fault Code 15 296 See VFD Fault Code 15 315 See VFD Fault Code 15 316 See VFD Fault Code 15 Checking Power Modules and Motor Input with Input Power Off Use the following procedure to check the drive s power module circuitry with power off 1 Turn off and lock out input power Wait five minutes Table 7 Diode Chocks METER LEAD 2 Verify there is no voltage at the drive s input power termi a o METER READING ak infinite 3 Using a voltmeter check the DC bus potential as de R DC Infinite OL scribed above to ensure the DC bus capacitors are dis Infinite OL charged ii DC Infinite OL 4 Disconnect the motor from the drive Infinite OL 5 Check all AC line and DC bus fuses t DC Infinite OL 6 Use a multimeter to check the input diodes and output U 0 5 V IGBTs ifa fuse is open See Table 7 DC infinite OL 7 Check motor impedance V 0 5 V 8 Reconnect the motor to the drive DC Infinite 0 5 V 9 Reapply input power W DC Infini
38. IT valves or clogged oil filter Check oil cooler refrigerant thermal expansion valves Confirm that TXV thermostatic expansion valve bulb is secured in place and insulated Check for sensor wiring and accuracy This fault can result from extended operation at low load with low water flow to the evaporator or condenser 235 PROTECTIVE LIMIT HIGH CONDENSER 235 gt Pressure Check for high condenser water temperatures low PRESSURE VALUE exceeded limit of water flow fouled tubes LIMIT Check for division plate gasket bypass Check for noncondensables Check transducer wiring and accuracy 236 PROTECTIVE LIMIT COMPRESS SURGE 236 Compressor Surge Check for high condenser water temperatures low LOW SPEED Check condenser water temp water flow fouled tubes and flow Check for division plate gasket bypass Check for noncondensables Check surge prevention parameters in OPTIONS screen Increase VFD Increase Step in SETUP2 Check VFD Minimum Speed in SETUP2 screen 237 PROTECTIVE LIMIT SPARE SAFETY 237 gt 5 Safety Device Spare safety input has tripped or factory installed DEVICE jumper is not present on Terminal Block 4 terminals 17 and 20 in the VFD enclosure 238 PROTECTIVE LIMIT EXCESSIVE COMPR 238 Compressor Surge Check for high condenser water temperatures low Check condenser water temp water flow fouled tubes and flow Check for division plate gasket bypass Check for noncondensables C
39. IT INVALID DIFFUSER 246 gt Control Invalid Check 25 50 and 75 Guide Vane and Dif CONFIG Configuration Check SETUP2 fuser Load Point entries in SETUP2 screen Entries PROTECTIVE LIMIT DIFFUSER POSITION 247 Diffuser Position Fault Confirm that Diffuser Option in SETUP 2 screen Check Guide Vane Diffuser has not been Enabled if compressor does not Actuator have a split ring diffuser May indicate rotating stall condition Check rotating stall transducer wiring accuracy and sealing Check diffuser schedule and guide vane sched ule in SETUP2 screen Check for proper operation of diffuser and inlet guide vane actuators including inlet guide vane calibration Check diffuser actuator coupling for rotational slip Check RC snubber on CCM J4 23 and J4 24 Check 4 3k ohm resistor between termi nals J3 7 and J3 8 Check for electrical noise in CCM Diffuser Pres sure wiring Do not continue to operate com pressor except for diagnostic purposes PROTECTIVE LIMIT SPARE TEMPERATURE 248 Spare Temperature 1 Check Spare Temperature Enable and Spare 1 VALUE exceeded limit of Temperature Limit in SETUP1 Screen LIMIT PROTECTIVE LIMIT SPARE TEMPERATURE 249 Spare Temperature 2 Check Spare Temperature Enable and Spare 2 VALUE exceeded limit of Temperature Limit in SETUP1 Screen LIMIT UNUSED UNUSED 250 Unused State PROTECTIVE LIMIT VFD CONFIG CONFLICT 251 VFD Config Conf
40. ND WIRING ICE BUILD TB4 TB4 1070 5 Sub WEE NEA SHIELD 9 REMOTE START p 4 256 85 RED 10 13 SIGNAL COM 1010 3 5 255 2 BLACK comm 241 240 SONAL B sup 4 254 254 WHITE TB4 1 17 TB4 gt NEG 1 ANALOG SIGNAL A orance 33 288 341 120 PRESSURE 1 SHLD gt REFERENCE V TB4 4 20mA TERM OIL INT LOCK 1011 3 TB4 14 DIL INT LDCK EVAP_ PUMP CRI Ng Ng 1 22 1 1011 TB4 6 1010 3 20 COMM CARRIER ADAPTER TRIP ALARM CAT 20 750 20 0 1 6 NO 1 22 NC 24VDC DELUXE 1 0 5 SLOT 5 EVAP PUMP TRIP ALARM ii gap rea 1223 1 17 1 20 POWERFLEX 755 Taj 4 4 MAIN CONTROL BOARD 20 21 23 dis 1 TEC M v J v 2 24 POWER EVAP PUMP TRIP ALARM H 781 5 000 120VAC COND PUMP CR4 1 4 ODI COMMON 1281 1282 DI COMMO 1 34 TOWER FAN LOW TOWER FAN HIGH m TB4 190 1291 1992 1293 TR TB 243 18 19 E P 35h d 36 We 1 34 1 37 COND PUNE 1310 TB4 TB4 TB4 TB4 BLACK SEE Lerown 1 TB4 25 26 27 DETAIL L 24V COMMON J 2 B 15 Y WO TOWER FAN LOW TOWER FAN HIGH COND PUNR 1 28 er z POWER MAIN 4 NC 1340 1341 NC PANEL CIRCUITE ma _ o 0 185 BREAKER DRIVE 1224 1224 HP RATING SIZE TOWER FAN HIGH 200HP 248A 6004 360 NO1 29 aeL 7 C NC T 300HP 36
41. NES SETTINGS LH AMPS SEE CHART N AS SHIPPED COMMON MODE 600VOLTS CAP JUMPER OUT mE OZ LINE PE aL J1 HARDWARE ENABLE CHASSIS SETTINGS Ex ENCLOSURE ENCLOSURE AS SHIPPED J2 SAFETY ENABLE EMBEDDED ETHERNET e HUNDREDS 1062 EMBEDDED DPI ETHERNET ADAPTER ROTARY SWITCHES Ju PORT 2 AS SHIPPED SETTINGS CONTROL BREAKER CB2 2218 TB4 YELLOW 48 epp _ TB4 BLACK OIL PUMP 45 CONTACTOR ep 184 RED 15 AMPS 600 VOLTS 240 480 VAC 3000 VA 110 120 VAC Q 224 120VAC H P 226 BLACK T 20 OIL HEATER CONTACTOR 38 40 CLASS 8e D WHITE FU2 TB4 1 5 42 43 600V NOT CLASS CC n USED FAN 2250 T 45 46 Eon 145 CFM 145 CFM CLASS CC 115 VAC 115 VAC ENCLOSURE FANS 33 APPENDIX A WIRING SCHEMATICS cont ROCKWELL POWERFLEX 755 WIRING SCHEMATIC Typical cont EAT EAT DETAIL A DRIVE CONTROL POD SLOT 4 DRIVE CONTROL POD SLOT 6 CONTROL 1 0 COMMUNICATION POWER EA1 4 24VDC DELUXE 1 0 RECOMM CARRIER RS485 DFT 4 6 PANEL THDPI SI SLOT 4 DPI SI SLOT 6 79 34 50 TBt44 JUMPER CARRIER GATEWAY CARD TB4 33 B1 SPARE SAFETY CARRIER POWER 4 4 TB4 9784 oer E FACTORY PANEL 8 CHASSIS G
42. O NOT VALVE 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 ANWARNING 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 a
43. PED LIFT POINTS FOR REMOVABLE EYE BOLTS NOT SUPPLIED WITH VFD AIR EXHAUST VENT L p METER PACKAGE AIR EXHAUST VENTS I perum AC VOLTMETERS AND AC AMMETER WITH PHASE SELECTOR SWITCH OPTIONAL I 2 50 VFD WIRING IZ A DIAGRAM T 5 51 ys 1 16 2 50 12 00 CHANNEL POWER DISCONNECT HANDLE FRONT VIEW HANDLE FOR STANDARD CIRCUIT BREAKER SHOWN CIRCUIT BREAKER IS SHIPPED PACKAGED INSIDE VFD NOTE Dimensions shown in inches Fig 8 23XRV Enclosure Dimensions Frame 7 6 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 th
44. PTION SENSOR AUTO DEMAND LIMIT 157 Sensor Fault Option Check sensor resistance or voltage drop FAULT INPUT Disabled Auto Demand Limit Check for proper wiring to CCM connector J5 Input SENSOR ALERT SPARE TEMPERATURE 1 158 gt 5 Temperature 1 Check sensor resistance or voltage drop 1 VALUE exceeded limit of Check for proper wiring to CCM connector J4 LIMIT Check Spare Temp 1 Limit in SETUP1 screen POTENTIAL COND PRESS TEMP FREEZE UP TOO LOW LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 14 Table 4 ICVC Alert Codes cont CHILLER ALERTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 159 SENSOR ALERT SPARE TEMPERATURE 1 159 gt 5 Temperature 2 Check sensor resistance or voltage drop 2 VALUE exceeded limit of Check for proper wiring to CCM connector J4 LIMIT Check Spare Temp 2 Limit in SETUP1 screen 161 LOSS OF WITH WSM 1615 WSM Cool Source Check settings in WSMDEFME screen COMMUNICATION Loss of Communication Check CCN communications link with WSM Water System Manager Module Check Supervisory Part of WSM SENSOR ALERT EVAPORATOR 162Evaporator Approach Check that refrigerant charge level is adequate APPROAC
45. and verify load limit set tings on the ICVC Check motor and wiring insulation c Check parameter settings on VFD CONF screen in the 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 11 There are two jumper wires that connect a particular termi nal to chassis ground The MOV and AC EMI jumper should be connected to the PE A terminal The COMMON MODE CAPACITORS to GROUND jumper should be connected to a standoff rather than the PE B terminal Use the recommended tools as follows when connecting jumper wires in Frame 6 and in Frame 7 e Recommended torque screws and nuts 1 36 Nem 120 0 Ib in Recommended hex socket 7 mm Recommended screwdriver T20 star type See Fig 12A and Fig 12B for the correct positions of the jumpers LEGEND DESCRIPTION HIM Connector DPI Port 1 HIM Cradle connection Fan Connector Power supply for internal cooling fan Frames 2 and 3 Battery User installed CR1220 lithium coin cell battery provides power to the Real Time Clock Optional not supplied 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
46. arts Depress the RESET softkey if additional start ALERT EXCEEDED 8 in 12 hours is required Reassess start up requirements 101 PRESTART HIGH BEARING 101 Comp Thrust Brg Temp VALUE Check oil heater for proper operation ALERT TEMPERATURE exceeded limit of Check for low oil level partially closed oil sup ply valves clogged oil filters Check the sensor wiring and accuracy Check Comp Thrust Brg Alert setting in SETUP1 screen 102 PRESTART HIGH MOTOR 102 Comp Motor Winding Temp Check motor sensors for wiring and accuracy ALERT TEMPERATURE _ VALUE exceeded limit of LIMIT Check motor cooling line for proper operation or restrictions Check for excessive starts within a short time span Check Comp Motor Temperature Override setting in SETUP1 screen 103 PRESTART HIGH 103 Comp Discharge Temp VALUE Allow discharge sensor to cool ALERT DISCHARGE exceeded limit of LIMIT Check sensor wiring and accuracy TEMP Check for excessive starts Check Comp Discharge Alert setting in SETUP1 screen 104 PRESTART LOW 104 Evaporator Refrig Temp VALUE Check transducer wiring and accuracy ALERT REFRIGERANT exceeded limit of LIMIT Check for low chilled fluid supply TEMP temperatures Check refrigerant charge Check Refrig Override Delta T in SETUP1 screen 105 PRESTART LOW OIL 105 gt Sump Temp VALUE Check oil heater contactor relay and power ALERT TEMPERATURE exceeded limit of LIMIT Check oil level and oi
47. between DC and DC TOP 5 and from each DC terminal to the chassis is zero before Part Identification and Location See Fig 28 31 proceeding See Fig 18 for parts descriptions and locations 3 Remove the enclosure See Fig 19 TB1 TB2 SECONDARY SIDE 4 TOWARD DOOR FRONT VIEW LEFT SIDEWALL DOOR REMOVED VIEW FROM INSIDE LEGEND Power Module Input Circuit Breaker 15 Amp Control Circuit Breaker Control Fuses 1 2 3 4 Control Transformer 5 6 Control Relays CR1 CR6 Fig 28 19XRV Assembly Parts 27 5 eoooc 0008 22229 seco E o ooooo 5050 9 oOeeoo oooeo 5 ocoooo ooooo 606550 o oo0o0o0 o LINEdPE PS1 FU4FUS Cc 5 FRONT VIEW DOORS REMOVED RIGHT SIDEWALL INSIDE VIEW 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 29 23XRV Assembly Parts 28 quA ON Y B d LA LEGEND 1 PF750 Series Precharge Kit 2 PF750 Series Gate Interface 3 PF750 Series Power Interface 4 PowerFlex 750 Series Flange Gasket 5 PF755 Main Control Board 6 PF750 Series Backplane Interface 7 PF750 S
48. d accuracy Pressure VALUE Check Oil Check power supply to pump Pump and Filter Check pump operation Check oil level Check for partially closed service valves Check oil filters Check for foaming oil at start up Check transducer calibration 229 PROTECTIVE LIMIT LOW CHILLED WATER 229Low Chilled Water Flow Perform pump control test FLOW Check Switch Delta P Config Check optional transducer calibration and amp Calibration wiring Check Evaporator Refrigerant Temperature sensor Check chilled water valves Check for evaporator saturation temperature lt 34 F if not in Pumpdown Lockout mode Place unit in Pumpdown mode before removing charge 230 PROTECTIVE LIMIT LOW CONDENSER 230 Low Condenser Water Perform pump control test WATER FLOW Flow Check Switch Delta P Check optional transducer calibration and Config amp Calibration wiring Check condenser water valves Check for COND PRESS OVERRIDE 5 psig 231 PROTECTIVE LIMIT HIGH DISCHARGE TEMP 231 gt Discharge Temp for closed compressor discharge isola VALUE Exceeded Limit of tion valve LIMIT Check if chiller was operating in surge Check sensor resistance or voltage drop Check for proper wiring Check for proper condenser flow and temperature Check compressor discharge isolation valve Check for proper inlet guide vane and optional diffuser actuator operation 232 PROTECTIVE LIMIT LOW REFRIGERANT 232Evaporator Refri
49. d side current imbalance when running at full load Check entering condenser water temperature and water flow rate Check Motor Rated Load Amps in VFD_CONF screen PROTECTIVE LIMIT VFD RECTIFIER 2189 VFD Rectifier Temp Check that VFD refrigerant isolation valves are OVERTEMP Exceeded Check Cooling and open VFD Config Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage PROTECTIVE LIMIT VFD INVERTER 2195 VFD Inverter Temp Check that VFD refrigerant isolation valves are OVERTEMP Exceeded Check Cooling and open VFD Config Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped NOTE ICVC Alarms 212 226 are declared as a result of VFD Faults 16 Table 5 ICVC Alarm Codes cont CHILLER PROTECTIVE LIMIT FAULTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 220 PROTECTIVE LIMIT GROUND FAULT 220 Ground Fault Trip Check for condensation on motor terminals Check Motor and Current Check motor power leads for phase to phase or Sensors phase to ground shorts
50. discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53190027 01 Printed in U S A Form 19 23 4SS Pg 44 4 13 Replaces 19 23 2SS
51. e Temp Sensor Check for proper wiring Check for disconnected or shorted wiring 267 SENSOR FAULT OIL SUMP TEMP 267 gt Fault Check Check sensor resistance or voltage drop Sump Temp Sensor Check for proper wiring Check for disconnected or shorted wiring 268 SENSOR FAULT COMP OIL PRESS DIFF 268 Sensor Fault Check Oil Check sensor resistance or voltage drop Pump Delta P Sensor Check for proper wiring Check for disconnected or shorted wiring 269 SENSOR FAULT CHILLED WATER FLOW 269 Sensor Fault Check Check sensor wiring and accuracy Chilled Water Delta P Sensor Check for disconnected or shorted wiring If pressure transducers are not installed check for presence of resistors and jumpers on lower CCM terminal block J3 270 SENSOR FAULT COND WATER FLOW 270 Sensor Fault Check Check sensor wiring and accuracy Cond Water Delta P Sensor Check for disconnected or shorted wiring If pressure transducers are not installed check for presence of resistors and jumpers on lower CCM terminal block J3 271 SENSOR FAULT EVAP SATURATION TEMP 271 gt Fault Check Check sensor resistance or voltage drop Evap Saturation Temp Sensor Check for proper wiring Check for disconnected or shorted wiring 20 283 PROTECTIVE LIMIT INVALID VFD CONFIG VFD FAULT CODE ON VFD HIST SCREEN NONE 0 N 12 13 15 17 20 21 24 33 36 Table 6
52. e controller s power termi nals labeled Gnd and HOT The controller reads the DIP Switches and jumpers each time power is applied to it Set the BAS Port DIP switch DS3 to enable Set the BAS Port DIP switch DS4 to EIA 485 Set the BMS Protocol DIP switches 058 through 055 to MSTP See Table A Table A SW3 Protocol Switch Settings for MS TP DS8 DS7 056 055 054 DS3 off off Verify that the EIA 485 jumpers below the CCN Port are set to EIA 485 and 2W The example in Fig C shows the BAS Port DIP Switches set for 76 8k Carrier default and MS TP Set the BAS Port DIP Switches DS2 and DS1 for the appro priate communications speed of the MS TP network 9600 19 2k 38 4k or 76 8k bps See Fig C and Table B Table B Baud Selection Table BAUD RATE DS1 9 600 Off 19 200 Off 38 400 On 76 800 On WIRING THE UPC OPEN CONTROLLER TO THE MS TP NETWORK The UPC Open controller communicates using BACnet on an MS TP network segment communications at 9600 bps 19 2 kbps 38 4 kbps or 76 8 kbps Terminator BACnet MS TP m 485 Enable 76 8k baud rate Fig C DIP Switches Wire the controllers on an MS TP network segment in a dai sy chain configuration Wire specifications for the cable are 22 AWG American Wire Gage or 24 AWG low capacitance twisted stranded shielded copper wire The maximum length is 2000 ft Install a BT485 terminator on the first
53. e 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 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 In the case where the incoming power wire size does not fit the standard lug alternate lugs may be used See Table 1 Note that lugs rated for a higher current than the circuit breaker may be used Table 1 Wire Lugs CIRCUIT STANDARD STANDARD ALrernarTe ALTERNATE BREAKER ABBLUG UGCABLE LUGCABLE 65 KAIC Standard 3 2 0 400 2 250 500 100 KAIC K6TH Optional Verify Installation Record the following job information 1 Job Name 2 Job Number City State Zip Code Ww we 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
54. ed 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 START UP us coste LER HEURE ERE 7 9 Alternate Wire 605 7 Verify 7 Configure the 8 Commissioning the Unit 8 Check Internal Jumpers 8 10 30 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 23 Servicing the 24 REMOVING THE DRIVE RIGGING THE ENCLOSURE REPLACING THE GATEWAY A B20 750 20COMM OPTION CARD CHILL PLATE FAN AND INTERNAL FAN REPLACEMENT Parts Identification and Location 27
55. er NEC National Electrical Code O D Outside Diameter TC Tinned Copper UL Underwriters Laboratories 37 Halar 40 to 302 F 40 to 150 C APPENDIX B BACNET COMMUNICATION OPTION cont Table D Open System Wiring Specifications and Recommended Vendors WIRING SPECIFICATIONS Wire Type Description 22 AWG single twisted shielded pair low capacitance CL2P TC foam FEP plenum rated See MS TP Installation Guide for MS TP specifications Network RS 485 24 AWG single twisted shielded pair low capacitance TC foam FEP plenum rated See MS TP Installation Guide for specifications Rnet AWG CL2P Class 2 Plenum Cable CMP Communications Plenum Rated FEP Fluorinated Ethylene Polymer TC Tinned Copper LOCAL ACCESS TO THE UPC OPEN CONTROL LER The user can use a BACview handheld keypad dis play unit or the Virtual BACview software as a local user inter face to an Open controller These items let the user access the controller network information These are accessory items and do not come with the UPC Open controller The unit connects to the local access port on the UPC Open controller See Fig F The BACview software must be running on a laptop computer that is connected to the local access port on the UPC Open controller The laptop will re quire an additional USB link cable for connection See the BACview Installation and User Guide fo
56. eries Type 4X 12 Chill Plate 8 Chill Plate Fan marked J1 HARDWARE ENABLE must be removed and the jumper NOTE When replacing the Main Control Board Item No 5 the jumper marked J2 SAFETY ENABLE must be left in place Heatsink Fan Kit Fig 30 Frame 6 Parts 29 LEGEND Slot for Gateway Gateway Not Shown PF750 Series Backplane Interface PF750 Series Type 4X 12 Heatsink Fan Kit PF750 Series Power Interface PF750 Series Bus Cap Assembly PF750 Series Power Interface Cable PF750 Series Current Transducer Kit PF750 Series Precharge Kit 9 Slot for 24V I O Module 24V I O Module Not Shown 10 PF755 Main Control Board NOTE When replacing the Main Control Board Item No 10 the jumper marked J1 HARDWARE ENABLE must be removed and the jumper marked J2 SAFETY ENABLE must be left in place Fig 31 Frame 7 Parts 30 Aa Ee 4 P Uu 77 42 UR S m XA SS Mm os oe a APPENDIX A WIRING SCHEMATICS CHILLER CONTROL SCHEMATIC
57. g Temp Check for proper refrigerant charge TEMP VALUE exceeded limit of Check float valve operation LIMIT Check for closed condenser liquid line isolation valve If problem occurs at high load check for low condenser pressure which causes inade quate flasc orifice differential pressure Check for proper water flow and temperature Confirm that condenser water enters bottom row of condenser tubes first Check Evaporator Refrigerant Temperature sensor Check for division plate gasket bypass Check for fouled tubes LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 17 Table 5 ICVC Alarm Codes cont CHILLER PROTECTIVE LIMIT FAULTS cont ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY 233 PROTECTIVE LIMIT HIGH MOTOR 233 Comp Motor Winding Check motor sensors wiring and accuracy TEMPERATURE Temp VALUE exceeded Check motor cooling line and spray nozzle for limit of LIMIT proper operation or restrictions Check for excessive starts within a short time span 234 PROTECTIVE LIMIT HIGH BEARING 234 gt Thrust Brg Temp Check oil heater for proper operation TEMPERATURE VALUE exceeded limit of Check for low oil level partially closed oil supply LIM
58. ge and to make resistance checks The drive s DC bus capacitors retain hazardous voltages after input power has been disconnected Opening the VFD Access Door ANWARNING Before removing the drive enclosure open access door and verify that the DC bus voltage has dropped to zero by checking the terminals behind the access door Failure to observe this precaution could result in severe bodily injury or loss of life 1 Using recommended screwdriver 6 4 mm 0 25 in flat or 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 1s zero before proceeding See Fig 3 Fig 2 Opening Access Door 2 AN DC BUS TEST TERMINALS 3 LOCATED INSIDE ACCESS DOOR MULTIMETER Fig 3 Check DC Bus Terminals 21 1 0248 3 3 0 21P PF755 VFD Voltage Rating 1 460 to 480 v 60 Hz 2 380 to 415 v 50 Hz 3 380 to 400 v 60 Hz 4 401 to 439 v 60 Hz PF755 Full Load Amp Rating Maximum Continuous Amps 0248 248 0361 361 0477 477 For Carrier applications maximum continuous amp ratings are 230 335 and 445 Drive Assembly Catalog Number See Fig 4 for an example of the Rockwell Automation Drive Assembly Cat alog Number Components and Physical Data The 19XRV chillers use the Allen Bradley PF755 Frame 6 drive for the 230 amp rated application Carrier Part No 19
59. h all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment THIS DRIVE contains ESD electrostatic discharge 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 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
60. h condenser water temperatures or low flow rate Verify that isolation valves are open Check Cond Press Override setting in SETUP1 Check for closed valves or restriction in motor cooling lines Check for closed refrigerant isolation valves Check Comp Motor Temp Override setting in SETUP1 Check refrigerant charge Check that optional cooler liquid line isolation valve is fully open Check for excessive condenser flow or low chilled water flow Check for low entering cooler temperature Check that condenser inlet and outlet water nozzles are piped correctly Check for waterbox division plate gasket bypass Check for high condenser water temperature or low suction temperature Check for high Evaporator or Condenser approaches Check surge prevention parameters in OPTIONS screen Target Guide Vane Position has been forced in the COMPRESS screen Select and RELEASE force to return to normal automatic operation Check for oil loss or excess refrigerant charge Verify that the valves in the oil reclaim lines are open Check Rectifier Temp Override in SETUP1 screen Check that VFD refrigerant isolation valves are open Check VFD refrigerant cooling solenoid Check for proper VFD cooling fan operation and blockage Chiller is not in automatic temperature control Check Inverter Temp Override in SETUP1 screen Check that VFD refrigerant isolation valves are open Check VFD refrigerant cooling solenoid Check
61. heck surge prevention parameters in OPTIONS Screen Check cooling tower control settings and perfor mance to design selection temperatures across the entire operating range of the chiller Check cooler approach and water flow 239 PROTECTIVE LIMIT TRANSDUCER 239 Transducer Voltage Ref Check that CCM transducer voltage reference is VOLTAGE FAULT VALUE exceeded limit of between 4 5 v and 5 5 v LIMIT Check that pressure transducers are not shorted to ground This fault is normally declared the first time an ICVC is powered up if it was downloaded with software when it was not connected to a CCM Contact Carrier Service 240 PROTECTIVE LIMIT LOW DISCHARGE 240 Check for Oil in Or Check for oil loss or excessive refrigerant If oil level SUPERHEAT Overcharge of Refrigerant is low refrigerant charge may be too low resulting ineffective oil reclaim Excessive refrigerant charge may cause liquid carryover into compressor Check calibration of evaporator pressure and con denser pressure sensors Check calibration of compressor discharge temper ature sensor 241 PROTECTIVE LIMIT RECTIFIER 241 Rectifier Overcurrent Check for high water temperatures or changes in OVERCURRENT Fault Check VFD Status water flow rates 242 LOSS OF WITH CCM MODULE 242 gt 1055 of Communica wiring and control power to CCM COMMUNICATION tion With CCM Check Confirm that all CCM SW1 switches are in the Comm Connectors OFF po
62. ions list two acceptable alterna tives The Halar specification has a higher temperature rating and a tougher outer jacket than the SmokeGard specification and it is appropriate for use in applications where the user is concerned about abrasion The Halar jacket is also less likely to crack in extremely low temperatures NOTE Use the specified type of wire and cable for maximum signal integrity Table C MS TP Wiring Recommendations SPECIFICATION RECOMMMENDATION Cable Single twisted pair low capacitance CL2P 22 AWG 7x30 TC foam FEP plenum rated cable Conductor 22 or 24 AWG stranded copper tin plated Insulation Foamed FEP 0 015 in 0 381 mm wall 0 060 in 1 524 mm O D Color Code Black White Twist Lay 2 in 50 8 mm lay on pair 6 twists foot 20 twists meter nominal Shielding Aluminum Mylar shield with 24 AWG TC drain wire Jacket SmokeGard Jacket SmokeGard PVC 0 021 in 0 5334 mm wall 0 175 in 4 445 mm O D Halar Jacket E CTFE 0 010 in 0 254 mm wall 0 144 in 3 6576 mm O D DC Resistance 15 2 Ohms 1000 feet 50 Ohms km nominal Capacitance 12 5 pF ft 41 pF meter nominal conductor to conductor Characteristic Impedance 100 Ohms nominal Weight 12 16 1000 feet 17 9 kg km UL Temperature Rating SmokeGard 167 F 75 C Voltage 300 Vac power limited Listing UL NEC or better LEGEND AWG American Wire Gage CL2P Class 2 Plenum Cable DC Direct Current FEP Fluorinated Ethylene Polym
63. l pump operation 106 PRESTART HIGH 106 Condenser Pressure VALUE Check transducer wiring and accuracy ALERT CONDENSER exceeded limit of LIMIT Check for high condenser water PRESSURE temperatures Check high condenser pressure switch wiring 107 PRESTART LOW LINE 107 gt Line Voltage VALUE Check voltage supply ALERT VOLTAGE exceeded limit of LIMIT Check voltage transformers and switch gear Consult power utility if voltage is low 108 PRESTART HIGH LINE 108 Percent Line Voltage VALUE Check voltage supply ALERT VOLTAGE exceeded limit of LIMIT Check power transformers Consult power utility if voltage is high 109 PRESTART GUIDE VANE 109 4Actual Guide Vane Pos Press STOP button on ICVC and perform ALERT CALIBRATION Calibration Required Before Startup Guide Vane Calibration in Controls Test Screen Check guide vane actuator feedback potentiometer 110 PRESTART HIGH 110Rectifier Temperature VALUE Check that VFD refrigerant isolation valves ALERT RECTIFIER exceeded limit of LIMIT are open TEMP Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage 111 PRESTART HIGH 111 Inverter Temperature VALUE Check that VFD refrigerant isolation valves ALERT INVERTER TEMP exceeded limit of LIMIT are open Check VFD refrigerant cooling solenoid and refrigerant strainer Check for proper VFD cooling fan operation and blockage L
64. leared by pressing the RESET softkey See Table 5 TEST EQUIPMENT NEEDED TO TROUBLESHOOT An isolated multimeter adequately rated for the DC bus volt age will be needed to measure DC bus voltage and to make resistance checks Note that dedicated troubleshooting test points are not provided Fig 13 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 EN 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 connecti
65. lict The VFD CONF table the Gateway does not VFD Uploaded Verify to match that which is in the ICVC This is a normal Reset Alarm fault if an ICVC has been uploaded with soft ware when it was not attached to the CCM Enter CONF screen and then exit VFD CONF screen by pressing EXIT then CANCEL Re enter the VFD CONF screen press EXIT then SAVE Parameters stored in the Gateway will be uploaded into the ICVC Confirm valid settings in VFD_CONF screen PROTECTIVE LIMIT VFD CONFIG CONFLICT 2529 VFD Config Conflict The VFD CONF table in the Gateway does not VFD Downloaded Verify to match that which is in the ICVC Reset Alarm PROTECTIVE LIMIT GUIDE VANE 253 gt Vane Fault Enter CONTROL TEST and execute Guide CALIBRATION VALUE Check Calibration Vane Calibration Check COM guide vane feedback terminals J4 9 and J4 10 Check guide vane feedback potentiometer Alarm before start indicates guide vane opening is not less than 4 Alarm running indicates guide vane position is 196 or gt 103 or feed back voltage is 045 or 3 15 VDC PROTECTIVE LIMIT VFD CHECKSUM ERROR 254 gt Error Actual VFD checksum does not match calcu Press Reset to Restore lated value Configuration PROTECTIVE LIMIT VFD DEW PREVENTION 255 gt Dew Prevention Cool VFD COLDPLATE TEMP is too close to dew ant Too Cold Check Solenoid point based on VFD ENCLOSURE TEMP and amp Cond T RELATIVE
66. ller s address Set the Tens 10 s switch to the tens dig it of the address and set the Ones 1 s switch to the ones BACNET DEVICE INSTANCE ADDRESS The UPC digit Open controller also has a BACnet Device Instance address This Device Instance MUST be unique for the complete BAC net system in which the UPC Open controller is installed The Fig B Address Rotary Switches As an example in Fig B if the controller s address is 25 point the arrow on the Tens 10 s switch to 2 and the arrow on the O T itch to 5 Device Instance is auto generated by default and is derived by e Ones 1 s switch to 5 adding the MAC address to the end of the Network Number NOTE The UPC Open Controller should not be polled by the The Network Number of a new UPC Open controller is 16101 Building Management System BMS at a rate greater than 2 but it can be changed using i Vu Tools or BACView device polls min Also the UPC Open Controller should not poll the By default a MAC address of 20 will result in a Device In chiller at a rate greater than 2 polls min If the poll rate is stance of 16101 20 which would be a Device Instance of within the acceptable range of 2 polls min and a response prob 1610120 lem occurs contact Carrier Service
67. m each DC terminal to the chassis must be zero before proceeding 4 Once the drive has been serviced reapply input power HIGH TEMPERATURE ALARMS Coolant flow through the cold plate is controlled by an orifice in the refriger ant line leaving the cold plate The orifice looks like one of the O ring face seal connectors and in fact is used as one of the connections on the coolant tubing The difference is that the passage through the fitting 1s 0 375 in 9 5 mm If the orifice is present and condenser liquid flow is present the liquid will flash to cooler temperature at the orifice This temperature dif ference is great enough to be easily felt MAIN CONTROL BOARD MCB COMPONENTS Figure 14 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 15 Note the location of the terminals labeled MCB I O The high pressure switch is wired to these terminals as shown in Fig 16 In the event of a high condenser pressure alarm the connections at these terminals should be checked and tightened if necessary A typical wiring schematic is shown in Appendix A SWING UP KEY PAD o
68. nd no residual 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 53190027 01 Printed in U S A Form 19 23 4SS Pg 1 4 13 Replaces 19 23 2SS ANWARNING 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 wit
69. neering See Table 2 Table 2 VFD Configurations DEFAULT PARAMETER VALUE Motor Nameplate Voltage 460 Compressor 100 Speed Line Freq 60 Hz No 50 Yes Rated Line Voltage 1 460 Rated Line Amps 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 2 kHz 1 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 Voltage Imbalance 10 Line Volt Imbalance Time 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 T Parameters marked with a T 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 e
70. o e BLK BLK COMP R OIL 5 3 RED n E Ps BRN SUMP TEMP 2 5o 5 DEREN 19 lt 20 imi wee OPTIONAL amr 2 5 818 24 3o BLE MOTOR TEMP LAAN o SUPPRESSOR 20 mnn OIL PUMP n s RED 10 tomi NOS in OIL HEATER SPARE TEMP ay 3 WHT 25 imn ISRN OPTIONAL LAAA tein 4 26 um SPARE TEMP 12 27 OPTIONAL LA tB 28 9 uui 1 CCM OIL SUMP 1 PRESS 2 mum RED 3 BLK 4 OIL PuwP gt cun 5 Ht DISCH PRESS 4 t iibi gt NOTE GND SHIELDS AT THIS END ONLY SHIELD SHIELD LOAD RESISTOR RELATIVE 4 Ax 4 5 RED BE RED HUMIDITY 5 CLR Lo idi CJ BLK 10 roin SESISTOR 11 ALL SWITCHES SET 12 TO OFF POSITION REDI 5 10K 13 GRY 2 14 LOAD RESISTOR i 16 JUMPER ja J LIE ALARM 9 ol OAD RESISTOR dl N 3 i LOAI _ 20 RED RED 3 ICVC 5 GRY 4 22 1041 cam 3 23 2 6 JUMPER A torr RED STOP E 1 SERVICE EVAP PRESS 3 ciun 2 RED 3 E ui 4 COND PRESS 3 cm 5 RED 6 31 APPENDIX A WIRING SCHEMATICS cont CHILLER CONTROL SCHEMATIC cont
71. o observe this precaution could result in severe bodily injury or loss of life UNUSED WIRES in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages Also if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled to eliminate the possible shock hazard from cross coupled motor leads 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 D
72. olyswitches are not replaceable and will reset themselves if the condition that caused the fault returns to normal Rx Lights when the controller receives data from the network segment there is an Rx LED for Ports 1 and 2 Tx Lights when the controller transmits data to the network segment there is a Tx LED for Ports 1 and 2 Run Lights based on controller status See Table F Error Lights based on controller status See Table F Table F Run and Error LEDs Controller and Network Status Indication RUN LED STATUS 2 flashes per second Normal 2 flashes per second 2 flashes per second 2 flashes per second 2 flashes per second 5 flashes per second 5 flashes per second 7 flashes per second 14 flashes per second 39 Five minute auto restart delay after system error Controller has just been formatted Controller is alone on the network Exec halted after frequent system errors or control programs halted Exec start up aborted Boot is running Firmware transfer in progress Boot is running Ten second recovery period after brownout 14 flashes per second alternating with Run LED Brownout APPENDIX B BACNET COMMUNICATION OPTION cont Table G Network Points List CCN READ DEFAULT BACNET BACNET 1st Current Alarm State R NA 020 v4 alarm 01 1 Active Demand Limit DEM LIM 40 to 100 dem lim 1 Actual Guide Vane Position GV POS R 0 to 100 gv_pos_1 Actual VFD Speed R
73. on has timed out ENET AS 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 None Unli LINK Green Adapter is not powered or is not transmitting on the network 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 1 A Type 1 alarm indicates that a condition exists Type 1 alarms are user configurable 2 A Type 2 alarm indicates that a configuration error exists and the drive cannot be started Type 2 alarms are not configurable VERIFYING THAT DC BUS CAPACITORS ARE DIS CHARGED The drive s DC bus capacitors retain hazard ous voltages after input power has been disconnected Perform the following steps before touching any internal components 1 Turn off and lock out input power Wait five minutes 2 Verify that there is no voltage at the drive s input power terminals 3 Measure the DC 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 5 for the 248 amp drive and Fig 6 for the 361 and 477 amp drives The voltage between DC and DC and fro
74. pen 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 207 Auxiliary Input Input is open Heat Sink Over 219 Transistor Over temp 219 VFD CONF screen grounded condition 206 Ground Warning current has exceeded the level set If this fault appears there may be a problem with check ICVC VFD CONF settings and save set software configuration tings when exiting VFD CONF screen The DC bus ripple Check phase to phase and phase to ground dis 216 has exceeded a Line Voltage imbalance tribution bus voltage Increase Line Voltage preset level Imbalance in CONF screen TorgPrv Spd Band See VFD Fault Code 15 See VFD Fault Code 15 Verify input voltage is within drive specified limits Verify system ground impedance follows proper 204 Decel Inhibit The drive is not following a commanded decelera grounding techniques tion because it is attempting to limit bus voltage 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 Check the motor motor terminal
75. precaution 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 CAUTION USE only repair or replacement parts that meet the code requirements of the original equipment PERIODICALLY INSPECT all valves fittings and piping for corrosion rust leaks or damage 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 plet
76. r instruc tions on connecting and using BACview device To order a BACview Handheld BV6H consult Commer cial Products i Vu Open Control System Master Prices CONFIGURING THE UPC OPEN CONTROLLER S PROPERTIES The UPC Open device and ComfortLink controls must be set to the same CCN Address Element num ber and CCN Bus number The factory default settings for CCN Element and CCN Bus number are 1 and 0 respectively e BACview UPC OPEN LOGIN sUserPw 03 05 2010 01 39 28 pm NETWORK 2BACnet ClockSet 4 conductor unshielded 18 AWG plenum rated W184C 2099BLB 6302UE 21450 LEGEND American Wire Gage RECOMMENDED VENDORS AND PART NUMBERS Connect Air Contractors International RMCORP Wire and Cable W221P 22227 25160PV CLPO520LC W241P 2000F 82841 25120 OR CLP0442 If modifications to the default Element and Bus number are required both the ComfortLink and UPC Open configurations must be changed The following configurations are used to set the CCN Ad dress and Bus number in the ComfortLink control These con figurations can be changed using the scrolling marquee display or accessory Navigator handheld device Configuration CCN CCN A CCN Address Configuration CCN CCN B CCN Bus Number The following configurations are used to set the CCN Ad dress and Bus Number in the UPC Open controller These con figurations can be changed using the accessory BACview dis
77. s and external A current path to earth ground greater than 25 ri E 220 Ground Fault of drive rating has occurred wiring to the drive output terminals for a To reset the processor cycle power to chiller 206 Load Loss Check VFD parameters with Drive Explorer The current in one or more phases has been lost Check Motor Current Imbalance in Output PhaseLoss remains below a preset level VFD_CONF screen drive output current has exceeded the 1 ms Check for excess load improper DC boost set 21 VFD FAULT CODE ON VFD HIST SCREEN 38 39 40 41 42 43 44 45 46 55 61 62 64 65 77 78 79 80 87 91 93 94 95 96 97 100 107 113 124 141 142 143 144 145 Table 6 Powerflex 755 Fault Code Descriptions and Corrective Actions cont FAULT TYPE DESCRIPTION CORRECTIVE ACTION Gnd U to Gnd Check wiring between drive and motor Check motor for grounded phase Phase Vio Gnd Phase Vio Gnd AC GROUND FAULI Check motor terminals Phase W to Gnd Replace drive Phase UV Short Check wiring between drive and motor Phase VW Short VW Phase VW Short GROUND FAULT Check motor terminals Phase WU Short Replace drive Phase UNot Check wiring between drive and motor Phase VNot ToGnd GROUND FAULT no LF2 equivalent Check motor terminals 206 PhaseWNot WNot Replace drive temperature sensor on the main control Check tha
78. sition 243 POTENTIAL EVAP PRESS TEMP 243 Evaporator Refrig Check for proper refrigerant charge FREEZE UP TOO LOW Temp VALUE exceeded Check float valve operation limit of LIMIT Check for proper fluid flow and temperature Confirm that condenser water enters bottom row of condenser tubes first Check Evaporator Refrigerant Temperature sensor Check for division plate gasket bypass Check for fouled tubes 244 POTENTIAL COND PRESS TEMP 244 Condenser Refrig Condenser water too cold or chiller shut down with FREEZE UP TOO LOW Temp VALUE exceeded limit of LIMIT brine below 32 F in cooler so equalization tempera ture in chiller approached 32 F Check condenser pressure transducer Check refrigerant charge LIMIT is shown on the ICVC as the temperature pressure voltage etc set point predefined or selected by the operator as an override alert or alarm condition VALUE is the actual pressure temperature voltage etc at which the control tripped 18 Table 5 ICVC Alarm Codes cont CHILLER PROTECTIVE LIMIT FAULTS cont ICVC FAULT STATE 245 246 247 248 249 250 251 252 253 254 255 256 257 258 PRIMARY SECONDARY MESSAGE M SSAGE PRIMARY CAUSE ADDITIONAL CAUSE REMEDY PROTECTIVE LIMIT HIGH VFD SPEED 245 4Actual VFD Speed Actual VFD Speed on COMPRESS screen must exceeded limit of Target VFD not exceed Target VFD Speed by more than Speed 10 10 PROTECTIVE LIM
79. t VFD refrigerant isolation valves are NONE board detected excessive heat open Check VFD refrigerant strainer 206 ShearPin 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 2 See VFD Fault Code 15 See VFD Fault Code 15 Check that guide vanes are closed completely 206 Excessive Load Motor did not come up to speed in the allotted Check for high entering water temperature or low Repeat Autotune mor manete See VFD Fault Code 15 See VED Faull Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 Press ICVC reset 206 Parameter Chksum 12277 P ard does not Check VFD CONF parameters 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 1 Tair a ieee Verify application version See VFD Fault Code 15 See VFD Fault Code 18 See VFD Fault Code 15 See VFD Fault Code 15 See VFD Fault Code 15 22 VFD FAULT CODE Table 6 Powerflex 755 Fault Code Descriptions and Corrective Actions cont ON VFD H
80. te OL R O AWARNNG DC Infinite OL Confirm that the DC bus has discharged before performing aS R O LO T ne did NOTE Digital meters require a special diode check function because the current sourced by the meter during a normal resis tance Ohms test is too low to accurately test a diode Make sure the meter is set to the diode test function Voltage readings may not be exact as shown in above tables but look for consistency during each of the 4 tests When performing a test that should return infinity OL as shown in above tables you may see a value slowly climbing toward infinity This is a result of the meter charging a capacitor and is normal 23 Servicing the Drive ANWARNING To guard against possible personal injury and or equipment damage 1 Inspect all lifting hardware for proper attachment be fore lifting drive 2 Do not allow any part of the drive or lifting mecha nism to make contact with electrically charged con ductors or components 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 ANWARNING DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for the DC bus capacitors to discharge and then check the voltage with
81. to 420 AV 28 erp 1 Evaporator Refrigerant Temp ERT R F 40 to 245 AV 13 ert 1 Leaving Chilled Water i Leaving Condenser Water LCDW R F NA 40 to 245 AV 32 Icdw 1 Line Active Current AMPS_ACT NA 0 01099999 0 amps act 1 Line Active Voltage VOLT_ACT R v 0 01099999 0 volt act 1 Entering Chilled Water Entering Condenser Water ECDW Line Frequency LINEFREQ R Hz NA 009 AV30 linefreq 1 Line Power Factor R 0001200 AV34 line pf 1 Local Schedule NA R NA NoComm Normal schedule 1 Occupied OCC NA NO noves oco 1 Oil Sump Temperature OILT R F NA 40t0245 AV 33 oilt_1 Remote Start Contact REM_CON OPEN OPEN CLOSE 11 rem con 1 O Timeout 1 Ready 2 Recyle 3 Startup 4 Running 5 Demand 6 Ramping Run Status STATUS N A N A Atores AV 35 status_1 8 Override 9 Tripout 10 Control Test 11 Lockout 12 Pumpdown 13 Prestart 0 to 32767 AV 36 s_hrs_1 Service Ontime S_HRS Surge Line Delta T DETATX R F NA 0 to 200 AV 38 delta tx 1 1 Normal System Alert Alarm SYS_ALM wa NA 2 Alert 3 Alarm AV 40 sys_alm_1 APPENDIX B BACNET COMMUNICATION OPTION cont Table G Network Points List cont CCN READ DEFAULT BACNET BACNET POINT DESCRIPTION point NAME wriTE UNITS VALUE RANGE OBJECTID OBJECT NAME System Demand Limiting NA R NA
82. vaporate 2 Enter parameters in the VFD CONF screen Install surge suppression devices if required Review the power wiring and grounding to ensure that it has been properly connected 5 Visually examine the inside of the drive enclosure to a Look for signs of corrosion or moisture residue b Remove any dirt or debris c Make sure all vents are clear 6 Apply power to the drive and take thermal measurements of the capacitor bank and power connections Do this again before start up 7 Measure and record the incoming line voltage Line to line voltages should be balanced within 3 as calculated by Rockwell s procedure below Measure voltages phase to phase and phase to ground Bow 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 d 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 fa 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

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