Carrier D2-3466-2 Computer Drive User Manual
Contents
1. Initial DC Bus Measurement Figure 6 1 DC Bus Voltage Terminals 414 Amp Drives Carrier VFD Quick Reference 6 2 1 po je BSN Coe OL Ox p Cp i ttl Do Momo oo 000 0000 00 ooo w0 0 00000 000000 Co oe Figure 6 2 DC Bus Voltage Terminals 500 Amp and 643 Amp Drives Troubleshooting the Drive 6 3 Checking the Power Modules and Motor with Input Power Off Use the following procedure to check the drive s Power Module circuitry with power off2. ATTENTION 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 touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of life Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Turn off and lock out input power Wait five minutes Verify that there is no voltage at the drive s input power terminals Check the DC bus potential with a voltmeter as described in section 6 2 to ensure that the DC bus capacitors are discharged Disconnect the motor from the drive Check all AC line and DC bus fuses If a fuse is open use a multimeter to check the input diodes and output IGBTs See table 6 1 Check motor impedance Reconnect the motor to the drive Reapply input power 6 4 Carrier VFD Quick Reference Table 6 1 Resistance Checks Meter Connection Component is OK if resistance R is Component is defective if _ 10 lt R lt 1 megohm Continuity short circuit or open when the meter is connected with reversed polarity 2 3 4 5 6 7 8 9 o kk DC Bus Volts power terminal DC Bus Volts power terminal Table 6 1 Resistance
3. 643 Amp 19XRV Drive Module Component Locations and Parts List 2 4 2 4 Front View of 414 Amp VFD with Parts List 19XV04003001 rev 2 0 2 5 2 5 414 Amp 19XRV Drive Module Component Locations and Parts List 2 6 2 6 414 Amp 19XRV Drive Wiring Diagrams ennen nennen nennen 2 7 2 7 VFD System Wiring Diagram 19XV05007901 rev A 2 9 2 8 500 Amp and 643 Amp 19XRV Drive Wiring Diagrams nnen 2 14 Using the Keypad Display to Program Monitor and Control the Drive 3 1 Identifying Parameter Defaults For Carrier Drives 4 1 Verifying the Installation neen oeeeneneeeneeneneneneennneneeeenennenvenennn 5 1 Troubleshooting the Drive 6 1 Test Equipment Needed To Troubleshoot nnee eneen 6 1 6 2 Verifying That DC Bus Capacitors Are Discharged nnen ennen 6 1 6 3 Checking the Power Modules and Motor with Input Power Off 6 4 6 4 Troubleshooting the Drive Using Error Codes 6 6 6 4 1 Identifying Alarm Codes and Recovering nnee nennen eneen 6 7 6 4 2 Identifying Fault Codes and Recovering nennen vennen 6 8 6 4 3 Accessing Reading and Clearing the Faults in the Error Log 6 11 6 5 Identifying Fatal Fault Codes and Recovering unne ennen eenen 6 14 6 6 Indentifying PMC Board Fault Codes and Recovering neee 6 15 6 7 Resetting a Checksum CHS Fault nn eneen enneerenneneneneeeenneeenn
4. Checks Continued Meter Connection Component is OK if resistance R is Component is defective if 1 10 lt R lt 1 megohm Continuity short circuit or open when the meter is connected with reversed polarity 2 3 4 5 6 DC Bus Volts power terminal DC Bus Volts power terminal Troubleshooting the Drive 6 5 Troubleshooting the Drive Using Error Codes The drive can display two kinds of error codes called alarm and fault codes to signal a problem detected during self tuning or drive operation Fault and alarm codes are shown in tables 6 2 and 6 3 A special type of fault code which occurs rarely is the fatal fault code If the code you see is not in tables 6 2 or 6 3 refer to section 6 5 Alarm Codes An alarm condition is signified by a two or three letter code flashing on the display The drive will continue to operate during the alarm condition You should investigate the cause of the alarm to ensure that it does not lead to a fault condition The alarm code remains on the display as long as the alarm condition exists The drive automatically clears the alarm code when the condition causing it is removed Fault Codes A fault condition is also signified by a two or three letter code flashing on the display If a fault occurs the drive coasts to stop and the RUNNING LED turns off The first fault detected is maintained flashing on the display regardless of whether othe
5. Power Module sizing versus overload H 007 or Torque Boost H 003 application Check DC Braking Current value H 007 Check Torque Boost H 003 SF Self tuning status See parameter U 009 Vector only 6 10 Carrier VFD Quick Reference Table 6 3 List of Fault Codes Continued Fault Description Fault Cause Corrective Action Communication Serial port communication cable PC Check connection cable and loss between or OIM communication port setup communication port setup Regulator PC OIM Spurious host PC Regulator board failure Replace Regulator board comm interrupt Asymmetrical bus One of 3 differnet faults has occurred fault Look at the 3 1 Input Ground Fault Excessive 1 Check the connection from the LEDs on the Power current flowing bwtween any of the current transformer to the Bus Control Module Interface three input phases and earth ground board board They 2 Asymmetrical Bus When 2 Replace shorted capacitor fix loose indicate which fault measuring between the cap bank connection or replace discharge has occurred by midpoint and the DC bus and DC resistor flashing in unison bus there is a 200 V or greater mismatch 1 Input Ground 3 Slow Ramp Rate of DC Bus DC 3 Turn on drive If UbS is displayed Fault bus did not change to the ful value turn drive off and then on again very 2 Asymmetrical given time allowed Can occur only at quickly If the UbS fault goes a
6. Reference Using the Keypad Display to Program Monitor and Control the Drive If you are unfamiliar with the detailed operation of the keypad display refer to chapter 3 of the LiquiFlo Software Start Up and Reference Manual D2 3410 Display Pf AUTO Forward EER speen CJ RUNNING MAN Reverse Monitor Mode J voirs REMOTE AMPS JOG en Im BE rom DI Kw EN FORWARD JOG TORQUE REVERSE Password LED C Password J PROGRAM STOP RESET START RELIANCE ELECTRICHE Drive Status Keypad LEDs Stop Reset Key Figure 3 1 Keypad Display ATTENTION When switching from auto to manual or manual to auto the drive will ramp to the reference level provided by the new source at the rate specified in P 001 Accel Time 1 P 002 Decel Time 1 P 017 Accel Time 2 or P 018 Decel Time 2 Be aware that an abrupt speed change may occur depending upon the new reference level and the rate specified in these parameters Failure to observe this precaution could result in bodily injury Using the Keypad Display to Program Monitor and Control the Drive 3 1 Carrier VFD Quick Reference Identifying Parameter Defaults For Carrier Drives Use the following table to identify and set the parameter defaults for Carrier drives Important Setting P 050 Restore Defaults to ON will restore the drive to Reliance defaults not Carrier defaults If this has been done set the follow
7. if a CHS fault repeats Step 1 Press and hold STOPIRESET PROGRAM and DOWN ARROW for 5 to 10 seconds A PUn error should appear Step 2 Press PROGRAM P is displayed Step 3 Press ENTER P 000 is displayed Perform steps 4 through 7 if access to the second menu has not already been enabled Step 4 Press UP ARROW until P 006 is displayed Step 5 Press ENTER Step 6 Press UP ARROW until 107 is displayed Step 7 Press ENTER Perform steps 8 through 11 if changing modes of operation V Hz or Vec Otherwise skip to step 12 Troubleshooting the Drive 6 15 Step 8 Press UP ARROW until P 048 is displayed Step 9 Press ENTER Step 10 Press UP or DOWN ARROW to select UEC or U H mode Step 11 Press ENTER Observe SELF is displayed briefly Step 12 Press UP or DOWN ARROW until P 006 is displayed Step 13 Press ENTER Step 14 Press UP ARROW until 75 is displayed Step 15 Press ENTER Step 16 Press UP ARROW until R998 is displayed Step 17 Press ENTER Step 18 Press UP ARROW until ON is displayed Step 19 Press ENTER Step 20 Press UP ARROW until P 999 is displayed Depending on software version the display may show PUGH or P 999 If PUCH is displayed wait for 0 to display The procedure is complete If P 999 is displayed continue with step 21 Step 21 Press ENTER Step 22 Press UP ARROW until the correct power unit current and voltage rating code appears The codes are as follows Mode
8. minimum clearances around drive OL Motor overload Excess motor current Vector Check actual Motor Rated V Hz Torque boost too high therm Nameplate Amps U 004 overload level too low V Hz Check actual current Torque Boost H 003 Check that Power Module is sized correctly Reduce load on motor for example at low frequency Excess load on motor for example at Check that Power Module is sized too low speeds correctly Reduce load on motor e g at low frequency Loss of phase connection Check output lines to the motor OPL Motor output phase Phase lost between drive and motor Check connections and cable of all 3 loss phases and motor windings Replace any damaged cable OSP Overspeed RPM above 130 Maximum Speed Check Encoder PPR U 001 Motor Vector only P 004 speed regulator response not Poles U 002 Base Frequency optimized U 003 Motor Nameplate RPM Speed U 005 Check Reg Proportional U 012 Integral Gain U 013 PUc Missing Power Bad or disconnected cable between Check cables between Regulator Module ID Regulator and Power Module board and Power Module connector PUn Power Module not Drive parameters have been restored Power Module must be configured by identified to power up defaults Regulator has Reliance service personnel not been configured to match Power Module PUo Drive power Power Module overloaded Check load to Power Module electronic Too high DC Braking Current Check
9. precaution could result in severe bodily injury or loss of life ATTENTION The drive can operate at and maintain zero speed The user is responsible for assuring safe conditions for operating personnel by providing suitable guards audible or visual alarms or other devices to indicate that the drive is operating or may operate at or near zero speed Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION Do not install modification kits with power applied to the drive Disconnect and lock out incoming power before attempting such installation or removal Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION The user must provide an external hardwired emergency stop circuit outside of the drive circuitry This circuit must disable the system in case of improper operation Uncontrolled machine operation may result if this procedure is not followed Failure to observe this precaution could result in bodily injury ATTENTION The user is responsible for conforming with all applicable local national and international codes Failure to observe this precaution could result in damage to or destruction of the equipment Copyright 2005 Rockwell Automation All rights reserved ATTENTION When the level sense start feature is enabled P 054 ON the user must ensure that automatic start up of the driven equipment will not cause injury to operat
10. 6 15 Contents Carrier VFD Quick Reference Using This Manual The Carrier VFD Quick Reference is intended for qualified Carrier service personnel and is to be used during start up operation and maintenance of the variable speed drive 1 1 Required Publications The Carrier VFD Quick Reference must be used with the following manuals e D2 3410 LiquiFlo AC General Purpose Volts Hertz and Vector Duty Drive Software Start Up and Reference Manual e D2 3411 LiquiFlo AC Power Modules Hardware Reference Installation and Troubleshooting D2 3341 Super Remote Meter Interface RMI Board for GV3000 and LiquiFlo AC Drives e D2 3448 Control and Configuration Software 531 982 19XR XRV Start Up Operation and Maintenance Instructions 19XR 5SS 1 2 Getting Assistance from Reliance Electric If you have any questions or problems with the products described in this manual contact your local Reliance Electric sales office For technical assistance call 1 864 284 5444 Before calling have the following information available from the Reliance label Reliance model number e Carrier part number e Serial number e Carrier drawing number and revision Using This Manual 1 1 Carrier VFD Quick Reference Identifying Drive Components Using Reference Drawings and Parts Lists Replace with 2 fm 11 X 17 Z fold Identifying Drive Components Using Reference Drawings and Parts Lists 2 1 Carrier VFD Quick
11. If intermittent check for causes of noise for proper grounding and that outputs are not exceeding rated current capacities Replace the option board if necessary Refer to the appropriate option board instruction manual for more information about the option board Carrier VFD Quick Reference 6 6 6 7 Indentifying PMC Board Fault Codes and Recovering ATTENTION Viewing the PMC board LEDs requires electrical circuits to be exposed Stay clear if unit must be running Disconnect and lock out or tag power source if contact must be made Failure to observe this precaution could result in severe bodily injury or loss of life Table 6 5 lists PMC board fault codes These faults can be identified using the three LEDs located on the Regulator board Table 6 5 PMC Board Fault Codes Status of LEDs 1 3 Fault Description Corrective Action LEDs 1 3 all on Normal operation None required 60 Hz 50 duty no fault LEDs 1 3 all off VAC_LINE lo None required The board will recover when the line becomes present LEDs 1 3 flash ina VDC_CHG lo Reset board 3 flash sequence LEDs 1 3 flash ina ASYM_FAULT lo Reset board 2 flash sequence LEDs 1 3 flash ina ACGNDFLT lo Reset board This circuit was 1 flash sequence removed on the 350 HP assembly Resetting a Checksum CHS Fault Perform the following procedure when a new Regulator board is installed or
12. access the error log in order to view all of the faults that have occurred See section 6 4 3 for instructions on how to view the error log Fault Description Analog input signal loss Table 6 3 List of Fault Codes Fault Cause P 011 4 or 5 and 4 to 20 mA analog input is below 1 mA Corrective Action Verify that P 011 is set correctly Check that the analog input source supply gt 1 mA Incorrect precharge status Precharge initiated and incorrect precharge status is returned Check operation of the precharge Default parameter restore checksum error During drive operation Regulator board failure Contact Reliance or replace Regulator board After Regulator board replacement Contact Reliance EC Earth current failure Unintentional grounding of the input Check isolation between ground and ground fault output terminals Possible leakage current sensor defects replace sensor EEr Non volatile Failure on write to non volatile Connect CS3000 software to upload memory write memory parameters or record by hand Then failure replace Regulator board Parameter values will be lost when power is cycled EL Encoder loss Drive is not detecting feedback from Check the connection between the the encoder encoder and the drive Check the encoder motor coupling For SVC operation conditions exist for For SVC operation check motor data more than 5 second
13. aution could result in severe bodily injury or loss of life ATTENTION If P 062 Option Port Communication Loss Response 2 and P 054 Level Sense Start Enable ON and network communication is lost while the drive is running the terminal strip stop input will function as a STOP RUN input If the terminal strip stop input is opened the drive will stop If the terminal strip stop input is closed the drive will re start Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION When starting with search enabled H 016 is set to any value but OFF there will be a several second delay and the motor may drift in the forward and reverse direction before the motor begins operating in the desired direction even if reverse has been disabled in P 027 Stay clear of rotating machinery Failure to observe this precaution could result in bodily injury ATTENTION When connected to a non regenerative common DC bus regeneration may cause a rise in DC bus voltage Be aware that other drives on the bus may experience an unexpected speed increase due to the high bus voltage Failure to observe this precaution may result in bodily injury ATTENTION The motor shaft can rotate in either direction by up to one 1 revolution providing minimum torque immediately after the identification procedure initiated in H 020 has been started Stay clear of rotating machinery Failure to observe this precaution could
14. d 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 Publication D2 3466 2 May 2005 Supercedes D2 3466 1 June 2002 Copyright 2005 Rockwell Automation Inc All Rights Reserved Printed in USA
15. destruction of the equipment ATTENTION Most codes require that upstream branch circuit protection be provided to protect input power wiring Install the fuses recommended in table 3 7 of the LiquiFlo Hardware Reference manual D2 3411 Do not exceed the fuse ratings Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION Do not route signal and control wiring with power wiring in the same conduit This can cause interference with drive operation Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION Distribution system short circuit capacity shall not exceed the rating of the drive Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION H 002 Motor Nameplate Amps must not exceed the rated amps found on the motor nameplate Overcurrent or excess heating of the motor could result if this is not done Failure to observe this precaution could result in damage to or destruction of the equipment The following ATTENTION statements do not apply to the default Carrier VFD configuration However they do apply to the Reliance LiquiFlo AC Power Module ATTENTION As a safety precaution Reliance Electric recommends that you provide an audible or visual alarm to indicate that the level sense start feature is enabled and the motor can start when power is applied to the drive You should also post
16. eference 6 4 1 Identifying Alarm Codes and Recovering Drive alarm codes are shown in table 6 2 Note that the alarm code will only be displayed for as long as the problem exists Once the problem has been corrected the alarm code will disappear from the display Alarm Description High DC bus voltage Table 6 2 List of Alarm Codes Alarm Cause The DC bus is charged above the trip threshold If U 018 gt 415 DC bus is above 741 VDC If U 018 lt 415 DC bus is above 669 VDC Corrective Action Increase the deceleration time in P 002 P018 Install optional snubber resistor braking kit Verify that the AC input is within specification Install an isolation transformer if required Check the actual line voltage against U 018 V Hz identification procedure active V Hz identification procedure is enabled and in progress Allow identification procedure to finish Press keypad STOP RESET to cancel identification procedure if desired V Hz identification procedure enabled Low AC input line H 020 On V Hz identification procedure has been enabled but not started AC input line is low For SVC indicates DC bus is being regulated No corrective action is required Proceed with V Hz identification procedure start drive and allow procedure to begin Display will change to I Ac when drive is started Change H 020 to OFF to cancel identification and clear I En if desired Adjust
17. erating Acceleration time too short Check Encoder PPR U 001 Motor Poles U 002 Base Frequency U 003 Motor Nameplate Amps U 004 Magnetizing Current U 006 Speed Regulator Prop Gain U 012 Check encoder wiring Perform vector self tuning See OC fault corrective actions Increase acceleration time P 001 P 017 P 021 Troubleshooting the Drive 6 9 Table 6 3 List of Fault Codes Continued Fault Code Description Fault Cause Corrective Action OCb Overcurrent DC voltage too high Check parameters H 006 H 007 at DC braking OCd Overcurrent at Overcurrent condition occurred while See OC fault corrective actions deceleration decelerating Increase deceleration time P 002 Deceleration time too short P 018 P 022 OF Overfrequency Drive has exceeded maximum Vector Check parameters Encoder allowable output frequency PPR U 001 Motor Poles U 002 Regenerating energy is too high Base Frequency U 003 Stability or slip compensation circuit V Hz Check DC bus voltage increase adds frequency reference decelerating time Check values Max If H 016 ON searching current is too Speed P 004 Overfreq H 022 high Motor is too small Check slip compensation H 004 If H 016 ON check motor size versus Power Module size recheck setting of P 005 too high OH Drive Cooling fan failure Check ambient temperature cooling overtemperature fan
18. ich is based on a 24 hour clock Use the arrow 5 keys to move between the day and time VAN Reverse data RELIANCE ELEGTRIGHL Step 7 Press the PROGRAM key which displays the error log entries again The display shows the error log entry viewed prior to or associated with the time stamp Step 8 Repeat steps 4 though 7 for each additional error log entry to view the time and date for each error log entry Step 9 When you have viewed all the entries you should clear the error log Press the W key while you are viewing any entry in the log until the display shows CLr Press ENTER to clear the error log All entries will be cleared RELIANCE ELECTRIGHL Step 10 Err will be displayed again to indicate that the log is empty RELIANCE BLECTAHICZO Step 11 Press the PROGRAM key to access monitor mode Troubleshooting the Drive 6 13 Identifying Fatal Fault Codes and Recovering Fatal fault codes are distinguished by the letter F preceding the code They normally indicate a malfunction of the microprocessor on the Regulator board In some cases fatal fault codes can be reset and the drive can be re started Table 6 4 lists the fatal fault codes which can be reset If any other fault code appears on the display you will need to replace the Regulator board If the fault code FUE appears in error log entry O it indicates a fatal fault occurred as powe
19. ing parameters to restore Carrier defaults Parameter No Parameter Name Setting P 000 Control Source rE P 001 Accel Time 1 8 P 002 Decel Time 1 20 P 003 Minimum Speed 0 5 P 004 Maximum Speed Job specific 50 or 60 P 005 Current Limit 110 P009 Terminal Strip Analog Input Offset 10 P010 Terminal Strip Analog Input Gain 0 99 50LR4060 64LR4060 1 030 41LR4060 P 011 Terminal Strip Analog Input Configure 4 P 013 Output Relay Configuration 2 P 027 Forward Reverse Configuration 1 P 028 Speed Display Scaling Job specific P 043 Fault Auto Reset Attempts 10 P 044 Fault Auto Reset Time 30 P 052 AUTO MAN Key Disable ON H 000 Motor Nameplate Volts Job specific H 001 Motor Nameplate Base Frequency Job specific H 002 Motor Nameplate Amps 1 03 x Motor Nameplate Amps H 021 AC Line Volts Job specific H 022 Overfrequency Limit Job specific 57 or 69 r 00 Analog Output ource 4 r 0021 Analog Output 1 Offset 60 50LR4060 64LR4060 135 41LR4060 r 003 Analog Output 1 Gain 0 505 50LR4060 64LR4060 0 503 41LR4060 r 035 Relay Output 1 NO Configuration 5 r 036 Relay Output 2 NO NC Configuration 2 r 037 Relay Output 3 NO NC Configuration 1 r 046 Relay Output 3 Delay Time 999 r 050 Speed Detection Level 1 35 These parameters must be tuned or calibrated per the VFD Control Verification procedures running and non running found in the Car
20. ing personnel or damage to the driven equipment In addition the user is responsible for providing suitable audible or visual alarms or other devices to indicate that this function is enabled and the drive may start at any moment Refer to the LiquiFlo Software Start Up and Reference manual D2 3410 for additional information Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION When P 055 is set to ON the STOP RESET key is functional only from the selected control source As a safety precaution Reliance recommends that an emergency stop input be located near the equipment As a further safety precaution the user should post a warning on the drive to alert personnel that the STOP RESET key is not functional Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION 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 ATTENTION The drive contains printed circuit boards that are static sensitive Anyone who touches the drive components should wear an anti static wrist band Erratic machine operation and damage to or destruction of equipment can resu
21. l Amps Code Number 41LR4060 414 41 4 50LR4060 500 50 4 64LR4060 643 64 4 Step 23 Press ENTER PUCH should appear briefly The drive is ready to operate If in vector mode enter the correct values for U parameters and perform SELF TUNING 6 16 Carrier VFD Quick Reference Documentation Improvement Form Use this form to give us your comments concerning this publication or to report an error that you have found For convenience you may attach copies of the pages with your comments After you have completed this form please return it to Rockwell Automation Reliance Electric Drives Technical Documentation 6040 Ponders Court Greenville SC 29607 Fax 864 284 5483 Publication Name LiquiFlo 1 5 AC Drive Hardware Reference Version 1 2 Publication Number D2 3466 2 Publication Date May 2005 Comments Your Name Date Company Name Phone Address Thank you for your comments Date DIF Number Technical Writing Internal Use Follow Up Action Rockwell www rockwellautomation com Motors Drives and Power Transmission Solutions Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation Herman Heinrich Gossen Strasse 3 50858 K ln Germany Tel 49 0 2234 379410 Fax 49 0 2234 3794164 Asia Pacific Rockwell Automation 55 Newton Roa
22. line voltage parameter H 021 or U 018 to match actual AC line voltage Vector self tuning active Vector self tuning is enabled and in progress Allow vector self tuning procedure to finish Press keypad STOP RESET to cancel vector self tuning procedure if desired Vector self tuning enabled U 008 On vector self tuning has been enabled but not started Proceed with vector self tuning start drive and allow self tuning procedure to begin Display will change to S Ac when drive is started Change U 008 to OFF to cancel self tuning and clear S En if desired Troubleshooting the Drive 6 7 6 4 2 Identifying Fault Codes and Recovering ATTENTION DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of life Drive fault codes are shown in table 6 3 To clear a single fault that has occurred so that the drive can be started again correct any problems indicated by the fault code and press the STOP RESET key on the keypad or assert the fault reset from the selected control source P 000 Because multiple faults can occur and only the first will be displayed you must
23. lt if this procedure is not followed Failure to observe this precaution can result in bodily injury ATTENTION If a maintained start contact is used when the control source rE switching from local to remote from the terminal strip will cause power to be applied to the motor if the remote start contact is closed Stay clear of rotating machinery in this case Failure to observe this precaution could result in bodily injury ATTENTION The drive is not equipped with a coast stop pushbutton You must install a hardwired operator accessible pushbutton that provides a positive interrupt and shuts down the drive See the LiquiFlo AC Power Modules Hardware Reference Installation and Troubleshooting manual D2 3411 for wiring information Failure to observe this precaution could result in bodily injury ATTENTION The user is responsible for ensuring that driven machinery all drive train mechanisms and application material are capable of safe operation at the maximum operating speed of the drive In V Hz regulation overfrequency protection in the drive is provided by means of H 022 Failure to observe this precaution could result in bodily injury ATTENTION The setting of parameters H 001 Motor Nameplate Base Frequency and P 004 Maximum Speed determines the motor maximum speed These parameters must be set by a qualified person who understands the significance of setting them accurately Failure to observe this precaution could result in bodi
24. ly injury ATTENTION When switching from auto to manual or manual to auto the drive will ramp to the reference level provided by the new source at the rate specified in P 001 Accel Time 1 P 002 Decel Time 1 P 017 Accel Time 2 or P 018 Decel Time 2 Be aware that an abrupt speed change may occur depending upon the new reference level and the rate specified in these parameters Failure to observe this precaution could result in bodily injury ATTENTION It is the user s responsibility to determine how to distribute the passwords Reliance Electric is not responsible for unauthorized access violations within the user s organization Failure to observe this precaution could result in bodily injury ATTENTION Do not alter the setting of any jumper not described in LiquiFlo Hardware Reference manual D2 3411 Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION For single motor applications with no external thermal overload relay P 040 Motor Overload Enable should always be set to ON Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION Use of power correction capacitors on the output of the drive can result in erratic operation of the motor nuisance tripping and or permanent damage to the drive Remove power correction capacitors before proceeding Failure to observe this precaution could result in damage to or
25. ons with the AutoMax network have been lost Check DC bus voltage If incorrect replace diode set Check network cabling from network master to network option board Check that network master is operating properly Identification Request not yet performed V Hz only Overcurrent steady state Trips between 185 to 200 load based on inverter type current check Power Module rating Overcurrent at acceleration Drive started but Identification Result Zero Output phase to phase short Bus voltage line to line Reset fault Perform Identification Request Restart drive Check isolation between each output line Check transistor modules for correct output If incorrect possible board defect replace Possible Hall effect current sensor defective replace Ground fault Check isolation between ground and output terminals Possible leakage current sensor defect replace sensor Momentary overload Check for motor overload reduce load on motor Bad motor Check motor for correct operation Torque boost V Hz too high V Hz Check parameters H 001 H 002 and or H 003 Enable Identification Request H 020 Motor unknown to regulator V Hz Check that regulator was updated with actual motor characteristics via Identification Request H 020 Parameter settings vector Encoder wired incorrectly wrong PPR Overcurrent condition occurred while accel
26. r faults occur after it The fault code remains on the display until it is cleared by the operator using the STOP RESET key or using the fault reset input from the selected control source P 000 Error Log The drive automatically stores all fault codes for faults that have occurred in the system error log The error log is accessible through the keypad the optional OIM or the optional CS3000 software There is no visual indication that there are faults in the log You must access the error log to view the faults The error log holds the 10 most recent faults that have occurred The last fault to occur is the first one to appear on the display when you access the error log The faults in the log are numbered sequentially The most recent fault is identified with the highest number up to 9 Once the log is full older faults are discarded from the log as new faults occur For each entry in the error log the system also displays the day and time that the fault occurred The day data is based on a relative 247 day counter rolls over after 247 55 The time is based on a 24 hour clock The first digits of the clock data represent hours The last two digits represent minutes The clock can be reset using P 030 Elapsed Time Meter Reset All entries in the error log and the day and time data are retained if power is lost Refer to section 6 4 3 for the procedure for accessing and clearing the error log using the keypad Carrier VFD Quick R
27. r was lost Contact Reliance Electric or observe the drive for subsequent fatal errors before turning off power Fatal fault codes are lost after power loss Fault Description Encoder power up diagnostic error Fault Cause Encoder voltage is less than 10 V Table 6 4 Fatal Fault Codes That Can Be Reset Corrective Action Turn off power to the drive Disconnect the encoder wiring from the terminal strip Turn power to the drive back on If the F3 error does not occur again the problem is in the wiring between the drive and the encoder If the F3 error does occur again the problem is in the Regulator board which should be replaced Option port identification error The option board could not be identified by the regulator Check the ribbon cable between the Regulator board and the option board Check the option board s jumper settings Refer to the appropriate option board instruction manual for more information about the option board Option board power up diagnostic failure Option board has failed one or more power up diagnostics Check the ribbon cable between the Regulator board and the network option board Replace the option board if necessary Refer to the appropriate option board instruction manual for more information about the option board Option board runtime error During operation the option board watchdog failed or handshaking with the drive failed
28. re bf ELECTRICHE Carrier VFD Quick Reference Instruction Manual D2 3466 2 Y Carrier Rockwell A United Technologies Company Technologies Company The information in this manual is subject to change without notice Throughout this manual the following notes are used to alert you to safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Important Identifies information that is critical for successful application and understanding of the product The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to signify new or revised text or figures ATTENTION Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION 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 touching any internal components Failure to observe this
29. result in bodily injury ATTENTION In V Hz regulation if P 000 Control Source is set to OP Option Port and P 062 is set to 1 Hold Last Reference and the drive loses communication with the network the drive will maintain the last frequency command sent to it Ensure that driven machinery all drive train mechanisms and application material are capable of safe operation at the maximum operating speed of the drive Failure to observe this precaution could result in bodily injury ATTENTION Carrier Frequency P 047 and Current Limit P 005 must be set correctly before activating the identification procedure H 020 to avoid motor overloading and or overheating Failure to observe this precaution could result in damage to or destruction of the equipment ATTENTION The motor can rotate in the reverse direction during the identification procedure H 020 even if reverse disable has been selected in P 027 Uncouple the motor from any driven machinery that could be damaged by reverse rotation Failure to observe this precaution could result in damage to or destruction of the equipment Using This Manual 1 1 Required Publications 1 1 1 2 Getting Assistance from Reliance Electric 1 1 Identifying Drive Components Using Reference Drawings and Parts Lists 2 1 VFD Chiller Installation Drawing 500A and 643A VFD seses 2 1 2 2 Front View of 500 and 643 Amp VFD with Parts List 19XV04000601 rev 4 0 iii 2 3 2 3 500 Amp and
30. rier 19XR XRV Start Up Operation and Maintenance Instructions on pages 59 60 For job specific parameters refer to the 19XR XRV Start Up Operation and Maintenance Instructions manual 531 982 for further instructions For descriptions of all parameters refer to the LiquiFlo Software Start Up and Reference manual D2 3410 Identifying Parameter Defaults For Carrier Drives Carrier VFD Quick Reference Verifying the Installation Record the following job information 1 Job Name 2 Job Number 3 City 4 State 5 Zip Code Record the following nameplate information Chiller Serial Number VFD Part Number VFD Serial Number Motor Rated Load Amps Incoming Voltage Incoming Frequency NOOB WD Carrier Part Number and Revision 8 ICVC Software Number Verifying the Installation 5 1 Carrier VFD Quick Reference Troubleshooting the Drive This chapter describes how to troubleshoot the drive and the equipment that is needed to do so 6 1 Test Equipment Needed To Troubleshoot An isolated multimeter will be needed to measure DC bus voltage and to make resistance checks Note that dedicated troubleshooting test points are not provided 6 2 Verifying That DC Bus Capacitors Are Discharged ATTENTION DC bus capacitors retain hazardous voltages after input power has been disconnected After disconnecting input power wait five 5 minutes for
31. s that may result in parameters Check U 006 Incorrect an inability to complete a ramp to rest magnetizing current may be generated stop by performing self tuning with a load connected to the motor FL Function loss Function loss input on control terminal Check external interlocks at terminals is opened 16 20 Hid High time Identification process for V Hz has See H 019 for identification result identification been aborted aborted HIL High line voltage Input voltage more than 15 above Check actual line voltage against nominal U 018 or H 021 6 8 Carrier VFD Quick Reference Fault Description Table 6 3 List of Fault Codes Continued Fault Cause Corrective Action High DC bus voltage DC bus voltage too high capacitor protection Check input line voltage if necessary add transformer Deceleration time too short Increase deceleration time P 002 P 018 P 023 versus Maximum Speed Hz P 004 Install DB option with resistors Input phase loss Voltage ripple on DC bus due to missing input phase or an imbalance between phases Verify that proper voltage is being applied to the drive Check all phases Low DC bus voltage Network comm loss DC bus voltage too low Line dip too long P 042 Check input voltage line fuses If necessary add transformer Check value of Ride Through Time P 042 Line Voltage H 021 U 018 Input rectifier diodes defective Communicati
32. the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components Failure to observe this precaution could result in severe bodily injury or loss of life The drive s DC bus capacitors retain hazardous voltages after input power has been disconnected Perform the following steps before touching any internal components Step 1 Turn off and lock out input power Wait five minutes Step 2 Verify that there is no voltage at the drive s input power terminals Step 3 Measure the DC bus potential with a voltmeter while standing on a non conductive surface and wearing insulated gloves 1000 V Measure the DC bus potential at the test points on the Power Module Interface board See figure 6 1 for 414 amp drives see figure 6 2 for 500 amp and 643 amp drives Step 4 Once the drive has been serviced reapply input power Troubleshooting the Drive 6 1
33. warnings on the motor the drive and any other applicable equipment to alert personnel that the application uses an automatic start up feature Failure to observe this precaution could result in severe bodily injury or loss of life ATTENTION Be aware of the following before enabling the level sense start function P 054 Setting P 054 to ON immediately applies output power to the motor when all start conditions are met If the drive is running from the terminal strip both the start and stop inputs are closed If P 054 ON and a fault occurs the drive coasts to rest and generates a fault In this case resetting and clearing the fault immediately restarts the drive without any change to the start or stop input states If P 026 Function Loss Response 1 the control source is the terminal strip start and stop inputs are closed and P 054 ON the drive coasts to rest if the function loss input is opened and does not generate a fault In this case closing the function loss input immediately starts the drive without any change to the start or stop input When this function is enabled the user must ensure that automatic start up of the driven equipment will not cause injury to operating personnel or damage to the driven equipment In addition the user is responsible for providing suitable audible or visual alarms or other devices to indicate that this function is enabled and the drive may start at any moment Failure to observe this prec
34. way and Bus power up the DC bus charges replace the Bus 3 Slow Ramp Control board Rate of DC Bus 6 4 3 Accessing Reading and Clearing the Faults in the Error Log The following procedure shows how to access and clear the error log Note that you cannot clear a single entry from the error log The entire log including all the fault codes and the day and time stamp of each fault will be cleared simultaneously using this procedure Step 1 Press the PROGRAM key The First Menu General parameters are P Z 50 displayed The PROGRAM LED will turn on UN ENTER RELIANCE ELECTRICAL Troubleshooting the Drive 6 11 Step 2 Press the W key until Err is displayed NTER RELIANCE ELECTRIGZD Step 3 Press the ENTER key If no faults have occured Err will be displayed again If only one fault has occurred the fault code will be displayed as the first entry in the log If more than one fault has ocurred the first entry is the latest fault that occurred AELIANGE ELECTRIG Step 4 Press the A or the W key The display steps through the error log entries which are numbered 0 through 9 maximum Step 5 Press the ENTER key The display shows the day stamp which can range from 0 to 248 days RELIANCE ELECTRICAL Carrier VFD Quick Reference Step 6 Press the W key The display shows the time stamp wh
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