Carrier 19XRV, 23XRV User Manual

19XRV, 23XRV

with PIC III/PIC 6 Controls

Rockwell PowerFlex 755 VFD Option

Start-Up and Service Instructions

SAFETY CONSIDERATIONS

Centrifugal and screw compressor 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.

DANGER

Failure to follow these procedures will result in severe personal injury or death.

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.

(Dangers continued in next column.)

DANGER

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 functioning before operating any chiller. THERE IS A RISK OF INJURY OR DEATH by electrocu-

tion. 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.

WARNING

Failure to follow these procedures may result in personal injury or death.

DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure.

To remove a component, wear protective gloves and goggles and proceed as follows:

a. Shut off electrical power to unit. b. Recover refrigerant to relieve all pressure from system

using both high-pressure and low-pressure ports.

c. Traces of vapor should be displaced with nitrogen and

the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.

d. Cut component connection tubing with tubing cutter and

remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to the system.

e. Carefully unsweat remaining tubing stubs when neces-

sary. Oil can ignite when exposed to torch flame.

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

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

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are de-energized before resuming work.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.

(Warnings continued on next page.)

Catalog No. 04-53190061-01 Printed in U.S.A. Form 19/23-8SS Pg 1 6-19 Replaces: 19/23-7SS

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

WARNING

DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller is under pressure or while chiller is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.

CAUTION

Failure to follow these procedures may result in personal injury or damage to equipment.

TO AVOID an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before 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 3 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.

(Cautions continued in next column.)

CAUTION

USE only repair or replacement parts that meet the code requirements of the original equipment.

PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.

DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations.

DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed.

CONTENTS

Page

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

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

ABBREVIATIONS AND EXPLANATIONS. . . . . . . . . . . . 3

Required Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Getting Assistance from Rockwell Automation. . . . . 3

IDENTIFYING DRIVE COMPONENTS . . . . . . . . . . . . . . . 3

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

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

Components and Physical Data . . . . . . . . . . . . . . . . . . . . 4

START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Alternate Wire Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Configure the VFD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Commissioning the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Check Internal Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Troubleshooting the Drive. . . . . . . . . . . . . . . . . . . . . . . . . 10

• CHILLER ALERT CODES

• CHILLER 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Servicing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

• REMOVING THE DRIVE

• RIGGING THE ENCLOSURE

• REPLACING THE GATEWAY

• CHILL PLATE FAN AND INTERNAL FAN REPLACEMENT

Part Identification and Location . . . . . . . . . . . . . . . . . . . 18

APPENDIX A — WIRING SCHEMATICS . . . . . . . . . . . 21

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

ID No.: 21P-104773-40 Input Rating: 480VAC 454A 60Hz 3PH Output Rating: 0-460VAC 477A 0-325Hz 3PH Short Circuit Rating: 65kA, 480V Max. Interrupt Capacity Rating: 100kAIC Enclosure Type: TYPE 1 Coolant Type: Refrigerant R134a Design Pressure: 185 PSIG Carrier Part Number: 19XVR0445335A1F VFD Serial Number: XXXXXXXXX Carrier Dwg. Number: 19XV04021001 Mfd. On: 08-13-10 FAC.LOC.: 1100

Max. Ambient Temperature: 40°C

ORDER NO: 0001772838-00001

L1 L2 L3

DC+ DC–

LOCKOUT/TAGOUT

MULTIMETER

DC BUS TEST TERMINALS LOCATED INSIDE ACCESS DOOR

Frequently used abbreviations in this manual include:

CCM — Chiller Control Module DC — Direct Current DPI — Drive Peripheral Interface ENET — Ethernet HMI — Human Machine Interface ICVC — International Chiller Visual Controller IGBT — Insulated Gate Bipolar Transistor I/O — Inputs/Outputs IP — Internet Protocol MCB — Main Control Board MOV — Metal Oxide Varistor PE — Protective Earthing Conductor PIC — Product Integrated Control PWM — Pulse Width Modulation SIO — Sensor Input/Output STS — Status VFD — Variable Frequency Drive

Required Publications

The Carrier VFD option Start-Up and Service Manual must be used with the following manuals:

• Latest version of the PowerFlex 755 AC Drives manuals

• Latest revision of the Start-Up, Operation, and Maintenance Instructions for the 19XRV or 23XRV 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, call the HVAC Hotline at 1-888-926-6786, Option 1.

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 (Carrier Part Number)

• Allen-Bradley serial number

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.

Opening the VFD Access Door

WARNING

Before removing the drive enclosure, open access door and verify that the DC bus voltage has dropped to zero by checking the terminals behind the access door. Failure to observe this precaution could result in severe bodily injury or loss of life.

1. Using recommended screwdriver (6.4 mm [0.25 in.] flat or T20 star), open access door. See Fig. 2.

2. Check to be sure that the voltage between DC+ and DC– and from each DC terminal to the chassis is zero before proceeding. See Fig. 3.

Fig. 1 — Allen Bradley Data Nameplate

IDENTIFYING DRIVE COMPONENTS

Chiller control schematics and VFD schematics are included in Appendix A.

Fig. 2 — Opening Access Door

Fig. 3 — Check DC Bus Terminals

Drive Assembly Catalog Number

See Fig. 4 and 5 for examples of the Rockwell Automation Drive Assembly Catalog Number.

Components and Physical Data

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

* For Carrier applications, maximum continuous amp ratings are 230, 269, 335, and 445. † For 600 v applications, CB1 = 65 KAIC and CB2 = 42 KAIC rating (575 v).

21PB -

1 0248

3 0

21PB - 23XRV Std Tier

Voltage Code 1 – 480 vac, 60 Hz

2 – 380 vac, 50 Hz 3 – 380 vac, 60 Hz 4 – 400 vac, 50 Hz 6 – 415 vac, 50 Hz 7 – 415 vac, 60 Hz 8 – 600 vac, 60 Hz

Full Load Amp Rating (Maximum Continuous Amps)*

0248 – 248 0289 – 289 0361 – 361 0477 – 477

Enclosure 1 – Unit Mount Type 1/IP23 Air Cooled/Filter 4 – Unit Mount Type 1/IP23 Liquid Cooled

Input Device 3 – 65 KAIC Capacity Breaker

4 – 100 KAIC Capacity Breaker

†

Meter Option 0 – No Meters 2 – Digital Meter

a19-2381

Control Power 0 – Standard 1 – High

CE (Conformité Européenne) 0 – No 1 – Ye s

The 19XRV chillers use the Allen-Bradley PF755 Frame 6 drive for the 230-amp rated application (Carrier Part No. 19XVR0230...). See Fig. 6.

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

1 0248

21P -

21P - 19XRV Std Tier

Voltage Code 1 – 480 vac, 60 Hz

2 – 380 vac, 50 Hz 3 – 380 vac, 60 Hz 4 – 400 vac, 50 Hz 5 – 400 vac, 60 Hz 6 – 415 vac, 50 Hz 7 – 415 vac, 60 Hz

Full Load Amp Rating (Maximum Continuous Amps)*

0248 – 248 0361 – 361 0477 – 477

See Fig. 8 for the dimensions of Frames 6 and 7 for 19XRV chillers.

The 23XRV chiller uses the Frame 7 drive for 335-amp and 455amp rated applications (Carrier Part No. 23XVR0335... and 23XVR0445...). Frame 6 is not used.

See Fig. 9 for the dimensions of Frame 7 for 23XRV chillers.

3 0

Meter Option 0 – No Meters 2 – Digital Meter

Input Device 3 – 65 KAIC Capacity Breaker

4 – 100 KAIC Capacity Breaker

Enclosure 4 – Unit Mount Type 1/IP23 Liquid Cooled 5 – Unit Mount Type 1/IP23 Liquid Cooled/Air Filter

a19-2380

Fig. 4 — Rockwell Automation Drive Assembly Catalog Number Nomenclature: 19XRV Units

Fig. 5 — Rockwell Automation Drive Assembly Catalog Number Nomenclature: 23XRV Units

Fig. 6 — Frame 6 Drive Components

LEGEND

NO. NAME DESCRIPTION

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

PE Grounding Studs Terminating point to chassis ground

for incoming motor shield

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

LEGEND

NO. NAME DESCRIPTION

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

PE Grounding Studs Terminating point to chassis ground

for incoming motor shield

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

Fig. 7 — Frame 7 Drive Components

50.00 REF

54.00

36.00 REF

40.00

FRONT VIEW

30.00

22.00

a19-2379

SIDE VIEW

NOTE: Dimensions shown in inches.

a19-2011

NOTE: Dimensions shown in inches.

Fig. 8 — 19XRV Enclosure Dimensions — Frames 6 and 7

Fig. 9 — 23XRV Enclosure Dimensions — Frame 7

START-UP Alternate Wire Lugs

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.

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.

If the incoming power wire size does not fit the standard lug, alternate lugs may be used. See Table 1. Note that lugs rated for a higher current than the circuit breaker may be used.

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 nameplate (Fig. 10) 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. Inverter PWM (pulse width modulation) frequency h. Voltage

3. From the drive module label (Fig. 11) located on the drive module: a. Model or Cat. Number

b. Serial Number

4. From the HMI control panel screen: a. Carrier Part Number and Revision

b. Software Number

CAUTION

When working with the Drive Explorer, never use the Rotate function as the motor will immediately start and severe compressor damage could result.

Table 1 — Wire Lugs

VOLTAGE

480

380/400/415

600 269 KT5300 (1) 250 - 500 MCM KT5400 (2) 3/0 - 250 MCM

CARRIER VFD MAX

INPUT AMPS

230 KT5300 (1) 250 - 500 MCM KT5400 (2) 3/0 - 250 MCM 335 K6TJ (3) 2/0 - 400 MCM K6TH (2) 250 - 500 MCM 445 K6TJ (3) 2/0 - 400 MCM K6TH (2) 250 - 500 MCM 230 KT5400 (2) 3/0 - 250 MCM KT5300 (1) 250 - 500 MCM 335 K6TJ (3) 2/0 - 400 MCM K6TH (2) 250 - 500 MCM 445 K6TJ (3) 2/0 - 400 MCM K6TH (2) 250 - 500 MCM

STANDARD

ABB LUG

STANDARD LUG

CABLE RANGE

ALTERNATE

ABB LUG

ALTERNATE LUG

CABLE RANGE

Fig. 10 — Machine Nameplate

Fig. 11 — Drive Module Label

Configure the VFD

All configurations required by the VFD are supplied by the HMI through the VFD Gateway. The 19XRV, 23XRV Std Tier VFD can operate with PIC III and PIC 6. Any configuration changes necessary and possible are made on the HMI screens. A complete

set of configurations is transmitted to the VFD each time the controls are powered up.

Table 2 lists parameters displayed on the 19XRV, 23XRV PIC3/ VFD_CONF screen. Table 3 shows parameters in the Unit Mounted VFD Configuration menu for PIC6. Parameters in ital- ics are to be entered or confirmed at start-up. Parameters in bold are to be changed only after consulting with Carrier service engineering.

Table 2 — VFD Configurations (PIC3/VFD_CONF)

PARAMETER

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 = 2 KHZ) 1

SKIP FREQUENCY 1 (HZ) 20.0 SKIP FREQUENCY 2 (HZ) 20.0 SKIP FREQUENCY 3 (HZ) 20.0

SKIP FREQUENCY BAND LINE (HZ) 0.0 VOLTAGE % IMBALANCE 10 LINE VOLT IMBALANCE TIME (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.

DEFAULT

VALUE

Table 3 — VFD Configuration (PIC6/UM VFD

Configuration) CFGUMVFD - UM VFD Configuration

PARAMETER

COMPRESSOR 100% SPEED 60

RATED LINE VOLTAGE* 460 MOTOR NAMEPLATE CURRENT 200 MOTOR RATED LOAD CURRENT 200 MOTOR NAMEPLATE VOLTAGE 460 MOTOR NAMEPLATE RPM 3000 MOTOR NAMEPLATE KW 1500

SKIP FREQUENCY 1 30 SKIP FREQUENCY 2 30 SKIP FREQUENCY 3 30 SKIP FREQUENCY BAND 0 INCREASE RAMP TIME 30 DECREASE RAMP TIME 30

LINE VOLTAGE IMBALANCE% 10 LINE VOLT IMBALANCE TIME 10 LINE CURRENT IMBALANCE% 40 LINE CURRENT IMBAL TIME 10 MOTOR CURRENT IMBALANCE% 40 MOTOR CURRENT IMBAL TIME 10

SINGLE CYCLE DROPOUT DISABLE PWM SWITCH FREQUENCY (0=2 KHZ, 1=4 KHZ) 0

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.

DEFAULT

VALUE

Commissioning the Unit

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

LEGEND

NO. NAME DESCRIPTION

1 HIM (Human

Interface Module) Connector

DPI Port 1 (HIM Cradle) connection.

Fan Connector Power supply for internal cooling fan

(Frames 2 and 3).

Battery Receptacle

User-installed CR1220 lithium coin cell battery provides power to the real-time clock (Optional, not supplied).

DPI Port 2 Cable connection for handheld and

remote HIM options.

Embedded Ethernet/ IP Address Selectors

Rotary switches for setting lowest octet of Ethernet address (forces address to 192.168.1.xxx).

Embedded Ethernet/ IP Connector

Network cable connection.

Jumper J2 SAFETY ENABLE

Safety enable jumper. Removed when safety option is installed. For additional information, refer to the Check Internal Jumpers section on page 9.

Jumper J1 HARDWARE ENABLE

Hardware enable jumper. Removed when a hardware enable configuration is utilized. For additional information, refer to the Check Internal Jumpers section on page 9.

9 TB1 I/O terminal block.

The commission procedure 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.

Vmax = Maximum measured phase-to-phase voltage

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

Vmin = Minimum measured phase-to-phase voltage

Imbalance Calculation Formula

Va v g =

Imbalance % =

(VAB + VBC + VCA)

(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 settings

on the HMI. b. Check motor and wiring insulation. c. Check parameter settings on VFD_CONF screen in

the HMI (PIC3) or UM VFD Configuration for PIC 6.

Check Internal Jumpers

On the Main VFD Control board there are 2 jumpers labeled J1 HARDWARE ENABLE and J2 SAFETY ENABLE. J1 should be removed and J2 should be in place. See Fig. 12.

Fig. 12 — PF755 Main Control Board

Two jumper wires connect a particular terminal to chassis ground.

CONNECTED

DISCONNECTED

COMMON MODE

MOV

A19-2325

CONNECTED

DISCONNECTED

COMMON MODE

MOV

A19-2326

1 3

Allen-Bradley

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. 13 and Fig. 14 for the correct positions of the jumpers.

Fig. 13 — Jumper Wire Locations — Frame 6

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.

Troubleshooting the Drive

The drive can display 2 kinds of error codes on the HMI called Alert and Alarm codes. These codes signal a problem detected during self-tuning or drive operation. Note the following differences between Carrier and Allen-Bradley terminology:

• A warning message on the HMI 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 HMI and as a VFD FAULT when viewed with Drive Explorer.

CONDITION CODES CHILLER ALERT =VFD ALARM CHILLER ALARM =VFD FAULT

See Tables 4-5 and Fig. 15.

CHILLER ALERT CODES

An alert condition is indicated by a message on the HMI 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 HMI when the condition causing the alert no longer exists. See the 19XRV or 23XRV Start-Up, Operation and Maintenance Instructions for ICVC alert codes or appropriate Controls Operation and Troubleshooting manual for PIC6 controls.

CHILLER ALARM CODES

An alarm condition is also indicated by a message on the HMI 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 4). The detected fault message is maintained on the display until it is cleared by pressing the RESET softkey. See the 19XRV or 23XRV Start-Up, Operation and Maintenance Instructions for ICVC alarm codes or appropriate Controls Operation and Troubleshooting manual for PIC6 controls.

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.

Fig. 14 — Jumper Wire Locations — Frame 7

Fig. 15 — Drive Status Indicator

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