Carrier 19XRV User Manual

Start-Up and Service Instructions

DANGER

WARNING

CAUTION

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and
reliable service when operated within design specifica­tions. When operating this equipment, use good judgment
and safety precautions to avoid damage to equipment and
property or injury to personnel.

Be sure you understand and follow the procedures and
safety precautions contained in the chiller instructions as
well as those listed in this guide.

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.
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

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 outdoors in accordance with the
latest edition of ANSI/ASHRAE 15 (American National Standards Insti­tute/American Society of Heating, Refrigerating, and Air Conditioning
Engineers). The accumulation of refrigerant in an enclosed space can dis­place oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,
especially for enclosed and low overhead spaces. Inhalation of high con­centrations of vapor is harmful 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.

NEVER EXCEED specified test pressures, VERIFY the allowable test
pressure by checking the instruction literature and the design pressures on
the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and func-

tioning before operating any chiller.
THERE IS A RISK OF INJURY OR DEATH by electrocution. High volt­age may be present on the motor leads even though the motor is not run­ning. Open the power supply disconnect before touching motor leads or
terminals.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all
refrigerant (liquid and vapor) has been removed from chiller. Traces of
vapor should be displaced with dry air or nitrogen and the work area
should be well ventilated. Refrigerant in contact with an open flame pro-
duces toxic gases.

DO NOT work on high-voltage equipment unless you are a qualified elec­trician.

DO NOT WORK ON electrical components, including control panels,
switches, VFD, or oil heater until you are sure ALL POWER IS OFF and
no residual voltage can leak from capacitors or solid-state components.

19XRV

with PIC III Controls

Rockwell PowerFlex 755 VFD Option

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS
INTERRUPTED, confirm that all circuits are deenergized 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.
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.

TO AVOID an electric shock hazard, verify that the voltage on the bus
capacitors has discharged completely before servicing. Check the DC bus
voltage at the Power Terminal Block by measuring between the +DC and ­DC terminals, between the +DC terminal and the chassis, and between the

-DC terminal and the chassis. The voltage must be zero for all three mea­surements.

THE USER is responsible to conform with 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) sensitive 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 Electrostatic Damage, or
any other applicable ESD protection handbook.

DO NOT alter the setting of any jumper. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.

USE OF power correction capacitors on the output of the drive can result
in erratic operation of the motor, nuisance tripping, and/or permanent dam­age to the drive. Remove power correction capacitors before proceeding.
Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
MOST CODES require that upstream branch circuit protection 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 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.

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.

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.
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.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53190012-01 Printed in U.S.A. Form 19XRV-3SS Pg 1 711 3-11 Replaces: New

CONTENTS

Fig. 1 — Allen Bradley Data Nameplate

A19-1830

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 2

Required Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Getting Assistance from Rockwell Automation . . . 2

IDENTIFYING DRIVE COMPONENTS. . . . . . . . . . . . 2-5

Opening the VFD Access Door . . . . . . . . . . . . . . . . . . . 3

Drive Assembly Catalog Number . . . . . . . . . . . . . . . . . 3

Components and Physical Data . . . . . . . . . . . . . . . . . . 3

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Alternate Wire Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Verify Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Configure the VFD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Commissioning the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . 6

Check Internal Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

Troubleshooting the Drive . . . . . . . . . . . . . . . . . . . . . . . . 8

• ICVC ALERT CODES

• ICVC ALARM CODES

• TEST EQUIPMENT NEEDED TO TROUBLESHOOT

• VERIFYING THAT DC BUS CAPACITORS ARE
DISCHARGED

• HIGH TEMPERATURE ALARMS

• MAIN CONTROL BOARD (MCB) COMPONENTS

Checking Power Modules and Motor Input

with Input Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . 22



Servicing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

• 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 . . . . . . . . . . . . . . . . 26

APPENDIX A — WIRING SCHEMATICS . . . . . . . 28-31

APPENDIX B — OPTIONAL BACNET

COMMUNICATIONS WIRING . . . . . . . . . . . . . . . 32-38

Page

Required Publications — The Carrier VFD option

Start-Up and Service Manual must be used with the following
manuals:

• The latest version of the PowerFlex 750-Series AC
Drives manuals

• The latest revision of the Start-Up, Operation, and Main­tenance Instructions for the 19XRV with PIC III Controls

Getting Assistance from Rockwell Automa­tion — Contact the local Rockwell Automation sales office

with any questions or problems relating to the products de­scribed in this manual. For technical support on drives between
the hours of 7:00 am and 6:00 pm CST, M-F, call 1-262-512-

8176. For information about after-hours phone support and on-

site support call 1-800-800-0522.

Before calling, have the following information available

from the Allen-Bradley data nameplate located inside the en­closure on the right wall. See Fig. 1.

• Allen-Bradley ID or CAT. NO.

• Carrier VFD Code

• Allen-Bradley serial number

INTRODUCTION

The Carrier VFD option Start-Up and Service Manual is in­tended 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
ENET — Ethernet
ICVC — International Chiller Visual Controller
IGBT — Insulated Gate Bipolar Transistor
I/O — 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

IDENTIFYING DRIVE COMPONENTS

A chiller control schematic and a VFD schematic are in-

cluded in Appendix A.

WARNING

DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input
power, wait five (5) minutes for the DC bus capacitors to
discharge and then check the voltage with a voltmeter rated
for the DC bus voltage to ensure the DC bus capacitors are
discharged before touching any internal components. Fail­ure to observe this precaution could result in severe bodily
injury or loss of life.

An isolated multimeter will be needed to measure DC bus
voltage and to make resistance checks. The drive’s DC bus
capacitors retain hazardous voltages after input power has
been disconnected.

711

2

Opening the VFD Access Door

Fig. 2 — Opening Access Door

A19-1831

Fig. 3 — Check DC Bus Terminals

A19-1814

21P 1 0248 3 - 3 -0-0 C-

21P PF755 VFD

Voltage Rating
1
2

3

Customer
C –Carrier

Meter Package
0 – No Meter Package
1 –Analog Meter Package

– 460 to 480 v, 60 Hz
– 380 to 415 v, 50 Hz
– 380 to 400 v, 60 Hz

4

PF755 Full Load Amp Rating
(Maximum Continuous Amps)*
0248 – 248
0361 – 361

Disconnect/Breaker Options

Input Reactor
0 – No Input Reactor
1 – 3% Input Line Reactor

– 401 to 439 v, 60 Hz

0477–477

3–65 KAIC Capacity Breaker

4 – 100 KAIC Capacity Breaker

Drive Assembly

3 – Unit Mount NEMA 1 Liquid Cooled

Fig. 4 — Drive Assembly Catalog Number Nomenclature

A19-1842

* For Carrier applications, maximum continuous amp
ratings are 230, 335, and 445.

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 DC­and from each DC terminal to the chassis is zero before
proceeding. See Fig. 3.

Drive Assembly Catalog Number — See Fig. 4 for

an example Catalog Number.

Components and Physical Data — The Allen-

Bradley PF755 Frame 6 drive is used for the 230-amp rated ap­plication (carrier Part No. 19XRV0230...). See Fig. 5.

The Allen-Bradley PF755 Frame 7 drive is used for the
335-amp and 445-amp rated application (Carrier Part No.
19XVR0335... and 19XVR0445... respectively). See Fig. 6.

See Fig. 7 for the dimensions of Frames 6 and 7.

1

L1 L2 L3

I

LOCKOUT/TAGOUT

DC BUS TEST
TERMINALS
LOCATED INSIDE
ACCESS DOOR

2

DC+ DC–

0V

O

0V

MULTIMETER

3

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

2

PE Grounding Studs Terminating point to chassis ground

for incoming motor shield

3

DC Bus and Brake
Terminals

+DC, -DC, BR1, BR2

4 PE-A and PE-B MOV and CMC Jumper Wires
5 DC+ and DC- Bus Voltage Test Points

A19-

1832

LEGEND

Fig. 6 — Frame 7 Drive Components

NO. NAME DESCRIPTION

1 Power Terminals R/L1, S/L2, T/L3, U/T1, V/T2, W/T3

2

PE Grounding Studs Terminating point to chassis ground

for incoming motor shield

3

DC Bus and Brake
Te r mi n a ls

+DC, -DC, BR1, BR2

4 PE-A and PE-B MOV and CMC Jumper Wires
5 DC+ and DC- Bus Voltage Test Points

A19-1833

4

Fig. 7 — Enclosure Dimensions - Frames 6 and 7

A19-1834

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.

START-UP

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 resis­tor terminals B+/R+, R- are live when the drive is con­nected 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 indica­tors on the keypad go out (if no keypad is attached see the
indicator through the keypad base). Wait 5 more minutes
before doing any work on drive connections. Do not even
open the cover before this time has expired..

Before connecting the drive to the incoming power, make
sure that the switchgear enclosure door is closed.

WARNING

The control I/O-terminals are isolated from the mains
potential. However, the relay outputs and other I/O termi­nals 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.

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

BREAKER

65 KAIC

(Standard)

100 KAIC

(Optional)

STANDARD

ABB LUG

K6TJ

STANDARD

LUG CABLE

RANGE

(3) 2/0 - 400

MCM

ALTERNATE

ABB LUG

K6TH

ALTERNATE
LUG CABLE

RANGE

(2) 250 - 500

MCM

Verify Installation — Record the following job

information:

1. Job Name

2. Job Number

3. City

4. State

5. Zip Code

Record the following nameplate information:

1. From the Allen-Bradley nameplate (Fig. 1) located inside
the VFD enclosure:

a. Allen-Bradley ID or CAT NO.
b. Allen-Bradley Serial Number
c. Carrier Part Number

2. From the machine nameplete (Fig. 8) located inside the
VFD enclosure:

a. Chiller Serial Number
b. Chiller Model
c. Motor rated load amps
d. Motor nameplate rpm
e. Motor nameplate kW
f. Motor nameplate voltage
g. IPWM (pulse width modulation) frequency
h. Voltage

3. From the drive module label (Fig. 9) 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 750 drive start-up must be registered
on the Rockwell website. Rockwell Registration site URL:
http://www.automation.rockwell.com/warp/default.asp

5

MODEL NUMBER

SERIAL NUMBER

VOLTS/PHASE/HERTZ

LOCKED ROTOR AMPS

OVERLOAD TRIP AMPS

MAX FUSE/CIRCUIT BREAKER SIZE

MIN SUPPLY CIRCUIT AMPACITY

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

MACHINE NAMEPLATE SUPPLY DATA

MACHINE ELECTRICAL DATA

SAFETY CODE CERTIFICATION

THE COMPRESSOR MOTOR CONTROLLER AND OVERLOAD PROTECTION MUST BE
IN ACCORDANCE WITH CARRIER SPECIFICATION Z-420.

19XV05008701 REV. 3

A United Technologies Company

Fig. 8 — Machine Nameplate

a19-

1846

Fig. 9 — Drive Module Label

a19­1924

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
the ICVC screens. A complete set of configurations is transmit­ted to the VFD each time the controls are powered up.

The following is from the 19XRV PIC III ICVC screen. Pa­rameters in italics are to be entered or confirmed at start-up. Pa­rameters in bold are to be changed only after consulting with
Carrier service engineering. See Table 2.

Table 2

PARAMETER DEFAULT VALUE
Motor Nameplate Voltage 460
Compressor 100% Speed

Line Freq=60 Hz? (No=50) Yes

Rated Line Voltage* 460
Rated Line Amps* 200

Rated Line Kilowatts * 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 =
2kHz)

Skip Frequency 1 (Hz) 102.0
Skip Frequency 2 (Hz) 102.0
Skip Frequency 3 (Hz) 102.0
Skip Frequency Band Line (Hz) 0.0
Voltage % Imbalance 10
Line Volt Imbalance Time (sec) 10
Line Current % Imbalance 40
Line Current Imbal Time (sec) 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.
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 ser­vice engineering.

— VFD Configurations

1

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 commis­sioning. Ensure any condensation that occurs as a result
of the ambient temperature is allowed to evaporate.

2. Enter parameters in the VFD_CONF screen.

3. Install surge suppression devices if required.

4. Review the power wiring and grounding to ensure that it
has been properly connected.

5. Visually examine the inside of the drive enclosure to:
a. Look for signs of corrosion or moisture residue.
b. Remove any dirt or debris.
c. Make sure all vents are clear.

6. Apply power to the drive and take thermal measurements
of the capacitor bank and power connections. Do this
again before start-up.

7. Measure and record the incoming line voltage. Line-to­line voltages should be balanced within 3% as calculated
by Rockwell’s procedure below:

Measure voltages phase-to-phase and phase-to-ground.

6

Vmax = Maximum measured phase-to-phase voltage

LEGEND

NO. NAME DESCRIPTION

1 HIM Connector DPI Port 1 (HIM Cradle) connection.

2

Fan Connector Power supply for internal cooling fan

(Frames 2 & 3).

3

Battery
Receptacle

User installed CR1220 lithium coin cell
battery provides power to the Real Time
Clock (Optional, not supplied).

4

DPI Port 2 Cable connection for handheld and

remote HIM options.

5

Embedded EtherNet/
IP Address Selectors

Rotary switches for setting lowest octet
of EtherNet address (forces address to

192.168.1.xxx).

6

Embedded EtherNet/
IP Connector

Network cable connection.

7

Jumper J2 SAFETY Safety enable jumper. Removed when

safety option is installed.

8

Jumper J1 ENABLE Hardware enable jumper. Removed

when a hardware enable configuration is
utilized.

9 TB1 I/O terminal block.

Fig. 10 — PF755 Main Control Board

TB1 I/O Terminal Designations

FIXED I/O TERMINAL NAME DESCRIPTION

Di 0ac

Digital Input 120V AC Connections for AC power supply.

Di C

Digital Input Common Digital input common

Di 0dc

Digital Input 24V DC Connections for DC power supply.

+24V

+24 Volt Power Connections for drive supplied 24V power.

24VC

24 Volt Common

IMPORTANT: Wiring to pluggable terminal block connectors
should be supported by wire ties or other means to help pre­vent unintentional disconnection

Di 0ac

Di C

Di 0dc

+24V

24VC

a19-1921

(A to B, B to C, C to A)

Vmin = Minimum measured phase-to-phase voltage

Imbalance Calculation Formula

Va v g =

Imbalance % =

(VAB + VBC + VCA)

3

(Vmax – Vmin) x 100

Va v g

8. Take a final thermal measurement of the capacitor bank
and power after finalizing the installation to ensure all
connections are good.

9. If a 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. If an Overcurrent fault occurs, then do the following:
a. Check for excessive load and verify load limit set-

tings on the ICVC.

b. 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 J1 HARDWARE EN­ABLE and J2 SAFETY ENABLE. J1 should be removed and
J2 should be in place. See Fig. 10.

There are two jumper wires that connect a particular termi­nal to chassis ground. The MOV and AC EMI jumper should
be connected to the PE-A terminal. The COMMON MODE
CAPACITORS to GROUND jumper should be 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:

• Recommended torque (screws and nuts) = 1.36 N·m

(120.0 lb·in)

• Recommended hex socket = 7 mm

• Recommended screwdriver = T20 star type

See Fig. 11A and Fig. 11B for the correct positions of the
jumpers.

7

Troubleshooting the Drive —

Fig. 11A — Jumper Wire Locations — Frame 6

A19-1835

Fig. 11B — Jumper Wire Locations — Frame 7

A19-1836

2

8

5

79

13

46

Allen-Bradley

Fig. 12 — Drive Status Indicator

A1
9­1815

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 locat­ed in the 19XRV Start-Up, Operation and Maintenance Instruc­tions. 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 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 = VFD FAULT
See Tables 3-6 and Fig. 12.

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 indi­cated by a message at the top of the ICVC default screen. If an
alarm occurs, the drive coasts to stop. The STS (status) light on
the drive will turn from Green to Red or Yellow (see Table 3).
The detected fault message is maintained on the display until it
is cleared by pressing the RESET softkey. See Table 5.

TEST EQUIPMENT NEEDED TO TROUBLESHOOT —
An isolated multimeter adequately rated for the DC bus volt­age will be needed to measure DC bus voltage and to make
resistance checks. Note that dedicated troubleshooting test
points are not provided.

SERVICE

WARNING

DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input
power, wait five (5) minutes for the DC bus capacitors to
discharge and then check the voltage with a voltmeter to
ensure the DC bus capacitors are discharged before touch­ing any internal components. Failure to observe this pre­caution could result in severe bodily injury or loss of life.

8

Table 3

SWING UP KEY PAD
MOUNT TO ACCESS

CONTROL BOARDS

Fig. 13 — Drive Module with Cover Removed

a19-1843

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

Steady Drive is not running, a type 1 alarm condition exists. The drive can be started.

STS (Status)

ENET

LINK

NOTES:

1. A Type 1 alarm indicates that a condition exists. Type 1 alarms
are user configurable.

Red Flashing A major fault has occurred. Drive cannot be started until fault condition is

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

Green/Red Flashing Alternately Drive is flash updating.
None (Unlit) Off Adapter and/or network is not powered, adapter is not properly connected to

Red Flashing An EtherNet/IP connection has timed out.

Steady 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

Steady Adapter is properly connected and communicating on the network.
None (Unlit) Off Adapter is not powered or is not transmitting on the network.
Green Flashing Adapter is properly connected and transmitting data packets on the network.

Steady Adapter is properly connected but is not transmitting on the network.

— Drive Status Indicator Descriptions

drive cannot be started.

cleared.

brought to a stop under system control. Fault must be cleared to continue. Use
parameter 950 [Minor Flt Config] to enable. If not enabled, acts like a major
fault.

the network, or adapter needs an IP address.

the network.

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 DIS­CHARGED — The drive’s DC bus capacitors retain hazard­ous 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 insu­lated 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
from each DC terminal to the chassis must be zero before
proceeding.

4. Once the drive has been serviced, reapply input power.

HIGH TEMPERATURE ALARMS — Coolant flow
through the cold plate is controlled by an orifice in the refriger­ant 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 is 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 dif­ference is great enough to be easily felt.

MAIN CONTROL BOARD (MCB) COMPONENTS —
Figure 13 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. 14. Note the location of the terminals labeled
MCB I/O. The high pressure switch is wired to these terminals
as shown in Fig. 15. 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.

9

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

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

STATE

100 PRESTART

101 PRESTART

102 PRESTART

103 PRESTART

104 PRESTART

105 PRESTART

106 PRESTART

107 PRESTART

108 PRESTART

109 PRESTART

110 PRESTART

111 PRESTART

*[LIMIT] 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.

PRIMARY

MESSAGE

ALERT

ALERT

ALERT

ALERT

ALERT

ALERT

ALERT

ALERT

ALERT

ALERT

ALERT

ALERT

SECONDARY

MESSAGE

STARTS LIMIT
EXCEEDED

HIGH BEARING
TEMPERATURE

HIGH MOTOR
TEMPERATURE

HIGH
DISCHARGE
TEMP

LOW
REFRIGERANT
TEMP

LOW OIL
TEMPERATURE

HIGH
CONDENSER
PRESSURE

LOW LINE
VOLTAGE

HIGH LINE
VOLTAGE

GUIDE VANE
CALIBRATION

HIGH
RECTIFIER
TEMP

HIGH
INVERTER
TEMP

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

100Excessive compressor starts
(8 in 12 hours).

101Comp Thrust Brg Temp [VALUE]
exceeded limit of [LIMIT]*.

102Comp Motor Winding Temp
[VALUE] exceeded limit of [LIMIT]*.

103Comp Discharge Temp [VALUE]
exceeded limit of [LIMIT]*.

104Evaporator Refrig Temp [VALUE]
exceeded limit of [LIMIT]*.

105Oil Sump Temp [VALUE]
exceeded limit of [LIMIT]*.

106Condenser Pressure [VALUE]
exceeded limit of [LIMIT]*.

107Percent Line Voltage [VALUE]
exceeded limit of [LIMIT]*.

108Percent Line Voltage [VALUE]
exceeded limit of [LIMIT]*.

109Actual Guide Vane Pos
Calibration Required Before Startup.

110Rectifier Temperature [VALUE]
exceeded limit of [LIMIT]*.

111Inverter Temperature [VALUE]
exceeded limit of [LIMIT]*.

Depress the RESET softkey if additional start
is required. Reassess start-up requirements.

Check oil heater for proper operation.
Check for low oil level, partially closed oil sup­ply valves, clogged oil filters.
Check the sensor wiring and accuracy.
Check Comp Thrust Brg Alert setting in
SETUP1 screen.

Check motor sensors for wiring and accuracy.
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.

Allow discharge sensor to cool.
Check sensor wiring and accuracy.
Check for excessive starts.
Check Comp Discharge Alert setting in
SETUP1 screen.

Check transducer wiring and accuracy.
Check for low chilled fluid supply
temperatures.
Check refrigerant charge.
Check Refrig Override Delta T in SETUP1
screen.

Check oil heater contactor/relay and power.
Check oil level and oil pump operation.

Check transducer wiring and accuracy.
Check for high condenser water
temperatures.
Check high condenser pressure switch wiring.

Check voltage supply.
Check voltage transformers and switch gear.
Consult power utility if voltage is low.

Check voltage supply.
Check power transformers.
Consult power utility if voltage is high.

Press STOP button on ICVC and perform
Guide Vane Calibration in Controls Test
screen.
Check guide vane actuator feedback
potentiometer.

Check that VFD refrigerant isolation valves
are open.
Check VFD refrigerant cooling solenoid and
refrigerant strainer.
Check for proper VFD cooling fan operation
and blockage.

Check that VFD refrigerant isolation valves
are open.
Check VFD refrigerant cooling solenoid and
refrigerant strainer.
Check for proper VFD cooling fan operation
and blockage.

11

NORMAL RUN WITH OVERRIDES

Table 4 — ICVC Alert Codes (cont)

ICVC FAULT

STATE

120 RUN CAPACITY

121 RUN CAPACITY

122 RUN CAPACITY

123 RUN CAPACITY

124 RUN CAPACITY

125 RUN CAPACITY

126 RUN CAPACITY

127 RUN CAPACITY

128 RUN CAPACITY

*[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.

PRIMARY

MESSAGE

LIMITED

LIMITED

LIMITED

LIMITED

LIMITED

LIMITED

LIMITED

LIMITED

LIMITED

SECONDARY

MESSAGE

HIGH CONDENSER
PRESSURE

HIGH MOTOR
TEMPERATURE

LOW EVAP REFRIG
TEMP

HIGH COMPRESSOR
LIFT

MANUAL GUIDE VANE
TA R GE T

LOW DISCHARGE
SUPERHEAT

HIGH RECTIFIER TEMP 126Rectifier Temperature

MANUAL SPEED
CONTROL

HIGH INVERTER TEMP 128Inverter Temperature

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

120Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.

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. Check for oil loss or excess refrigerant charge.

[VALUE] exceeded limit of
[LIMIT]*.

No Alert message. Chiller is not in automatic temperature control.

[VALUE] exceeded limit of
[LIMIT]*.

Check condenser water pump operation.
Check for high 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.

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.

Check Inverter 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.

12

CHILLER ALERTS

Table 4 — ICVC Alert Codes (cont)

ICVC FAULT

STATE

140 SENSOR ALERT LEAVING COND WATER

141 SENSOR ALERT ENTERING COND WATER

142 LOW OIL

143 AUTORESTART

144 AUTORESTART

145 AUTORESTART

146 AUTORESTART

147 AUTORESTART

148 AUTORESTART

149 SENSOR ALERT HIGH DISCHARGE TEMP 149

150 SENSOR ALERT HIGH BEARING

151 CONDENSER

152 RECYCLE ALERT EXCESSIVE RECYCLE

153 no message:

154 POTENTIAL

155 OPTION SENSOR

156 OPTION SENSOR

157 OPTION SENSOR

158 SENSOR ALERT SPARE TEMPERATURE#1158Spare Temperature 1

*[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.

PRIMARY

MESSAGE

PRESSURE ALERT

PENDING

PENDING

PENDING

PENDING

PENDING

PENDING

PRESSURE ALERT

ALERT
only

FREEZE-UP

FAULT

FAULT

FAULT

SECONDARY

MESSAGE

TEMP

TEMP
CHECK OIL FILTER 142Low Oil Pressure Alert.

LINE CURRENT
IMBALANCE

LINE VOLTAG E
DROP OUT

HIGH LINE VOLTAGE 145High Percent Line

LOW LINE VOLTAGE 146Low Percent Line

VFD MODULE RESET 147->VFD Module Power-On

POWER LOSS 148Control Power-Loss

TEMPERATURE

PUMP RELAY
ENERGIZED

STARTS

no message; ALERT only 153Lead/Lag Disabled-

COND PRESS/TEMP
TOO LOW

REMOTE RESET
SENSOR

AUTO CHILLED WATER
RESET

AUTO DEMAND LIMIT
INPUT

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

140Sensor Fault: Check
Leaving Cond Water Sensor.

141Sensor Fault: Check
Entering Cond Water Sensor.

Check Oil Filter.

143Line Current Imbal­ance: Check VFD Fault His­tory for Values.

144Single Cycle Line
Voltage Dropout.

Voltage [VALUE].

Voltage [VALUE].

Reset When Running.

When Running.

Comp Discharge Temp
[VALUE] Exceeded Limit of
[LIMIT]*.

150Comp Thrust Brg Temp
[VALUE] exceeded limit of
[LIMIT]*.

151High Condenser Pres­sure [VALUE]: Pump Ener­gized to Reduce Pressure.

152Excessive recycle
starts.

Config: Duplicate Chiller
Address.

154Condenser freeze up
prevention.

155Sensor Fault/Option
Disabled: Remote Reset
Sensor.

156Sensor Fault/Option
Disabled: Auto Chilled Water
Reset.

157Sensor Fault/Option
Disabled: Auto Demand Limit
Input.

[VALUE] exceeded limit of
[LIMIT]*.

Check sensor resistance or voltage drop.
Check for proper wiring.

Check sensor resistance or voltage drop.
Check for proper wiring.

Check for partially or closed shut-off valves.
Check oil filter.
Check oil pump and power supply.
Check oil level.
Check for foaming oil at start-up.
Check transducer wiring and accuracy.

Power loss has been detected in any phase.
Chiller automatically restarting.

A drop in line voltage has been detected within
2 voltage cycles.
Chiller automatically restarting if Auto Restart is
enabled in OPTIONS screen.

Check phase to phase and phase to ground line
power.

Check phase to phase and phase to ground line
power.

VFD Module has detected a hardware fault due
to electrical noise, power loss or software and
has reset. Chiller automatically restarting.
Check for power loss and sources of electro­magnetic interference.

Check 24 vac control power supply to ICVC.

Check sensor resistance or voltage drop.
Check for proper wiring.
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.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for partially closed service valves.
Check oil cooler TXV.
Check oil level and oil temperature.

Check sensor wiring and accuracy.
Check condenser flow and water temperature.
Check for fouled tubes.
This alarm is not caused by the High Pressure
Switch.

Chiller load is too low to keep compressor on
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.

Illegal chiller address configuration in Lead/Lag
screen. Both chillers require a different address.

The condenser pressure transducer is reading a
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.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J4.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J5.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J5.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J4.
Check Spare Temp #1 Limit in SETUP1 screen.

13

CHILLER ALERTS (cont)

Table 4 — ICVC Alert Codes (cont)

ICVC FAULT

STATE

159 SENSOR ALERT SPARE TEMPERATURE#2159Spare Temperature 2

161 LOSS OF

162 SENSOR ALERT EVAPORATOR

163 SENSOR ALERT CONDENSER APPROACH 163Condenser Approach

164 VFD SPEED ALERT LOW VFD SPEED 164Actual VFD Speed

165 AUTORESTART

166 AUTORESTART

167 SYSTEM ALERT HIGH DISCHARGE TEMP 167Comp Discharge Temp

168 SENSOR ALERT HUMIDITY SENSOR

*[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.

PRIMARY

MESSAGE

COMMUNICATION

PENDING

PENDING

SECONDARY

MESSAGE

WITH WSM 161WSM Cool Source —

APPROACH

LOW DC BUS VOLTAGE 165Low DC Bus Voltage:

HIGH DC BUS VOLTAGE 166High DC Bus Voltage:

INPUT

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

[VALUE] exceeded limit of
[LIMIT]*.

Loss of Communication.

162Evaporator Approach
[VALUE] Exceeded Limit of
[LIMIT]*.

[VALUE] Exceeded Limit of
[LIMIT]*.

exceeded limit of Target VFD
Speed –10%.

[VALUE] Exceeded Limit of
[LIMIT]*.

[VALUE] Exceeded Limit of
[LIMIT]*.

[VALUE] exceeded limit of
[LIMIT]*.

168Sensor Fault: Check
Humidity Sensor Input Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring to CCM connector J4.
Check Spare Temp #2 Limit in SETUP1 screen.

Check settings in WSMDEFME screen.
Check CCN communications link with WSM
(Water System Manager) Module.
Check Supervisory Part of WSM.

Check that refrigerant charge level is adequate,
waterbox division plate gaskets are sealing,
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.

Check sensors resistance or voltage drop.
Check for proper wiring.
Check Cond Approach Alert setting in SETUP1
screen.
Check for noncondensable gas in the
condenser.
Check that the condenser tubes are not fouled.

Actual VFD Speed on COMPRESS screen must
be at least 90% of Target VFD Speed.

Verify phase to phase and phase to ground line
voltage.

Verify phase to phase and phase to ground line
voltage. Monitor AC line for high transient volt­age conditions.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for excessive starts.
Check Comp Discharge Alert setting in SETUP1
screen.

Check humidity sensor wiring on CCM connec­tors J3 and J5. CCM switch SW2-1 must be in
“OFF” position.
Check Humidity Sensor Input in Controls Test.

14

CHILLER PROTECTIVE LIMIT FAULTS

Table 5 — ICVC Alarm Codes

ICVC FAULT

STATE

200 PROTECTIVE LIMIT RECTIFIER POWER

201 PROTECTIVE LIMIT INVERTER POWER FAULT 201Inverter Power Fault:

202 PROTECTIVE LIMIT MOTOR AMPS NOT

203 FAILURE TO START MOTOR ACCELERATION

204 FAILURE TO STOP VFD SHUTDOWN FAULT 204VFD Shutdown Fault:

205 PROTECTIVE LIMIT HIGH DC BUS VOLTAGE 205High DC Bus Voltage:

206 PROTECTIVE LIMIT VFD FAULT 206VFD Fault Code:

207 PROTECTIVE LIMIT HIGH CONDENSER

208 PROTECTIVE LIMIT EXCESSIVE MOTOR

209 PROTECTIVE LIMIT LINE CURRENT

210 PROTECTIVE LIMIT LINE VOLTAGE DROPOUT 210Single Cycle Line Volt-

211 PROTECTIVE LIMIT HIGH LINE VOLTAGE 211High Percent Line Volt-

212 PROTECTIVE LIMIT LOW LINE VOLTAGE 212Low Percent Line Volt-

213 PROTECTIVE LIMIT VFD MODULE RESET 213VFD Module Power-On

214 PROTECTIVE LIMIT POWER LOSS 214Control Power Loss

215 PROTECTIVE LIMIT LOW DC BUS VOLTAGE 215Low DC Bus Voltage:

216 PROTECTIVE LIMIT LINE VOLTAGE

217 PROTECTIVE LIMIT MOTOR OVERLOAD TRIP 217Motor Overload Trip;

218 PROTECTIVE LIMIT VFD RECTIFIER

219 PROTECTIVE LIMIT VFD INVERTER

*[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.

PRIMARY

MESSAGE

SECONDARY

MESSAGE

FAULT

SENSED

FAULT

PRESSURE

AMPS

IMBALANCE

IMBALANCE

OVERTEMP

OVERTEMP

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

200Rectifier Power Fault:
Check VFD Status.

Check VFD Status.
202Motor Amps Not

Sensed — Average Load
Current [VALUE].

203Motor Acceleration Fault
— Average Load Current
[VALUE].

Check Inverter Power Unit.

[VALUE] exceeded limit of
[LIMIT]*.

[VALUE]; Check VFD Fault
Code List.

207High Cond Pressure
trip. [VALUE] exceeded Switch
Trippoint.

208Percent Load Current
[VALUE] exceeded limit of
[LIMIT]*.

209Line Current Imbal­ance: Check VFD Fault His­tory for Values.

age Dropout.

age [VALUE].

age [VALUE].

Reset When Running.

When Running.

[VALUE] exceeded limit of
[LIMIT]*.

216Line Voltage Imbal­ance. Check VFD Fault His­tory for Values.

Check VFD configurations.

218VFD Rectifier Temp
Exceeded: Check Cooling and
VFD Config.

219VFD Inverter Temp
Exceeded: Check Cooling and
VFD Config.

Malfunction within VFD Power Module.
Call Carrier Service.

Malfunction within VFD Power Module.
Call Carrier Service.

Check main circuit breaker for trip. Increase
Current % Imbalance in VFD_CONF screen.

Check that inlet guide vanes are fully closed at
start-up.
Check Motor Rated Load Amps in VFD_CONF
screen. Reduce unit pressure if possible.

VFD Circuit Board malfunction.
Call Carrier Service.

Verify phase to phase and phase to ground line
voltage. Monitor AC line for high transient volt­age conditions. VFD Circuit Board malfunction.
Call Carrier Service.

See VFD Fault Code description and corrective
action.

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.

Check Motor Rated Load Amps in VFD_CONF
screen. Percent Load Current > 110
Check Motor Rated Load Amps setting.

Check phase to phase and phase to ground
power distribution bus voltage.
Check Line Current % Imbalance in VFD_CONF
screen. Consult power company.

Temporary loss of voltage. Disable Single Cycle
Dropout in VFD_CONF screen.

Check phase to phase and phase to ground dis­tribution bus voltage. Consult power company.

Check phase to phase and phase to ground dis­tribution bus voltage. Consult power company.

Temporary loss of VFD control voltage. Check
VFD control power breaker, transformer and
fuses.

Check phase to phase and phase to ground dis­tribution bus voltage.
Check VFD fuses.
Check 24 vac power supply to ICVC.
Consult power company.

Verify phase-to-phase and phase-to-ground line
voltage. VFD Circuit Board malfunction.
Call Carrier Service.

Check phase-to-phase and phase-to-ground
distribution bus voltage. Increase Line Voltage
% Imbalance in VFD_CONF screen.

Any phase current > 106% Rated Load Amps.
Can result from significant load 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.

Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling solenoid and
refrigerant strainer.
Check for proper VFD cooling fan operation and
blockage.

Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling solenoid and
refrigerant strainer.
Check for proper VFD cooling fan operation and
blockage.

%.

15

Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

ICVC FAULT

STATE

220 PROTECTIVE LIMIT GROUND FAULT 220Ground Fault Trip;

221 PROTECTIVE LIMIT UNUSED 221UNUSED
222 PROTECTIVE LIMIT LINE FREQUENCY TRIP 222Line Frequency —

223 LOSS OF

224 PROTECTIVE LIMIT VFD COMMUNICATIONS

225 PROTECTIVE LIMIT MOTOR CURRENT

226 PROTECTIVE LIMIT LINE PHASE REVERSAL 226Line Phase Reversal:

227 PROTECTIVE LIMIT OIL PRESS SENSOR

228 PROTECTIVE LIMIT LOW OIL PRESSURE 228Low Operating Oil

229 PROTECTIVE LIMIT LOW CHILLED WATER

230 PROTECTIVE LIMIT LOW CONDENSER

231 PROTECTIVE LIMIT HIGH DISCHARGE TEMP 231Comp Discharge Temp

232 PROTECTIVE LIMIT LOW REFRIGERANT

*[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.

PRIMARY

MESSAGE

COMMUNICATION

SECONDARY

MESSAGE

WITH VFD GATEWAY
MODULE

FAULT

IMBALANCE

FAULT

FLOW

WATER FLOW

TEMP

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

Check Motor and Current
Sensors.

[VALUE] exceeded limit of
[LIMIT]; Check Power Supply.

223Loss of SIO Comm with
VFD Gateway: Check VFG
Module and Power.

224Loss of DPI Comm with
VFD Gateway: Check VFG to
VFD Comm.

225Motor Current Imbal­ance: Check VFD Fault
History for Values.

Check Line Phases.
227Oil Pressure Delta P

[VALUE] (Pump Off): Check
Pump/Transducers.

Pressure [VALUE]: Check Oil
Pump and Filter.

229Low Chilled Water Flow;
Check Switch/Delta P Config
& Calibration.

230Low Condenser Water
Flow; Check Switch/Delta P
Config & Calibration.

[VALUE] Exceeded Limit of
[LIMIT]*.

232Evaporator Refrig Temp
[VALUE] exceeded limit of
[LIMIT]*.

Check for condensation on motor terminals.
Check motor power leads for phase to phase or
phase to ground shorts. Disconnect motor from
VFD and megger motor.
Call Carrier Service.

If operating from a generator, check generator
size and speed.
Check utility power supply.

Check VFD communication wiring and
connectors on VFD Gateway and DPI board.
Check for compatibility between ICVC and
Gateway software.

Check VFD communication wiring and
connectors.
Check status lights on DPI Communications
Interface Board.
Call Carrier Service.

Check Motor Current % Imbalance in
VFD_CONF screen.

Reverse connections of any two line conductors
to circuit breaker.

Check transducer wiring and accuracy.
Check power supply to pump.
Check pump operation.
Check transducer calibration.

Check transducer wiring and accuracy.
Check power supply to pump.
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.

Perform pump control test.
Check optional transducer calibration and
wiring.
Check Evaporator Refrigerant Temperature
sensor.
Check chilled water valves.
Check for evaporator saturation temperature
< 34 F if not in Pumpdown Lockout mode. Place
unit in Pumpdown mode before removing
charge.

Perform pump control test.
Check optional transducer calibration and
wiring.
Check condenser water valves.
Check for COND PRESS OVERRIDE + 5 psig.

Check for closed compressor discharge isola­tion valve.
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.

Check for proper refrigerant charge.
Check float valve operation.
Check for closed condenser liquid line isolation
valve. If problem occurs at high load, check for
low condenser pressure which causes inade­quate 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.

16

Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

ICVC FAULT

STATE

233 PROTECTIVE LIMIT HIGH MOTOR

234 PROTECTIVE LIMIT HIGH BEARING

235 PROTECTIVE LIMIT HIGH CONDENSER

236 PROTECTIVE LIMIT COMPRESS SURGE/

237 PROTECTIVE LIMIT SPARE SAFETY

238 PROTECTIVE LIMIT EXCESSIVE COMPR

239 PROTECTIVE LIMIT TRANSDUCER

240 PROTECTIVE LIMIT LOW DISCHARGE

241 PROTECTIVE LIMIT RECTIFIER

242 LOSS OF

243 POTENTIAL

244 POTENTIAL

*[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.

PRIMARY

MESSAGE

COMMUNICATION

FREEZE-UP

FREEZE-UP

SECONDARY

MESSAGE

TEMPERATURE

TEMPERATURE

PRESSURE

LOW SPEED

DEVICE

SURGE

VOLTAGE FAULT

SUPERHEAT

OVERCURRENT
WITH CCM MODULE 242Loss of Communica-

EVAP PRESS/TEMP
TOO LOW

COND PRESS/TEMP
TOO LOW

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

233Comp Motor Winding
Temp [VALUE] exceeded
limit of [LIMIT]*.

234Comp Thrust Brg Temp
[VALUE] exceeded limit of
[LIMIT]*.

235Condenser Pressure
[VALUE] exceeded limit of
[LIMIT]*.

236Compressor Surge:
Check condenser water temp
and flow.

237Spare Safety Device. Spare safety input has tripped or factory installed

238Compressor Surge:
Check condenser water temp
and flow.

239Transducer Voltage Ref
[VALUE] exceeded limit of
[LIMIT]*.

240Check for Oil in Or
Overcharge of Refrigerant.

241Rectifier Overcurrent
Fault: Check VFD Status.

tion With CCM, Check
Comm. Connectors.

243Evaporator Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.

244Condenser Refrig
Temp [VALUE] exceeded
limit of [LIMIT]*.

Check motor sensors wiring and accuracy.
Check motor cooling line and spray nozzle for
proper operation, or restrictions.
Check for excessive starts within a short time
span.

Check oil heater for proper operation.
Check for low oil level, par tially closed oil supply
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.

Check for high condenser water temperatures, low
water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check transducer wiring and accuracy.

Check for high condenser water temperatures, low
water flow, fouled tubes.
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.

jumper is not present on Terminal Block 4 terminals
17 and 20 in the VFD enclosure.

Check for high condenser water temperatures, low
water flow, fouled tubes.
Check for division plate/gasket bypass.
Check for noncondensables.
Check surge prevention parameters in OPTIONS
screen.
Check cooling tower control settings and perfor­mance to design/selection temperatures across the
entire operating range of the chiller.
Check cooler approach and water flow.

Check that CCM transducer voltage reference is
between 4.5 v and 5.5 v.
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.
Call Carrier Service.

Check for oil loss or excessive refrigerant. If oil level
is low, refrigerant charge may be too low resulting in
ineffective oil reclaim. Excessive refrigerant charge
may cause liquid carryover into compressor.
Check calibration of evaporator pressure and con­denser pressure sensors.
Check calibration of compressor discharge temper­ature sensor.

Check for high water temperatures or changes in
water flow rates.

Check wiring and control power to CCM.
Confirm that all CCM SW1 switches are in the
“OFF” position.

Check for proper refrigerant charge.
Check float valve operation.
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.

Condenser water too cold or chiller shut down with
brine below 32 F in cooler so equalization tempera­ture in chiller approached 32 F.
Check condenser pressure transducer.
Check refrigerant charge.

17

Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

ICVC FAULT

STATE

245 PROTECTIVE LIMIT HIGH VFD SPEED 245Actual VFD Speed

246 PROTECTIVE LIMIT INVALID DIFFUSER

247 PROTECTIVE LIMIT DIFFUSER POSITION

248 PROTECTIVE LIMIT SPARE TEMPERATURE #1248Spare Temperature #1

249 PROTECTIVE LIMIT SPARE TEMPERATURE #2249Spare Temperature #2

250 UNUSED UNUSED 250Unused State.
251 PROTECTIVE LIMIT VFD CONFIG CONFLICT 251VFD Config Conflict

252 PROTECTIVE LIMIT VFD CONFIG CONFLICT 252VFD Config Conflict

253 PROTECTIVE LIMIT GUIDE VANE

254 PROTECTIVE LIMIT VFD CHECKSUM ERROR 254Checksum Error:

255 PROTECTIVE LIMIT VFD DEW PREVENTION 255Dew Prevention - Cool-

256 PROTECTIVE LIMIT INDUCTOR OVERTEMP 256Inductor Overtemp Trip -

257 PROTECTIVE LIMIT VFD START INHIBIT 257VFD Start Inhibit: Check

258 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.

PRIMARY

MESSAGE

SECONDARY

MESSAGE

CONFIG.

FAULT

CALIBRATION

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

exceeded limit of Target VFD
Speed + 10%.

246Diffuser Control Invalid
Configuration: Check SETUP2
Entries.

247Diffuser Position Fault:
Check Guide Vane/Diffuser
Actuator.

[VALUE] exceeded limit of
[LIMIT]*.

[VALUE] exceeded limit of
[LIMIT]*.

(VFD Uploaded): Verify to
Reset Alarm.

(VFD Downloaded): Verify to
Reset Alarm.

253Guide Vane Fault
[VALUE]. Check Calibration.

Press Reset to Restore
Configuration

ant Too Cold. Check Solenoid
& Cond T.

Check Temp Switch and Cool­ing Fans.

VFD Diagnostic Parameters
212/214.

Actual VFD Speed on COMPRESS screen must
not exceed Target VFD Speed by more than
10%.

Check 25%, 50%, and 75% Guide Vane and Dif­fuser Load Point entries in SETUP2 screen.

Confirm that Diffuser Option in SETUP 2 screen
has not been Enabled if compressor does not
have a split ring diffuser. May indicate rotating
stall condition.
Check rotating stall transducer wiring accuracy
and sealing.
Check diffuser schedule and guide vane sched­ule 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 CCM termi­nals J3-7 and J3-8.
Check for electrical noise in CCM Diffuser Pres­sure wiring. Do not continue to operate com­pressor except for diagnostic purposes.

Check Spare Temperature Enable and Spare
Temperature Limit in SETUP1 Screen.

Check Spare Temperature Enable and Spare
Temperature Limit in SETUP1 Screen.

The VFD_CONF table in the Gateway does not
match that which is in the ICVC. This is a normal
fault if an ICVC has been uploaded with soft­ware when it was not attached to the CCM.
Enter VFD_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.

The VFD_CONF table in the Gateway does not
match that which is in the ICVC.

Enter CONTROL TEST and execute Guide
Vane Calibration.
Check CCM 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 < -1% or > 103%, or feed-
back voltage is < .045 or > 3.15 VDC.

Actual VFD checksum does not match calcu­lated value.

VFD COLDPLATE TEMP is too close to dew
point based on VFD ENCLOSURE TEMP and
RELATIVE 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.

Check for cooling fan air flow obstructions.

The VFD Start Inhibit is derived from the Alarm
bit being set in the VFD. The conditions causing
the alarm must be corrected in the VFD to
enable subsequent starts and operation. See
VFD parameters 212/214.

18

Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

ICVC FAULT

STATE

259 PROTECTIVE LIMIT CCN OVERRIDE STOP 259CCN Emergency/

282 PROTECTIVE LIMIT INVALID VFD CONFIG 282Line Frequency

283 PROTECTIVE LIMIT INVALID VFD CONFIG 283Compressor 100%

284VFD GATEWAY COMPATIBILITY

285VFD GATEWAY COMPATIBILITY

286 PROTECTIVE LIMIT INVERTER

*[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

PRIMARY

MESSAGE

SECONDARY

MESSAGE

CONFLICT

CONFLICT

OVERCURRENT

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

Override Stop.

[VALUE] Exceeded Configura­tion Range.

Speed Config Ranges: 50=Hz
45-52; 60 Hz=55-62.

284VFD Gateway Compati­bility Conflict: Check VFG/
VFD Versions.

285VFD Gateway Compati­bility Conflict: Check VFG/
ICVC Versions.

286Inverter Overcurrent
Fault: Check VFD Status.

CCN has signaled the chiller to stop.This fault
must be manually reset from the default screen
of the ICVC.

LINE FREQUENCY in POWER screen must be
maintained between 45-52 Hz if LINE
FREQ=60Hz? is set to NO(50 Hz). LINE FRE­QUENCY 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.

COMPRESSOR 100% SPEED in VFD_CONF
screen must be set between 45-52 Hz if LINE
FREQ=60Hz? is set to NO(50 Hz). COMPRES­SOR 100% SPEED must be set between
55-62 Hz if LINE FREQ=60Hz? is set to YES
(60 Hz).

VFD Gateway and VFD software versions are
not compatible.
Call Carrier Service.

VFD Gateway and ICVC software versions are
not compatible.
Call Carrier Service.

Check for high entering water temperature or
low condenser water flow.
Check current settings in VFD_CONF screen.

ICVC FAULT

STATE

260 SENSOR FAULT LEAVING CHILLED WATER 260Sensor Fault: Check

261 SENSOR FAULT ENTERING CHILLED

262 SENSOR FAULT CONDENSER PRESSURE 262Sensor Fault: Check

263 SENSOR FAULT EVAPORATOR

264 SENSOR FAULT COMPRESSOR BEARING

265 SENSOR FAULT COMPRESSOR MOTOR

266 SENSOR FAULT COMP DISCHARGE TEMP 266Sensor Fault: Check

267 SENSOR FAULT OIL SUMP TEMP 267Sensor Fault: Check Oil

268 SENSOR FAULT COMP OIL PRESS DIFF 268Sensor Fault: Check Oil

269 SENSOR FAULT CHILLED WATER FLOW 269 Sensor Fault: Check

270 SENSOR FAULT COND WATER FLOW 270Sensor Fault: Check

271 SENSOR FAULT EVAP SATURATION TEMP 271Sensor Fault: Check

PRIMARY

MESSAGE

SECONDARY

MESSAGE

WATER

PRESSURE

TEMP

TEMP

PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

Leaving Chilled Water Sensor.

261Sensor Fault: Check
Entering Chilled Water
Sensor.

Condenser Pressure Sensor.

263Sensor Fault: Check
Evaporator Pressure Sensor.

264Sensor Fault: Check
Comp Thrust Brg Temp Sensor.

265Sensor Fault: Check
Comp Motor Winding Temp
Sensor.

Comp Discharge Temp Sensor.

Sump Temp Sensor.

Pump Delta P Sensor.

Chilled Water Delta P Sensor.

Cond Water Delta P Sensor.

Evap Saturation Temp Sensor.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

Check sensor wiring.
Check for disconnected or shorted wiring.
Check for condensation in transducer
connector.

Check sensor wiring.
Check for disconnected or shorted wiring.
Check for condensation in transducer
connector.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

Check sensor wiring and accuracy.
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.

Check sensor wiring and accuracy.
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.

Check sensor resistance or voltage drop.
Check for proper wiring.
Check for disconnected or shorted wiring.

19

Table 6

VFD
FAULT
CODE

ON VFD

HIST

SCREEN

NONE 206 Processor memory fault Consult VFD manual to resolve generic fault.

0 No Entry

2 207 Auxiliary Input Input is open.

3 210 Power Loss Line voltage dropout

4 215 Undervoltage Low DC bus voltage

5 166 Overvoltage High DC bus voltage

7 217 Motor Overload An internal electronic overload trip has occurred.

8 219

9 219

12 286 HW Overcurrent

13 220 Ground Fault

14 206 Ground Warning

15 206 Load Loss

17 216

20 206 TorqPrv Spd Band See VFD Fault Code 15 See VFD Fault Code 15

21 225 Output PhaseLoss

24 204 Decel Inhibit

33 206 AuRsts Exhausted See VFD Fault Code 15 See VFD Fault Code 15

36 286 SW Overcurrent

ICVC
FAULT
STATE

Heat Sink Over­temp

Transistor Over­temp

The DC bus ripple
has exceeded a
preset level.

— Powerflex 755 Fault Code Descriptions and Corrective Actions

FAULT TYPE DESCRIPTION CORRECTIVE ACTION

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
Dropout in VFD_CONF sceen.

Verify phase-to-phase and phase-to-ground line
voltage. VFD Circuit Board malfunction.
Call Carrier Service.

Verify phase to phase and phase to ground line
voltage. Monitor AC line for high transient voltage
conditions.

Any phase current > 106% RLA. Can result from
significant load 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.

Check that VFD refrigerant isolation valves are

Heat sink temperature has exceeded the maxi­mum operating temperature

The output transistors have exceeded the maxi­mum operating temperature

The drive output current has exceeded the hard­ware current limit.

A current path to earth ground greater than 25%
of drive rating has occurred.

The ground current has exceeded the level set in
P467

If this fault appears, there may be a problem with
software configuration.

Line Voltage imbalance

The current in one or more phases has been lost
or remains below a preset level.

The drive is not following a commanded decelera­tion because it is attempting to limit the bus volt­age.

The drive output current has exceeded the 1 ms
current rating.

open.
Check VFD refrigerant cooling orifice and refrig­erant strainer.
Check for proper VFD cooling fan operation and
air flow blockage.

Check that VFD refrigerant isolation valves are
open.
Check VFD refrigerant cooling orifice and refrig­erant strainer.
Check for proper VFD cooling fan operation and
air flow blockage.

Check for high entering water temperature or low
condenser water flow. Check current settings in
VFD_CONF screen.

Check the motor, motor terminals, and external
wiring to the drive output terminals for a
grounded condition.

—

To reset the processor, cycle power to chiller,
check ICVC VFD_CONF settings and save set­tings when exiting VFD_CONF screen.
Check VFD parameters with Drive Explorer.

Check phase-to-phase and phase-to-ground dis­tribution bus voltage. Increase Line Voltage %
Imbalance in VFD_CONF screen.

Check Motor Current % Imbalance in
VFD_CONF screen.

Verify input voltage is within drive specified limits.
Verify system ground impedance follows proper
grounding techniques.
Disable bus regulation P186 and/or add dynamic
brake resistor and/or extend deceleration time
P537 and P538.

Check for excess load, improper DC boost set­ting, DC brake volts set too high.

20

Table 6

VFD
FAULT
CODE

ON VFD

HIST

SCREEN

38
39 Phase V to Gnd

40 Phase W to Gnd

41
42 Phase VW Short

43 Phase WU Short

44 206

45 206 Phase VNot ToGnd

46 206

55 NONE Inverter Overtemp

61 206 Shear Pin 1 See VFD Fault Code 15 See VFD Fault Code 15
62 206 Shear Pin 2 See VFD Fault Code 15 See VFD Fault Code 15

64 206 Drive Overload Drive is overloaded

65 206 OW TrqLvlTimeout See VFD Fault Code 15 See VFD Fault Code 15
77 206 IR Volts Range See VFD Fault Code 15 See VFD Fault Code 15

78 206

79 206 Excessive Load

80 206 AutoTune Aborted See VFD Fault Code 15 See VFD Fault Code 15

87 206 IXo VoltageRange

91 206 Pri VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15
93 206 HW Enable Check See VFD Fault Code 15 See VFD Fault Code 15
94 206 Alt VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15
95 206 Aux VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15
96
97 206 Auto Tach Switch See VFD Fault Code 15 See VFD Fault Code 15

100 206 Parameter Chksum

107 NONE Replaced MCB-PB

113 206 Tracking DataErr Internal data error.

124 206 App ID Changed Application firmware changed. Verify application version.
141 206 Autn Enc Angle P78 [Encdrlss AngComp] is out of range See VFD Fault Code 15
142 206 Autn Spd Rstrct See VFD Fault Code 15 See VFD Fault Code 15
143 206 Autotune CurReg See VFD Fault Code 15 See VFD Fault Code 15
144 206 Autotune Inertia See VFD Fault Code 15 See VFD Fault Code 15
145 206 Autotune Travel See VFD Fault Code 15 See VFD Fault Code 15

ICVC
FAULT
STATE

220

246

206 PositionFdbkLoss See VFD Fault Code 15 See VFD Fault Code 15

— Powerflex 755 Fault Code Descriptions and Corrective Actions (cont)

FAULT TYPE DESCRIPTION CORRECTIVE ACTION

Phase U to Gnd

Phase UV Short

Phase UNot

Phase WNot

FluxAmpsRef
Rang

GROUND FAULT

GROUND FAULT

GROUND FAULT (no LF2 equivalent)

The temperature sensor on the main control
board detected excessive heat.

See VFD Fault Code 15 See VFD Fault Code 15

Motor did not come up to speed in the allotted
time

Ixo voltae calculated from motor nameplate data
is too high.

The checksum read from the board does not
match the checksum calculated.

The main control board was moved to a different
power structure. Data set to default values.

Check the wiring between the drive and the
motor.
Check motor for grounded phase.
Check Motor terminals. d. Replace drive.

Check the wiring between the drive and the
motor.
Check Motor terminals.
Replace drive.

Check the wiring between the drive and the
motor.
Check Motor terminals.
Replace drive.

Check that VFD refrigerant isolation valves are
open.Check VFD refrigerant strainer

Check for high entering water temperature or low
condenser water flow. Check current settings in
VFD_CONF screen.

Check that guide vanes are closed completely.
Check for high entering water temperature or low
condenser flow.
Repeat Autotune

Re-enter motor nameplate data in VFD_CONF
screen.

Press ICVC reset.
Check VFD_CONF parameters.
Cycle power to the drive.

Press ICVC reset.
Check VFD_CONF parameters.
Cycle power to the drive.

Press ICVC reset.
Cycle power to the drive

21

Table 6

VFD
FAULT
CODE

ON VFD

HIST

SCREEN

168 206

210 206

211 206 Safety Brd Fault See VFD Fault Code 15 See VFD Fault Code 15
213 206 Safety Jumper In See VFD Fault Code 15 See VFD Fault Code 15
291 206 HSFan Lifwe See VFD Fault Code 15 See VFD Fault Code 15
292 206 InFan Life See VFD Fault Code 15 See VFD Fault Code 15
293 206 MtrBrg Life See VFD Fault Code 15 See VFD Fault Code 15
294 206 MtrBrg Lube See VFD Fault Code 15 See VFD Fault Code 15
295 206 MachBrg life See VFD Fault Code 15 See VFD Fault Code 15
296 206 MachBrg Lube See VFD Fault Code 15 See VFD Fault Code 15
315 206 Excess Psn Error See VFD Fault Code 15 See VFD Fault Code 15
316 206 Node Fault Error See VFD Fault Code 15 See VFD Fault Code 15

ICVC
FAULT
STATE

— Powerflex 755 Fault Code Descriptions and Corrective Actions (cont)

FAULT TYPE DESCRIPTION CORRECTIVE ACTION

HeatSinkUnder­Tmp

HW En Jumper
Out

Heatsink temperature sensor is reporting a value
below -18.7 C (-1.66 F) or the sensor feedback
circuit is open.

See VFD Fault Code 15 See VFD Fault Code 15

Check heat sink temperature sensor. Check heat
sink temperature.

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.

2. Verify there is no voltage at the drive’s input power termi­nals.

3. Using a voltmeter, check the DC bus potential as de­scribed above to ensure the DC bus capacitors are dis­charged.

4. Disconnect the motor from the drive.

5. Check all AC line and DC bus fuses.

6. Use a multimeter to check the input diodes and output
IGBTs if a fuse is open.

7. Check motor impedance.

8. Reconnect the motor to the drive.

9. Reapply input power. See Tables 7 and 8.

WARNING

Confirm that the DC bus has discharged before performing
diode checks.

Table 7

METER LEAD

(+) (-)

R DC+ 0.5 V

S DC+ 0.5 V
T DC+ 0.5 V

R DC- infinite (OL)

S DC- Infinite (OL)
T DC- Infinite (OL)

U DC+ 0.5 V

V DC+ 0.5 V

W DC+ 0.5 V

U DC- infinite (OL)

V DC- Infinite (OL)

W DC- Infinite (OL)
DC+ R Infinite (OL)
DC+ S Infinite (OL)
DC+ T Infinite (OL)

DC- R 0.5 V
DC- S 0.5 V

DC- T 0.5 V
DC+ U Infinite (OL)
DC+ V Infinite (OL)
DC+ W Infinite (OL)

DC- U 0.5 V

DC- V 0.5 V

DC- W 0.5 V

NOTE: Digital meters require a special diode check function
because the current sourced by the meter during a normal resis­tance (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.

— Diode Checks

METER READING

22

Servicing the Drive

Fig. 16 — Open Access Door

A19-1831

1

L1 L2 L3

O

I

2

DC+ DC–

0V

0V

LOCKOUT/TAGOUT

MULTIMETER

DC BUS TEST
TERMINALS
LOCATED INSIDE
ACCESS DOOR

Fig. 17 — Check DC Bus Terminals

A19-1814

90°

SLIDE
ENCLOSURE
FORWARD

LOOSEN
ENCLOSURE
FASTENERS

Fig. 18 — Removing Enclosure

A19-1816

WARNING

To guard against possible personal injury and/or equipment
damage:

1. Inspect all lifting hardware for proper attachment be­fore lifting drive.

2. Do not allow any part of the drive or lifting mecha­nism to make contact with electrically charged con­ductors or components.

3. Do not subject the drive to high rates of acceleration
or deceleration while transporting to the mounting lo­cation or when lifting.

Do not allow personnel or their limbs directly underneath
the drive when it is being lifted and mounted.

WARNING

DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input
power, wait five (5) minutes for the DC bus capacitors to
discharge and then check the voltage with a voltmeter to
ensure the DC bus capacitors are discharged before touch­ing any internal components. 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. 16.

2. Check to be sure that the voltage between DC+ and DC­and from each DC terminal to the chassis is zero before
proceeding. See Fig. 17.

3. Remove the enclosure. See Fig. 18.

REMOVING THE DRIVE — The dimensions and weights
specified must be taken into consideration when removing the
drive. All lifting equipment and lifting components (hooks,
bolts, lifts, slings, chains, etc.) must be properly sized and rated
to safely lift and hold the weight of the drive while removing it.
See Fig. 19. The drive weights are as follows:

• Drive weight for Frame 6: 85 lb.

• Drive weight for Frame 7: 160 - 249 lb.

When replacing the drive, reverse the procedures and tight­en to the torques for the Frames 6 and 7 Power Terminal Block
referred to in Table 8.

Table 8

FRAME

RIGGING THE ENCLOSURE —

— Frames 6 and 7 Power Terminal Block

MAXIMUM LUG

WIDTH
6 34.6 mm (1.36 in.) 11.3 N
7 43.5 mm (1.71 in.) 11.3 N

RECOMMENDED

TORQUE

·m (100 in.-lb) M8 x 1.25

·m (100 in.-lb) M8 x 1.25

Where overhead room

TERMINAL
BOLT SIZE

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. The total weight
for Frames 6 and 7, including drive weight and enclosure, is
720 lb. All lifting equipment and lifting components (hooks,
bolts, lifts, slings, chains, etc.) must be properly sized and rated
to safely lift and hold the weight of the enclosure and drive
while removing. See Fig. 20A and Fig. 20B.

23

DRIVE RIGGING ACCESS
DRIVE WIDTH + 4 IN.

FRONT VIEW

SIDE VIEW

DRIVE RIGGING
ACCESS

2 IN.

2 IN.

DRIVE POSITIONED FOR
VERTICAL LIFT

SUPPORT FROM
BELOW

DRIVE EXTENDS
BEHIND MAIN
ENCLOSURE

Fig. 19 — Enclosure Access for Removing Drive

A19-1818

a19-1817

>

1

/

2 A

A

<45°

Fig. 20A — Rigging the Enclosure, Frame 6

A19-1837

>

1

/

2 A

A

<45°

Fig. 20B — Rigging the Enclosure, Frame 7

A19-1838

REPLACING THE GATEWAY (A-B20-750-20COMM
OPTION CARD) — The following are the steps for remov­ing and replacing the existing gateway.

1. Disconnect power to the drive. Before removing the en­closure, open the access door on the front of the drive.
See Fig. 16.

2. Check to be sure that the voltage between DC+ and DC­and from each DC terminal to the chassis is zero before
proceeding. See Fig. 17.

3. Remove the enclosure. See Fig. 18.

4. Remove the 2 screws securing the mounting plate and re­move the mounting plate and COMM card. See Fig. 21.

5. Mount the new COMM card and mounting plate and at­tach with the 2 screws removed in Step 4. See Fig. 22.

6. Use the shorter ribbon cable to connect the plug on the
COMM card to the connector on the mounting plate. See
Fig. 21.

7. Install the enclosure. See Fig. 18.

24

0.45-0.67 N-m

(4.0-6.0 lb.-in.)

3 PLACES

MOUNTING PLATE

GATEWAY

RIBBON CABLE

Fig. 21 — COMM Card

A19-1819

MOUNTING PLATE

GATEWAY

Fig. 22 — Mount COMM Card Plate to Drive

A19-1820

T20

2.6 N•m (23 lb•in.)

CHILL PLATE
FAN POWER
CONNECTION

CHILL PLATE FAN

Fig. 23 — Chill Plate Fan, Frame 6

A19-1839

T20

2.6 N•m

(23 lb•in.)

T20

2.6 N•m

(23 lb•in.)

INTERNAL FAN

Fig. 24 — Internal Fan, Frame 6

A19-1840



CHILL PLATE FAN AND INTERNAL FAN REPLACE­MENT — The following are the steps to replace the chill plate
fan and internal fan in Frames 6 and 7.

Frame 6:

1. Disconnect power to the drive. Before removing the en­closure, open the access door on the front of the drive.
See Fig. 16.

2. Check to be sure that the voltage between DC+ and DC­and from each DC terminal to the chassis is zero before
proceeding. See Fig. 17.

3. Remove the enclosure. See Fig. 18.

4. Remove and replace the chill plate fan. See Fig. 23.

5. Remove and replace the internal fan. See Fig. 24.

6. Install the enclosure. See Fig. 18.

25

711

Frame 7:

Fig. 25 — Chill Plate and Internal Fans, Removal

and Replacement, Frame 7

A19-1841

3P

KTK/FNQ-R

30A

111

222

1 2 3 4 5 6

7 8
9 10 11 12 13

14
15 16 17 18

19
20 21 22 23 24 25

TB4

26 27 28 29 30 31

32 33
34 35 36 37 38 39 40 41 42 43 44

45 46
47 48 49 50 51 52

53
54 55 56 57

58
59 60 61 62 63 64 65 66 67 68 69 70 71

72 73
74 75 76 77 78 79 80

876 5

4 3 21

9

14

12 11 10

13

CR1

876 5

4 3 21

9

14

12 11 10

13

CR2

876 5

4 3 21

9

14

12 11 10

13

CR3

876 5

4 3 21

9

14

12 11 10

13

CR4

876 5

4 3 21

9

14

12 11 10

13

CR5

876 5

4 3 21

9

14

12 11 10

13

CR6

EA1

CB1

CABLE
ACCESS
CUTOUT

SECONDARY SIDE

PT1

CB

1
2
3 4
5
6 7 8

9 10 11 12

1314 15

16
1718 19 20 21

22
2324
25

TB4

2627
2829 30

31
32
3334 35

36
3738
3940

4142
43
4445
4647
4849 50 51 52 53

54
5556
57
5859 60 61 62 63

64
6566 67 68 69 707172 7374

75
76
7778
79
80

87654

3

21

9

14

1211
10

13

CR1

87654

3

21

9

14

1211
10

13

CR2

876

5

4

3

21

9

14

1211
10

13

CR3

876

5

4

3

21

9

14

1211
10

13

CR4

87654

3

21

9

14

1211
10

13

CR5

876

5

4

3

21

9

14

1211
10

13

CR6

PT1

SECONDARY
SIDE

TOWARD
DOOR

CB2

FRONT VIEW
DOOR REMOVED

LEFT SIDEWALL

VIEW FROM INSIDE

1

80

LINE-

PE

6

5

3

2

4

1

TB1,TB2,
FU1-FU3

TB4

CR1

CR6

DIST.
SIDE

TB1 TB2

FU2

FU1 FU3

Fig. 26 — Assembly Parts

LEGEND

1—Power Module
2—Input Circuit Breaker
3—15 Amp Control Circuit Breaker
4—Control Transformer
5—Control Fuses
6—Control Relays (CR1 - CR5)

a19-1847

1. Disconnect power to the drive. Before removing the en­closure, open the access door on the front of the drive.
See Fig. 16.

2. Check to be sure that the voltage between DC+ and DC­and from each DC terminal to the chassis is zero before
proceeding. See Fig. 17.

3. Remove the enclosure. See Fig. 18.

4. Remove and replace the Heat Sink and Internal and fans.
See Fig. 25.

Install the enclosure. See Fig. 18.

Part Identification and Location — See Fig. 26-28

for parts descriptions and locations.

INTERNAL FANS

2.6 N•m (23 lb•in.)

X2

5.20 N•m
(46 lb•in.)

T15

T15

T20

2.6 N•m (23 lb•in.)

CHILL PLATE FANS

26

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 Series, Type 4X/12 Chill Plate

(Heatsink) Fan Kit

8 — Chill Plate Fan

NOTE: When replacing the Main Control Board (Item No. 1) the jumper marked
“J1 ENABLE” must be removed and the jumper marked “J1 SAFETY” must be
left in place.

a19-1848

Fig. 27 — Frame 6 Parts

Fig. 28 — Frame 7 Parts

LEGEND

NOTE: When replacing the Main Control Board (Item No. 1) the jumper marked “J1 ENABLE” must be
removed and the jumper marked “J1 SAFETY” must be left in place.

1—Slot for Gateway (Gateway Not Shown)
2—PF750 Series, Backplane Interface
3—PF750 Series, Type 4X/12 Heatsink Fan Kit
4—PF750 Series, Power Interface
5—PF750 Series, Bus Cap Assembly
6—PF750 Series, Power Interface Cable
7—PF750 Series, Current Transducer Kit
8 — PF750 Series, Precharge Kit
9—Slot for 24V I/O Module (24V I/O Module Not Shown)

10 — PF755 Main Control Board

a19-1849

27

AUTO DEMAND LIMIT

a19-1946

(OPTIONAL)

AUTO CHILLED WATER
RESET (OPTIONAL)

EVAP ENT
WATER TEMP

EVAP LVG
WATER TEMP

COND ENT
WATER TEMP

COND LVG
WATER TEMP

G.V. POSITION
FEEDBACK

EVAP REFRIG

LIQUID TEMP

REMOTE TEMP
RESET
(OPTIONAL)

COMP'R
DISCH TEMP

COMP'R THRUST
BRG TEMP

COMP'R OIL
SUMP TEMP

COMP'R
MOTOR TEMP

NOISE
SUPPRESSOR

SPARE TEMP #1
(OPTIONAL)

SPARE TEMP #2
(OPTIONAL)

OIL SUMP
PRESS

OIL PUMP
DISCH PRESS

LOAD RESISTOR

RELATIVE

HUMIDITY

(WHT)

LOAD RESISTOR

LOAD RESISTOR

JUMPER

LOAD RESISTOR

JUMPER

EVAP PRESS

COND PRESS

APPENDIX A — WIRING SCHEMATICS

CHILLER CONTROL SCHEMATIC

+

+

(SHIELD)

SWITCH POSITION

O

1

32

N

SW "ON" = EXT 4-20mA

SW "OFF" = EXT 1-5Vdc

SW2

1 "OFF"

2 "ON"

3 "ON"

ALL SWITCHES SET
TO "OFF" POSITION

6

J6

CCM

(SHIELD)

+-

1J7234

3

SW1

12345678

0

N

2

J1

1

-+-+

1J82

J9J10

3

2

J11

1

6

5

4

J12

3

2

1

(RED)

CB1

(GRY) (GRY)

(GRY)

(CLR)

(BLK)

(SHIELD)

4-20mAkw

OUTPUT

(CLR)

(RED)

(BLK)

(BLK)

(

(BLU)

(BLK)

(WHT)

(ORN)

SERVICE

DIFFUSER ACTUATOR

COMMON

G.V. INCREASE

G.V. DECREASE

GUIDE VANE ACTUATOR

CB2

)NRB

31

C2

(WHT)

(RED)

(GRY)

(BLK)

(CLR)

(RED)

(RED)

(BLK)

(CLR)

(

(BLU)

(ORN)

)KLB

3C

C2 C1

C1

1C

(RED)

6

2C

(RED)

(GRY)

L1

L2

L1

L2

(YEL)

(BLK)

(BRN)

(BRN)

(BRN)

)RLC(

J7

J1

5

4

3

2G

J8

X

3

2

24VAC

+-1

(BLK)

(WHT)

VFD COOLANT
SOLENOID

*

)RLC

(

HGBP (OPTIONAL)

(BRN)

COMP'R OIL PUMP

COMP'R OIL HEATER

ALARM

R

STOP

NOTE: GND SHIELDS AT THIS END ONLY

)

DLEIHS()DLEIHS(

(RED)

+

(

G

)KLB

()KLB(

-

SP

1

2

ICVC

(YEL)

(RED)

(BLK)

(CLR)

(BLK)

(BRN)

(WHT)

(RED)

(GRY)

(WHT)

(BLK)

)THW(

NCC)THW

EXT
4-20mA

(1-5vdc)

EXT
4-20mA

(1-5vdc)

+-+-+-

6

5432J51

(RED)

(BLK)

(RED)

(BLK)

(RED)

(BLK)

(RED)

(BLK)

4

(CLR)

78

(BLK)

10K

(SHIELD)

(RED)

(BLK)

(WHT)

(BLK)

(RED)

(BLK)

1

(CLR)

2

(BLK)

3

(SPARE)

(RED)

(BLK)

1

(CLR)

2

(BLK)

3

(SPARE)

(WHT)

(BLK)

(WHT)

(BLK)

-

+

-

+

RMS

-

+

-

+

(BLK)

(CLR)

(RED)

(BLK)

(CLR)

(RED)
(BLK)

-

4.3K

S

(RED)

+

10K

4.3K

4.3K

(BLK)

(CLR)

(RED)

(BLK)

(CLR)

(RED)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

1

2

3

4

5

6

J4 (UPPER)

J4 (LOWER)

100»f

100»f

J3 (UPPER)

J3 (LOWER)

J2

28

APPENDIX A — WIRING SCHEMATICS (cont)

(RED)

(BLK)

(BRN) (BRN)

(WHT)

T2

24VAC

(GRN)

(RED)

(RED)

(BLU)

(BLU)

(BLK)

SOLENOID

HGBP

(YEL)

(YEL)

(BLK)

(BLK)

2123

3C

42

(WHT)

(BLK)

3

6

5

4

2

1

HOT GAS BYPASS

(FR #7 & 8 HT EXCH)

115V CONTROL ONLY

(RED)

ACTUATOR

HGBP

COM

OPEN

CLOSE

(GRN)

(BLK)

(BLU)

3C

3C

42

65

(WHT)

230V WIRING MODIFICATION

COMP'R OIL HEATER

(BLK)

(BLK)

(WHT)

(WHT)

(BLK)

13

11

12

1C

1C

1C

(FR #1 - 6 HT EXCH)

HOT GAS BYPASS

(BLU)

(BLK)

(GRN)

(RED)

(RED)

(BLU)

(BLU)

(BLK)

SOLENOID

HGBP

(YEL)

(YEL)

(BLK)

(BLK)

3C

SHOWN WIRED FOR 115V

230V WIRING MODIFICATION

42

(WHT)

(RED)

(BLK)(BLK)

(WHT)

WHT

)THW()TH

W(

COMP'R OIL PUMP MOTOR

WINDING HIGH TEMPERATURE

WHT

(WHT)

(BLK)

(BLK)

COMP'R DISCH

HIGH PRESS

(CLR)

(RED)

(SHIELD)

(BLK)

A

C

17

51

50

43

B

(BRN)

(RED)

(ORN)

(BLK)

COMP'R OIL HEATER

(WHT)

(BLK)

(WHT)

(WHT)

(BLK)

(BLK)

23

21

22

13

11

12

1C

1C

1C

115V

230V

COM

TO TB-G **

(RED)

(YEL)

(BLK)

RED

YEL

BLK

23

21

22

2C

2C

2C

13

11

12

VOLTAGE

PER JOB

REQM'T

M

COMP'R OIL

PUMP MOTOR

(1-1/2 HP)

TO VFD

T1

24VAC

(RED)

(BLK)

(BRN) (BRN)

(WHT)

(RED) (GRY)

(RED)

(GRY)

(WHT)

(WHT)

(BLK)

(BLK)

(BRN)

(YEL)

(RED)

(CLR)

(BLK)

(RED)

(BLK)

(BRN) (BRN)

(WHT)

T3

24VAC

(RED) (GRY)

UPC

1

2

a19-1947

LEGEND

* Standard on LF2 drive; optional on machines equipped with
other VFDs.

CB Circuit Breater
CCM Chiller Control Module
HGBP Hot Gas Bypass
ICVC International Chiller Visual Controller
RHS Relative Humidity Sensor
UPC Universal Protocol Controller
VFD Var iabl e Fre quency Drive

Denotes Control Panel Terminal

Denotes Oil Pump Terminal

Denotes Power Panel Terminal

**

Denotes Motor Starter Panel Conn
Denotes Component Terminal
Wire Splice
Denotes Conductor male/Female Connector
Option Wiring

CHILLER CONTROL SCHEMATIC (cont)

29

NOTNOT

USEDUSED

a19-1966

APPENDIX A — WIRING SCHEMATICS (cont)



ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical)

CONTINUED ON
FAC IN G PAGE

611

30

APPENDIX A — WIRING SCHEMATICS (cont)

3434

3333

TB4

TB4

CARRIER
F

ACTORY

WIRING

DETAIL A

SEE

DETAIL

A

3535

3636

TB4

TB4

CARRIER
F

ACTORY
WIRING

DETAIL B

POWER

PANEL

POWER

PANEL

SEE

DETAIL

B

43

19

a19-1967

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 — I/O Card Mounting Slot Board
REM — Remote
ROC — Relay Output Common
SHLD — Shield
TB — Terminal Block

* Located outside of starter; connected by field wiring.



ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)

31

611

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING

Fig. B — Address Rotary Switches

a48-8578

Fig. A — UPC Open Controller

8

7

6

5

4

3

2

1

0

9

8

7

6

5

4

3

2

1

0

9

BACNET
BAUD RATE
DIP SWITCHES

ADDRESS
ROTARY
SWITCHES

POWER LED

RUN LED

ERROR LED

BACNET
CONNECTION
(BAS PORT)

BT485
TERMINATOR

Tx2 LED

Rx2 LED

Tx1 LED

Rx1 LED

EIA-485
JUMPERS

* Sponsored by ASHRAE (American Society of Heating, Refrigerat­ing and Air Conditioning Engineers).

a48-8579

Optional BACnet* Communications Wiring —

The following section is used to configure the UPC Open con­troller which is used when the BACnet communications option
is selected. The UPC Open controller is mounted in a separate
enclosure below the main control box.

TO ADDRESS THE UPC OPEN CONTROLLER — The
user must give the UPC Open controller an address that is
unique on the BACnet network. Perform the following proce­dure to assign an address:

1. If the UPC Open controller is powered, pull the screw ter­minal connector from the controller's power terminals la­beled 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 con­troller's address. Set the Tens (10's) switch to the tens dig­it of the address, and set the Ones (1's) switch to the ones
digit.

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 Ones (1's) switch to 5.

0

1

9

2

8

3

7

8

7

10's

4

6

5

0

1

9

2

3

1's

4

6

5

BACNET DEVICE INSTANCE ADDRESS — The UPC
Open controller also has a BACnet Device Instance address.
This Device Instance MUST be unique for the complete BAC­net system in which the UPC Open controller is installed. The
Device Instance is auto generated by default and is derived by
adding the MAC address to the end of the Network Number.
The Network Number of a new UPC Open controller is 16101,
but it can be changed using i-Vu

®

Tools or BACView device.
By default, a MAC address of 20 will result in a Device In­stance of 16101 + 20 which would be a Device Instance of

1610120.

32

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Fig. C — DIP Switches

a48-

8580

Fig. D — Network Wiring

a48-8581

CONFIGURING THE BAS PORT FOR BACNET MS/
TP — Use the same baud rate and communication settings for
all controllers on the network segment. The UPC Open con­troller 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 the controller's power termi­nals 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 DS8 through DS5 to “MSTP.” See Table A.

Table A — SW3 Protocol Switch Settings

for MS/TP

DS8 DS7 DS6 DS5 DS4 DS3

OffOffOffOffOnOff

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 appro­priate 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 DS2 DS1

9,600 Off Off
19,200 On Off
38,400 Off On
76,800 On 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.

Wire the controllers on an MS/TP network segment in a dai­sy-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 and last controller on
a network segment to add bias and prevent signal distortions
due to echoing. See Fig. B, 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 current­ly 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.

33

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Fig. E — BT485 Terminator Installation

a48-8582

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

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

Twi st 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

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 lb/1000 feet (17.9 kg/km)

UL Temperature Rating

Vo lt ag e 300 Vac, power limited

Listing UL: NEC CL2P, or better

LEGEND

AWG — American Wire Gage
CL2P — Class 2 Plenum Cable
DC — Direct Current
FEP — Fluorinated Ethylene Polymer
NEC — National Electrical Code
O.D. — Outside Diameter
TC — Tinned Copper
UL — Underwriters Laboratories

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.

SmokeGard 167°F (75°C)
Halar -40 to 302°F (-40 to 150°C)

temperature rating specifications list two acceptable alterna­tives. 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.

34

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Fig. F — BACview6 Device Connection

Table D — Open System Wiring Specifications and Recommended Vendors

WIRING SPECIFICATIONS RECOMMENDED VENDORS AND PART NUMBERS

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

Network (RS-485)

Rnet 4 conductor, unshielded, CMP, 18 AWG, plenum rated. W184C-2099BLB 6302UE 21450 CLP0442

LEGEND

AWG — American Wire Gage
CL2P — Class 2 Plenum Cable
CMP — Communications Plenum Rated
FEP — Fluorinated Ethylene Polymer
TC — Tinned Copper

specifications.
24 AWG, single twisted shielded pair, low capacitance, CL2P,

TC foam FEP, plenum rated. See MS/TP Installation Guide
for specifications.

Connect Air

International

W221P-22227 — 25160PV CLP0520LC

W241P-2000F 82841 25120-OR —

Belden RMCORP

Contractors

Wire and Cable

LOCAL ACCESS TO THE UPC OPEN CONTROL­LER — The user can use a BACview

6

handheld keypad dis­play unit or the Virtual BACview software as a local user inter­face 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 BACview

6

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 re­quire an additional USB link cable for connection.

See the BACview Installation and User Guide for instruc-

tions on connecting and using the BACview

To order a BACview

6

Handheld (BV6H), consult Commer-

6

device.

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) num­ber and CCN Bus number. The factory default settings for
CCN Element and CCN Bus number are 1 and 0 respectively.

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 Ad­dress and Bus number in the ComfortLink control. These con­figurations 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 Ad­dress and Bus Number in the UPC Open controller. These con­figurations can be changed using the accessory BACview

6

dis-

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.

35

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (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. B 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.

Table E — LED Status Indicators

LED STATUS

Power

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.

Lights when power is being supplied to the controller. The UPC Open controller is protected by internal solid-state polyswitches on
the incoming power and network connections. These polyswitches are not replaceable and will reset themselves if the condition
that caused the fault returns to normal.

Table F — Run and Error LEDs Controller and Network Status Indication

RUN LED ERROR LED STATUS

2 flashes per second Off Normal
2 flashes per second 2 flashes, alternating with Run LED Five minute auto-restart delay after system error
2 flashes per second 3 flashes, then off Controller has just been formatted
2 flashes per second 1 flash per second Controller is alone on the network
2 flashes per second On Exec halted after frequent system errors or control programs halted
5 flashes per second On Exec start-up aborted, Boot is running
5 flashes per second Off Firmware transfer in progress, Boot is running
7 flashes per second 7 flashes per second, alternating with Run LED Ten second recovery period after brownout
14 flashes per second 14 flashes per second, alternating with Run LED Brownout

IMPORTANT: Power must be ON to the UPC Open 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 control­ler is shown in Table G.

36

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)



Table G — Network Points List

POINT DESCRIPTION

1st Current Alarm State ALARM_01 R N/A 0-270 AV:4 alarm_01_1
Active Demand Limit DEM_LIM R/W % N/A 40 to 100 AV:6 dem_lim_1
Actual Guide Vane Position GV_POS R % N/A 0 to 100 AV:7 gv_pos_1
Actual VFD Speed VFD_ACT R % N/A 0 to 110 AV:11 vfd_act_1
Calc Evap Sat Temp EAT R °F N/A -40 to 245 AV:13 ert_1
Chilled Water Deadband CWDB R ^F 1.0 0.5 to 2.0 AV:14 cwdb_1
Chilled Water Delta P CHWPD R ^F N/A -6.7 to 420 AV:15 chwpd_1
Chilled Water Delta T CHW_DT R ^F N/A -40 to 245 AV:16 chw_dt_1
Chilled Water Pump CHLP R N/A OFF OFF/ON BV:4 chlp_1
Chilled Water Temp CHW_TMP R °F N/A -40 to 245 AV:17 chw_tmp_1
Chiller Start/Stop CHIL_S_S R/W N/A STOP STOP/START BV:5 chil_s_s_1
Comp Discharge Temp CMPD R °F N/A -40 to 245 AV:18 cmpd_1
Comp Motor Winding Temp MTRW R °F N/A -40 to 245 AV:19 mtrw_1
Comp Thrust Brg Temp MTRB R °F N/A -40 to 245 AV:20 mtrb_1
Cond Water Flow CDW_FLOW R N/A NO NO/YES BV:6 cdw_flow_1
Cond Water Pump CDP R N/A OFF OFF/ON BV:7 cdp_1
Condenser Pressure CRP R PSI N/A -6.7 to 420 AV:21 crp_1
Condenser Refrig Temp CRT R °F N/A -40 to 245 AV:22 crt_1
Condenser Water Delta P CDWPD R PSI N/A -6.7 to 420 AV:23 cdwpd_1
Control Point LCW_STPT R/W °F N/A 10 to 120 AV:24 lcw_stpt_1
Current CHW Setpoint CHWSTPT R °F N/A 0.00 to 99.9 AV:25 chwstpt_1
Demand Level 1 N/A R % N/A 0 to 100 AV:1 dmv_lvl_1_perct_1
Demand Level 2 N/A R % N/A 0 to 100 AV:2 dmv_lvl_2_perct_1
Demand Level 3 N/A R % N/A 0 to 100 AV:3 dmv_lvl_3_perct_1
Element Comm Status N/A R N/A N/A No Comm/Normal BV:2999 element_stat_1
Element Communications

Alarm

Emergency Stop EMSTOP R N/A ENABLE

Entering Chilled Water ECW R °F N/A -40 to 245 AV:26 ecw_1
Entering Condenser Water ECDW R °F N/A -40 to 245 AV:27 ecdw_1

Equipment Alarm N/A R N/A N/A

Evaporator Pressure ERP R PSI N/A -6.7 to 420 AV:28 erp_1
Evaporator Refrigerant Temp
Leaving Chilled Water -

Prime Variable
Leaving Condenser Water LCDW R °F N/A -40 to 245 AV:32 lcdw_1
Line Active Current AMPS_ACT R A N/A 0.0 to 99999.0 AV:8 amps_act_1
Line Active Voltage VOLT_ACT R V N/A 0.0 to 99999.0 AV:9 volt_act_1
Line Frequency LINEFREQ R Hz N/A 0 to 99 AV:30 linefreq_1
Line Power Factor LINE_PF R N/A 0.00 to 2.00 AV:34 line_pf_1
Local Schedule N/A R N/A N/A No Comm/Normal BV:2 schedule_1
Occupied? OCC R N/A NO NO/YES BV:10 occ_1
Oil Sump Temperature OILT R °F N/A -40 to 245 AV:33 oilt_1
Remote Start Contact REM_CON R/W N/A OPEN OPEN/CLOSE BV:11 rem_con_1

Run Status STATUS R N/A N/A

Service Ontime S_HRS R/W hr N/A 0 to 32767 AV:36 s_hrs_1
Surge Line Delta T DELTA_TX R °F N/A 0 to 200 AV:38 delta_tx_1

System Alert/Alarm SYS_ALM R N/A N/A

CCN

POINT NAME

N/A R N/A N/A Inactive/Active BV:20 comm_lost_alm_1

ERT R °F N/A -40 to 245 AV:13 ert_1

LCW R °F N/A -40 to 245 AV:31 lcw_1

READ/
WRITE

UNITS

DEFAULT

VAL UE

RANGE

ENABLE/
EMSTOP

Comm Normal

Comm Lost

0=Timeout,

1=Ready,
2=Recyle,
3=Startup,

4=Running,
5=Demand,

6=Ramping,

7=Autorest,
8=Override,

9=Tripout,

10=Control Test,

11=Lockout,

12=Pumpdown,

13=Prestart

1=Normal,

2=Alert, 3=Alarm

BACNET

OBJECT ID

BV:8 emstop_1

BV:1 element_alarm_1

AV:35 status_1

AV:40 sys_alm_1

BACNET

OBJECT NAME

37

611

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Table G — Network Points List (cont)

POINT DESCRIPTION

System Cooling Demand
Level

System Demand Limiting N/A R N/A N/A OFF/ON BV:3 dem_lmt_act_1
Target Guide Vane Position GV_TRG R % N/A 0 to 100 AV:41 gv_trg_1
Target VFD Speed VFD_OUT R % N/A 0 to 100 AV:42 vfd_out_1
Tower Fan Relay High TFR_HIGH R N/A OFF OFF/ON BV:13 tfr_high_1
Tow er F an R el ay L ow TFR_LOW R N/A OFF OFF/ON BV:14 tfr_low_1
User Defined Analog 1 N/A R N/A N/A N/A AV:2901 user_analog_1_1
User Defined Analog 2 N/A R N/A N/A N/A AV:2902 user_analog_2_1
User Defined Analog 3 N/A R N/A N/A N/A AV:2903 user_analog_3_1
User Defined Analog 4 N/A R N/A N/A N/A AV:2904 user_analog_4_1
User Defined Analog 5 N/A R N/A N/A N/A AV:2905 user_analog_5_1
User Defined Binary 1 N/A R N/A N/A N/A BV:2911 user_binary_1_1
User Defined Binary 2 N/A R N/A N/A N/A BV:2912 user_binary_2_1
User Defined Binary 3 N/A R N/A N/A N/A BV:2913 user_binary_3_1
User Defined Binary 4 N/A R N/A N/A N/A BV:2914 user_binary_4_1
User Defined Binary 5 N/A R N/A N/A N/A BV:2915 user_binary_5_1

LEGEND

CHW — Chilled Water
R—Read
VFD — Va riable Fr equency Drive
W—Write

CCN

POINT NAME

N/A R N/A N/A N/A AV:9006 cool_demand_level_1

READ/
WRITE

UNITS

DEFAULT

VAL UE

RANGE

BACNET

OBJECT ID

BACNET

OBJECT NAME

38

Copyright 2011 Carrier Corporation

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53190012-01 Printed in U.S.A. Form 19XRV-3SS Pg 40 711 3-11 Replaces: New