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

Table 4 — Drive Status Indicator Descriptions

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

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 cleared.

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 the

Red Flashing An Ethernet/IP connection has timed out.

Red/Green Flashing Alternately Adapter is performing a self-test. Green Flashing Adapter is properly connected but is not communicating with any devices on the

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

Steady A non-resettable fault has occurred.

Steady Adapter failed the duplicate IP address detection test.

Steady Adapter is properly connected and communicating on the network.

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

drive cannot be started.

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.

network, or adapter needs an IP address.

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 5 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. 6 for the 248-amp drive and Fig. 7 for the 289, 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. 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 16 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. 17. Note the location of the terminals labeled MCB I/O. The high-pressure switch is wired to these terminals as shown in Fig. 18. In the event of a high condenser pressure alarm, the connections at these terminals should be checked and tightened if necessary.

Typical wiring schematics are shown in Appendix A.

SWING UP KEY PAD MOUNT TO ACCESS CONTROL BOARDS

Fig. 16 — Drive Module with Cover Removed

Fig. 17 — MCB (Main Control Board) Components

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)

a19-1844

*Located outside of starter; connected by field wiring.

a19-1925

VFD

FAULT

CODE

ON VFD

HIST

SCREEN

NONE 206 449 Processor memory fault Consult VFD manual to resolve generic fault.

0 No Entry

2 207 439 Auxiliary Input Input is open.

3 210 425 Power Loss Line voltage dropout

4 215 429 Undervoltage Low DC bus voltage

5 205 (166) 430 Overvoltage High DC bus voltage

7 217 434 Motor Overload

8 219 444

9 219 444

12 286 438 HW Overcurrent

13 220 432 Ground Fault

14 206 432 Ground Warning

ICVC FAULT STATE

Fig. 18 — High-Pressure Switch Wiring

Table 5 — Powerflex 755 Fault Code Descriptions and Corrective Actions

PIC6 FAULT STATE

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 (PIC III)/CFGUMVFD (PIC6) screen.

Verify phase-to-phase and phase-to-ground line voltage. VFD Circuit Board malfunction. Contact 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

An internal electronic overload trip has occurred.

running at full load. Check entering condenser water temperature and water flow rate. Check Motor Rated Load Amps in VFD_CONF (PICIII)/CFGUMVFD (PIC6) screen.

Check that VFD refrigerant isolation valves are

Heat Sink Overtemp

Transistor Overtemp

Heat sink temperature has exceeded maximum operating temperature.

The output transistors have exceeded maximum operating temperature.

The drive output current has exceeded hardware current limit.

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 (PIC III)/CFGUMVFD (PIC 6) screen.

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

The ground current has exceeded the level set in P467.

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

—

Table 5 — Powerflex 755 Fault Code Descriptions and Corrective Actions (cont)

VFD

FAULT

CODE

ON VFD

HIST

SCREEN

15 206 449 Load Loss

17 216 446

20 206 449 TorqPrv Spd Band See VFD Fault Code 15 See VFD Fault Code 15

21 225 445 Output PhaseLoss

24 204 442 Decel Inhibit

33 206 449 AuRsts Exhausted See VFD Fault Code 15 See VFD Fault Code 15

36 286 438 SW Overcurrent

38 39 Phase V to Gnd

40 Phase W to Gnd

41 42 Phase VW Short 43 Phase WU Short

44 206 432

45 206 432

46 206 432

55 NONE 444

61 206 449 Shear Pin 1 See VFD Fault Code 15 See VFD Fault Code 15 62 206 449 Shear Pin 2 See VFD Fault Code 15 See VFD Fault Code 15

64 206 449 Drive Overload Drive is overloaded.

77 206 449 IR Volts Range See VFD Fault Code 15 See VFD Fault Code 15

78 206 449

79 206 449 Excessive Load

80 206 449 AutoTune Aborted See VFD Fault Code 15 See VFD Fault Code 15

87 206 449 IXo VoltageRange

91 206 449 Pri VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15 93 206 449 HW Enable Check See VFD Fault Code 15 See VFD Fault Code 15 94 206 449 Alt VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15 95 206 449 Aux VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15 96 206 449 PositionFdbkLoss See VFD Fault Code 15 See VFD Fault Code 15 97 206 449 Auto Tach Switch See VFD Fault Code 15 See VFD Fault Code 15

100 206 451

106 284 453 Incompat MCB-PB

107 NONE 451 Replaced MCB-PB

113 206 451 Tracking DataErr Internal data error

124 206 451 App ID Changed Application firmware changed. Verify application version.

ICVC FAULT STATE

220 432

220 449

PIC6 FAULT STATE

FAULT TYPE DESCRIPTION CORRECTIVE ACTION

To reset the processor, cycle power to chiller, check VFD_CONF settings and save settings when exiting VFD_CONF (PIC3)/CFGUMVFD (PIC6) configuration 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 (PIC3)/CFGUMVFD (PIC6) screen.

Check Motor Current % Imbalance in VFD_CONF (PIC3)/CFGUMVFD (PIC6) 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.

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

Check wiring between drive and 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 (PIC3)/CFGUMVFD (PIC6) 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 (PIC3)/CFGUMVFD (PIC6) screen.

Press ICVC reset (PIC3)/Reset alarm (PIC6). Check VFD_CONF parameters. Cycle power to the drive.

Flash with newer Application version software.

Press ICVC reset (PIC3)/Reset alarm (PIC6). Check VFD_CONF (PIC3)/CFGUMVFD (PIC6) parameters. Cycle power to the drive.

Press ICVC reset (PIC3)/Reset alarm (PIC6). Cycle power to the drive.

The DC bus ripple has exceeded a preset level.

Phase U to Gnd

Phase UV Short

Phase UNot

Phase VNot

Phase WNot

Ctrl Bd Inverter Overtemp

FluxAmpsRef Rang

Parameter Chksum

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 bus voltage.

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

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 voltage calculated from motor nameplate data is too high.

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

The main control board did not recognize the power structure.

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

Table 5 — Powerflex 755 Fault Code Descriptions and Corrective Actions (cont)

VFD

FAULT

CODE

ON VFD

HIST

SCREEN

141 206 449 Autn Enc Angle P78 [Encdrlss AngComp] is out of range. See VFD Fault Code 15 142 206 449 Autn Spd Rstrct See VFD Fault Code 15 See VFD Fault Code 15 143 206 449 Autotune CurReg See VFD Fault Code 15 See VFD Fault Code 15 144 206 449 Autotune Inertia See VFD Fault Code 15 See VFD Fault Code 15 145 206 449 Autotune Travel See VFD Fault Code 15 See VFD Fault Code 15

168 206 444

210 206 449

211 206 449 Safety Brd Fault See VFD Fault Code 15 See VFD Fault Code 15 213 206 449 Safety Jumper In See VFD Fault Code 15 See VFD Fault Code 15

226 224 448 VFD Comm loss

291 206 449 HSFan Lifwe See VFD Fault Code 15 See VFD Fault Code 15 292 206 449 InFan Life See VFD Fault Code 15 See VFD Fault Code 15 293 206 449 MtrBrg Life See VFD Fault Code 15 See VFD Fault Code 15 294 206 449 MtrBrg Lube See VFD Fault Code 15 See VFD Fault Code 15 295 206 449 MachBrg life See VFD Fault Code 15 See VFD Fault Code 15 296 206 449 MachBrg Lube See VFD Fault Code 15 See VFD Fault Code 15 315 206 449 Excess Psn Error See VFD Fault Code 15 See VFD Fault Code 15

351 209 426 In Cur Share L1

352 209 426 In Cur Share L2

353 209 426 In Cur Share L3

ICVC FAULT STATE

PIC6 FAULT STATE

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

The device at the port has stopped communicating with the main control board.

There is an input current sharing imbalance between parallel converters in the AC line indicated that is greater than 15% of the converter rated current

Check heat sink temperature sensor. Check heat sink temperature.

Verify that the device is present and functional. Verify network connections. Verify options installed in appropriable ports are seated in the port and secured with mounting screws.

See VFD Fault Code 15

Checking Power Modules and Motor Input with Input Power Off

Use the following procedure to check the drive’s power module circuitry with power off:

1. Turn off and lock out input power. Wait 5 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 in the section Verifying That DC Bus Capacitors Are Discharged on page 11 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. See Table 6.

7. Check motor impedance.

8. Reconnect the motor to the drive.

9. Reapply input power.

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. Confirm that the DC bus has discharged before performing diode checks. Failure to observe this precaution could result in severe bodily injury or loss of life.

WARNING

Table 6 — Diode Checks

L1 L2 L3

DC+ DC–

LOCKOUT/TAGOUT

MULTIMETER

DC BUS TEST TERMINALS LOCATED INSIDE ACCESS DOOR

A19-1814

90°

SLIDE ENCLOSURE FORWARD

LOOSEN ENCLOSURE FASTENERS

A19-1816

METER LEAD

(+) (-)

DC+

DC-

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 table, but look for consistency during each of the 4 tests. When performing a test that should return infinity (OL) as shown in above table, you may see a value slowly climbing toward infinity. This is a result of the meter charging a capacitor and is normal.

DC+ 0.5 v DC- Infinite (OL) DC+ 0.5 v DC- Infinite (OL) DC+ 0.5 v

DC- Infinite (OL)

DC+ 0.5 v

DC- infinite (OL)

DC+ 0.5 v

DC- Infinite (OL)

DC+ 0.5 v

DC- Infinite (OL)

S T

V W R

T U

V W

METER READING

Infinite (OL)

0.5 v

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. 20.

3. Remove the enclosure. See Fig. 21.

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. For 19XRV chillers, see Fig. 22. For 23XRV chillers, see Fig. 23. The drive weights are as follows:

• Drive weight for Frame 6: 85 lb.

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

Fig. 19 — Open Access Door

Servicing the Drive

1. Using recommended screwdriver (6.4 mm [0.25 in.] flat or

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.

T20 star), open access door. See Fig. 19.

Fig. 20 — Check DC Bus Terminals

Fig. 21 — Removing Enclosure

When replacing the drive, reverse the procedures and tighten to

DRIVE RIGGING ACCESS DRIVE WIDTH + 4 IN.

FRONT VIEW

the torques for Frames 6 and 7 power terminal block listed in Table 7.

Table 7 — Frames 6 and 7 Power Terminal Block

FRAME

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

TERMINAL BOLT SIZE

RIGGING THE ENCLOSURE

Where overhead room and/or clearance in front of the drive en-

closure is insufficient to allow the drive to be safely removed from the enclosure, the entire enclosure may have to be removed from the chiller.

The dimensions and weights specified must be taken into consideration when removing the enclosure. For 19XRV chillers, the total weight for Frames 6 and 7, including drive weight and enclosure, is 720 lb. The 23XRV chiller enclosure, including all components, weighs 975 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. 24 and Fig. 25.

DRIVE RIGGING

ACCESS

2 IN.

DRIVE POSITIONED FOR VERTICAL LIFT

SIDE VIEW

Fig. 22 — 19XRV Enclosure Access for Removing Drive

DRIVE EXTENDS BEHIND MAIN ENCLOSURE

SUPPORT FROM BELOW

REPLACING THE GATEWAY (A-B20-750-20COMM

DRIVE EXTENDS BEHIND MAIN ENCLOSURE

SUPPORT FROM BELOW

DRIVE POSITIONED FOR VERTICAL LIFT

ENCLOSURE TOP IS REMOVABLE

FRONT CORNER OF DRIVE COMPARTMENT IS REMOVABLE

SIDE VIEW

A19-2012

2 A

<45°

A19-1837

2 A

<45°

A19-1838

A19-1819

PIC3 / 20-COMM-H (PIC6) OPTION CARD)

Follow these 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. 19.

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. 20.

3. Remove the enclosure. See Fig. 21.

4. Remove the 2 screws securing the mounting plate and remove the mounting plate and COMM card. See Fig. 26.

5. Mount the new COMM card and mounting plate and attach with the 2 screws removed in Step 4. See Fig. 27.

6. Use the shorter ribbon cable to connect the plug on the COMM card to the connector on the mounting plate. See Fig. 26.

7. Install the enclosure. See Fig. 21.

GATEWAY

MOUNTING PLATE

Fig. 23 — 23XRV Enclosure Access for

Removing Drive

Fig. 24 — Rigging the Enclosure, Frame 6

0.45-0.67 N-m (4.0-6.0 lb.-in.)

3 PLACES

RIBBON CABLE

Fig. 26 — COMM Card

Fig. 25 — Rigging the Enclosure, Frame 7

Fig. 27 — Mount COMM Card Plate to Drive

MOUNTING PLATE

GATEWAY

A19-1820

A19-1839

T20

2.6 N•m

(23 lb•in.)

T20

2.6 N•m

(23 lb•in.)

INTERNAL FAN

A19-1840

T20

5.20 N•m

(46 lb•in.)

T15

2.6 N•m (23 lb•in.)

T15

INTERNAL FANS

CHILL PLATE FANS

2.6 N•m (23 lb•in.)

A19-1841

CHILL PLATE FAN AND INTERNAL FAN REPLACEMENT

Follow these steps to replace the chill plate fan and internal fan in Frames 6 and 7.

Frame 6 (chill plate fan kit Z1P-FAN-A6-A):

1. Disconnect power to the drive. Before removing the enclosure, open the access door on the front of the drive. See Fig. 19.

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. 20.

3. Remove the enclosure. See Fig. 21.

4. Remove and replace the chill plate fan. See Fig. 28.

5. Remove and replace the internal fan. See Fig. 29.

6. Install the enclosure. See Fig. 21.

CHILL PLATE FAN POWER CONNECTION

Fig. 29 — Internal Fan, Frame 6

Frame 7 (chill plate fan kit Z1P-FAN-A7-A):

1. Disconnect power to the drive. Before removing the enclosure, open the access door on the front of the drive. See Fig. 19.

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. 20.

3. Remove the enclosure. See Fig. 21.

4. Remove and replace the chill plate and internal fans. See Fig. 30.

5. Install the enclosure. See Fig. 21.

CHILL PLATE FAN

T20

2.6 N•m (23 lb•in.)

Fig. 28 — Chill Plate Fan, Frame 6

Fig. 30 — Chill Plate and Internal Fans, Removal and

Replacement, Frame 7

Part Identification and Location

See Fig. 31-34 for parts descriptions and locations.

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

8 7 6 5

4 3 21

12 11 10

CR1

8 7 6 5

4 3 21

12 11 10

CR2

8 7 6 5

4 3 21

12 11 10

CR3

8 7 6 5

4 3 21

12 11 10

CR4

8 7 6 5

4 3 21

12 11 10

CR5

8 7 6 5

4 3 21

12 11 10

CR6

EA1

CB1

CABLE ACCESS CUTOUT

SECONDARY SIDE

PT1

1 2 3 4 5 6 7 8

9 10 11 12

1314 15

16 1718 1920 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 6970 7172 73 74

75 76 7778 79

8 7654

1211 10

CR1

8 7654

1211 10

CR2

8 76

1211 10

CR3

8 7654

1211 10

CR4

8 7654

1211 10

CR5

8 76

1211 10

CR6

PT1

SECONDARY SIDE

TOWARD DOOR

CB2

FRONT VIEW DOOR REMOVED

LEFT SIDEWALL

VIEW FROM INSIDE

LINE-

TB1,TB2, FU1-FU3

TB4

CR1

CR6

DIST. SIDE

TB1 TB2

FU2

FU1 FU3

LEGEND

1—Power Module 2—Input Circuit Breaker 3—15 amp Control Circuit Breaker 4—Control Transformer 5—Control Fuses 6—Control Relays (CR1 - CR6)

FRONT VIEW – DOORS REMOVED

RIGHT SIDEWALL INSIDE VIEW

LEGEND

1—Input Circuit Breaker 2—Power Module 3—Control Relays (CR1 - CR6) 4—Control Fuses 5—120 v Control Transformer 6—120 v Vaporizer Heater Transformer 7—15 amp Control Circuit Breaker 8 — Cooling Fan

a23-1653

Fig. 31 — 19XRV Assembly Parts

Fig. 32 — 23XRV Assembly Parts

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. 5) the jumper marked “J1 HARDWARE ENABLE” must be removed and the jumper marked “J2 SAFETY ENABLE” must be left in place.

a19-1848

LEGEND

NOTE: When replacing the Main Control Board (Item No. 10) the jumper marked “J1 HARDWARE ENABLE” must be removed and the jumper marked “J2 SAFETY ENABLE” must be left in place.

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 24 v I/O Module (24 v I/O Module Not Shown)

10 — PF755 Main Control Board

a19-1849

Fig. 33 — Frame 6 Parts

Fig. 34 — Frame 7 Parts

APPENDIX A — WIRING SCHEMATICS

LEGEND

CB — Circuit Breaker

CCM — Chiller Control Module

HGBP — Hot Gas Bypass

ICVC — International Chiller Visual Controller

UPC — Universal Protocol Controller

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

19XRV CHILLER CONTROL SCHEMATIC (PIC 3)

a19-2378

APPENDIX A — WIRING SCHEMATICS (cont)

19XRV CHILLER CONTROL SCHEMATIC (PIC 6)

APPENDIX A — WIRING SCHEMATICS (cont)

19XRV CHILLER CONTROL SCHEMATIC (PIC 6) (cont)

APPENDIX A — WIRING SCHEMATICS (cont)

a23-1731

NOTES:

1. Liquid flow circuit: to install optional flow device, wire as shown (NO) and replace jumper

with a 4.3k resistor.

2. For TP compressor, the condenser flow switch must be installed in series with the cooler

flow switch. Do not connect condenser flow switch to J3 (Lower) 23 and 24.

3. For TP compressor, remove 4.3k resistor between J3 (Lower) 20 and 21.

23XRV CHILLER CONTROL SCHEMATIC

APPENDIX A — WIRING SCHEMATICS (cont)

a19-2327

SEE METER OPTION DETAIL

See Legend on page 26.

ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical)

19XRV (Typical)

APPENDIX A — WIRING SCHEMATICS (cont)

a19-2331

PIC6 CAT# 20-COMM-H

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 Board Slot REM — Remote RO — Relay Output ROC — Relay Output Common SHLD — Shield TB — Terminal Block

ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)

19XRV (Typical) (cont)

APPENDIX A — WIRING SCHEMATICS (cont)

a19-2328

See Legend on page 28.

ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)

23XRV (Typical)

APPENDIX A — WIRING SCHEMATICS (cont)

a19-2329

LEGEND

CAP — Capacitor CB — Circuit Breaker COM — Common COMM — Communication COND — Condenser CR — Control Relay DPI/SI — Internal Communication Protocols

Connections

ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)

23XRV Typical (cont)

APPENDIX A — WIRING SCHEMATICS (cont)

ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)

19XRV,23XRV METER OPTION

a19-2330

Catalog No. 04-53190061-01 Printed in U.S.A. Form 19/23-8SS Pg 32 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.

Carrier 19XRV, 23XRV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY CONSIDERATIONS

INTRODUCTION

ABBREVIATIONS AND EXPLANATIONS

Required Publications

Getting Assistance from Rockwell Automation

Opening the VFD Access Door

IDENTIFYING DRIVE COMPONENTS

Drive Assembly Catalog Number

Components and Physical Data

START-UP Alternate Wire Lugs

Verify Installation

Configure the VFD

Commissioning the Unit

Check Internal Jumpers

SERVICE

Troubleshooting the Drive

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

REMOVING THE DRIVE

Servicing the Drive

RIGGING THE ENCLOSURE

Part Identification and Location

APPENDIX A — WIRING SCHEMATICS