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19XRV
with PIC III Controls
Rockwell PowerFlex 755 VFD Option
Start-Up and Service Instructions
SAFETY CONSIDERATIONS
Centrifugal liquid chillers are designed to provide safe and LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS
reliable service when operated within design specifica- INTERRUPTED, confirm that all circuits are deenergized before resuming
work.
tions. When operating this equipment, use good judgment
and safety precautions to avoid damage to equipment and
AVOID SPI
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CONTENTS Required Publications — The Carrier VFD option Start-Up and Service Manual must be used with the following Page manuals: SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 • The latest version of the PowerFlex 750-Series AC INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Drives manuals ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 2 • The latest revision of the Start-Up, Operation, and Main- Required Publications. . . . . . . . .
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Opening the VFD Access Door WARNING Before removing the drive enclosure, open access door and verify that the DC bus voltage has dropped to zero by checking the terminals behind the access door. Failure to observe this precaution could result in severe bodily injury or loss of life. 1. Using recommended screwdriver = 6.4 mm (0.25 in.) flat or T20 star, open access door. See Fig. 2. 2. Check to be sure that the voltage between DC+ and DC- and from each DC terminal to the chassis is zero before pr
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A19- 1832 LEGEND NO. NAME DESCRIPTION 1 Power Terminals R/L1, S/L2, T/L3, U/T1, V/T2, W/T3 PE Grounding Studs Terminating point to chassis ground 2 for incoming motor shield DC Bus and Brake +DC, -DC, BR1, BR2 3 Terminals 4 PE-A and PE-B MOV and CMC Jumper Wires A19-1833 5 DC+ and DC- Bus Voltage Test Points LEGEND Fig. 5 — Frame 6 Drive Components NO. NAME DESCRIPTION 1 Power Terminals R/L1, S/L2, T/L3, U/T1, V/T2, W/T3 PE Grounding Studs Terminating point to chassis ground 2 for incoming mo
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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. 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
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Configure the VFD — All configurations required by the VFD are supplied by the ICVC through the VFD Gateway. Any configuration changes necessary and possible are made on a19- the ICVC screens. A complete set of configurations is transmit- 1846 ted to the VFD each time the controls are powered up. The following is from the 19XRV PIC III ICVC screen. Pa- rameters in italics are to be entered or confirmed at start-up. Pa- rameters in bold are to be changed only after consulting with Carrier servic
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Vmax = Maximum measured phase-to-phase voltage b. Check motor and wiring insulation. (A to B, B to C, C to A) c. Check parameter settings on VFD_CONF screen in the ICVC. Vmin = Minimum measured phase-to-phase voltage Imbalance Calculation Formula Check Internal Jumpers — On the Main VFD Con- trol board there are two jumpers labeled J1 HARDWARE EN- (VAB + VBC + VCA) ABLE and J2 SAFETY ENABLE. J1 should be removed and Vavg = 3 J2 should be in place. See Fig. 10. (Vmax – Vmin) x 100 There are two
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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. Alert and Alarm codes are locat- ed in the 19XRV Start-Up, Operation and Maintenance Instruc- tions. Note the following differences between Carrier and Allen-Bradley terminology: • A warning message on the ICVC is an ALERT. • The same warning viewed with Rockwell Drive Explorer is a VFD ALARM. • A fa
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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. Red Flashing A major fault has occurred. Drive cannot be started until fault condition is STS (St
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DPI PORT 02 (COMPUTER PORT) DIGITAL INPUT TERMINAL BLOCKS (SLOTS 04 & 05) ETHERNET/IP ADDRESS SWITCHES DIGITAL OUTPUT TERMINAL BLOCKS (SLOTS 04 & 05) EMBEDDED ETHERNET/IP PORT MCB I/O TERMINALS (AUX FAULT / HIGH PRESSURE FAULT / ENABLE INPUT) Fig. 14 — MCB (Main Control Board) Components a19-1844 *Located outside of starter; connected by field wiring. Fig. 15 — High Pressure Switch Wiring a19-1925 10
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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 PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 100 PRESTART STARTS LIMIT 100 Excessive compressor starts 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 h
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Table 4 — ICVC Alert Codes (cont) NORMAL RUN WITH OVERRIDES ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 120 RUN CAPACITY HIGH CONDENSER 120 Condenser Pressure Check condenser water pump operation. LIMITED PRESSURE [VALUE] exceeded limit of Check for high condenser water temperatures or [LIMIT]*. low flow rate. Verify that isolation valves are open. Check Cond Press Override setting in SETUP1. 121 RUN CAPACITY HIGH MOTOR 121 Comp Motor Winding Chec
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Table 4 — ICVC Alert Codes (cont) CHILLER ALERTS ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 140 SENSOR ALERT LEAVING COND WATER 140 Sensor Fault: Check Check sensor resistance or voltage drop. TEMP Leaving Cond Water Sensor. Check for proper wiring. 141 SENSOR ALERT ENTERING COND WATER 141 Sensor Fault: Check Check sensor resistance or voltage drop. TEMP Entering Cond Water Sensor. Check for proper wiring. 142 LOW OIL CHECK OIL FILTER 142 Low Oi
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Table 4 — ICVC Alert Codes (cont) CHILLER ALERTS (cont) ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 159 SENSOR ALERT SPARE TEMPERATURE 159 Spare 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 161 WSM Cool Source — Check settings in WSMDEFME screen. COMMUNICATION Loss of Communication. Check C
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Table 5 — ICVC Alarm Codes CHILLER PROTECTIVE LIMIT FAULTS ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 200 PROTECTIVE LIMIT RECTIFIER POWER 200 Rectifier Power Fault: Malfunction within VFD Power Module. FAULT Check VFD Status. Call Carrier Service. 201 PROTECTIVE LIMIT INVERTER POWER FAULT 201 Inverter Power Fault: Malfunction within VFD Power Module. Check VFD Status. Call Carrier Service. 202 PROTECTIVE LIMIT MOTOR AMPS NOT 202 Motor Amps Not Ch
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Table 5 — ICVC Alarm Codes (cont) CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 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. Disconnect motor from VFD and megger motor. Call Carrier Service. 221 PROTECTIVE LIMIT UNUSED 221 UNUSED 222 PROTECTIVE LIMIT LINE
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Table 5 — ICVC Alarm Codes (cont) CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 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 Comp Thrust
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Table 5 — ICVC Alarm Codes (cont) CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 245 PROTECTIVE LIMIT HIGH VFD SPEED 245 Actual 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%. 246 PROTECTIVE LIMIT INVALID DIFFUSER 246 Diffuser Control Invalid Check 25%, 50%, and 75% Guide Vane and Dif- CONFIG. Configuration: Check SETUP2
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Table 5 — ICVC Alarm Codes (cont) CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT PRIMARY SECONDARY PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY STATE MESSAGE MESSAGE 259 PROTECTIVE LIMIT CCN OVERRIDE STOP 259 CCN Emergency/ CCN 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 282 Line Frequency LINE FREQUENCY in POWER screen must be [VALUE] Exceeded Configura- maintained between 45-52 H
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Table 6 — Powerflex 755 Fault Code Descriptions and Corrective Actions VFD FAULT ICVC CODE FAULT FAULT TYPE DESCRIPTION CORRECTIVE ACTION ON VFD STATE HIST SCREEN NONE 206 Processor memory fault Consult VFD manual to resolve generic fault. 0 No Entry Check Compressor Discharge High Pressure switch wiring and accuracy. Check for high condenser water temperatures, 2 207 Auxiliary Input Input is open. low water flow, fouled tubes. Check for division plate/gasket bypass. Check for nonconden
