Carrier D2-3466-2 User Manual

Carrier VFD Quick Reference

Instruction Manual

D2-3466-2

The information in this manual is subject to change without notice.

Throughout this manual, the following notes are used to alert you to safety considerations:

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and understanding of the product.

The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to signify new or revised text or figures.

ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment.

Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

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

ATTENTION: The drive can operate at and maintain zero speed. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating or may operate at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Do not install modification kits with power applied to the drive. Disconnect and lock out incoming power before attempting such installation or removal. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: When the level-sense start feature is enabled (P.054 = ON), the user must ensure that automatic start up of the driven equipment will not cause injury to operating personnel or

damage to the driven equipment. In addition, the user is responsible for providing suitable audible or visual alarms or other devices to indicate that this function is enabled and the drive may start at any moment. Refer to the LiquiFlo Software Start-Up and Reference manual (D2-3410)for additional information. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: When P.055 is set to ON, the STOP/RESET key is functional only from the selected control source. As a safety precaution, Reliance recommends that an emergency stop input be located near the equipment. As a further safety precaution, the user should post a warning on the drive to alert personnel that the STOP/RESET key is not functional. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages. Also, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled to eliminate the possible shock hazard from crosscoupled motor leads. Failure to observe these precautions could result in bodily injury.

ATTENTION: The drive contains printed circuit boards that are static-sensitive. Anyone who touches the drive components should wear an anti-static wrist band. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution can result in bodily injury.

ATTENTION: If a maintained start contact is used when the control source = rE, switching from local to remote from the terminal strip will cause power to be applied to the motor if the remote start contact is closed. Stay clear of rotating machinery in this case. Failure to observe this precaution could result in bodily injury.

ATTENTION: The drive is not equipped with a coast-stop pushbutton. You must install a hardwired operator-accessible pushbutton that provides a positive interrupt and shuts down the drive. See the LiquiFlo AC Power Modules Hardware Reference, Installation, and Troubleshooting manual (D2-3411) for wiring information. Failure to observe this precaution could result in bodily injury.

ATTENTION: The user is responsible for ensuring that driven machinery, all drive-train mechanisms, and application material are capable of safe operation at the maximum operating speed of the drive. In V/Hz regulation, overfrequency protection in the drive is provided by means of H.022. Failure to observe this precaution could result in bodily injury.

ATTENTION: The setting of parameters H.001 (Motor Nameplate Base Frequency), and P.004 (Maximum Speed) determines the motor maximum speed. These parameters must be set by a qualified person who understands the significance of setting them accurately. Failure to observe this precaution could result in bodily injury.

ATTENTION: When switching from auto to manual, or manual to auto, the drive will ramp to the reference level provided by the new source at the rate specified in P.001 (Accel Time 1), P.002 (Decel Time 1), P.017 (Accel Time 2), or P.018 (Decel Time 2). Be aware that an abrupt speed change may occur depending upon the new reference level and the rate specified in these parameters. Failure to observe this precaution could result in bodily injury.

ATTENTION: It is the user’s responsibility to determine how to distribute the passwords. Reliance Electric is not responsible for unauthorized access violations within the user’s organization. Failure to observe this precaution could result in bodily injury.

ATTENTION: Do not alter the setting of any jumper not described in LiquiFlo Hardware Reference manual (D2-3411). Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: For single-motor applications with no external thermal overload relay, P.040 (Motor Overload Enable) should always be set to ON. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: Use of power correction capacitors on the output of the drive can result in erratic operation of the motor, nuisance tripping, and/or permanent damage to the drive. Remove power

correction capacitors before proceeding. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: Most codes require that upstream branch circuit protection be provided to protect input power wiring. Install the fuses recommended in table 3.7 of the LiquiFlo Hardware Reference manual (D2-3411). Do not exceed the fuse ratings. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with drive operation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: Distribution system short circuit capacity shall not exceed the rating of the drive. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: H.002 (Motor Nameplate Amps) must not exceed the rated amps found on the motor nameplate. Overcurrent or excess heating of the motor could result if this is not done. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

The following ATTENTION statements do not apply to the default Carrier VFD configuration. However, they do apply to the Reliance LiquiFlo AC Power Module.

ATTENTION: As a safety precaution, Reliance Electric recommends that you provide an audible or visual alarm to indicate that the level sense start feature is enabled and the motor can start when power is applied to the drive. You should also post warnings on the motor, the drive, and any other applicable equipment to alert personnel that the application uses an automatic startup feature. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Be aware of the following before enabling the level sense start function (P.054):

• Setting P.054 to ON immediately applies output power to the motor when all start conditions are met.

• If the drive is running from the terminal strip, both the start and stop inputs are closed. If P.054 = ON and a fault occurs, the drive coasts to rest and generates a fault. In this case, resetting and clearing the fault immediately restarts the drive without any change to the start or stop input states

• If P.026 (Function Loss Response) = 1, the control source is the terminal strip (start and stop inputs are closed), and P.054 = ON, the drive coasts to rest if the function loss input is opened and does not generate a fault. In this case, closing the function loss input immediately starts the drive without any change to the start or stop input.

When this function is enabled, the user must ensure that automatic start up of the driven equipment will not cause injury to operating personnel or damage to the driven equipment. In addition, the user is responsible for providing suitable audible or visual alarms or other devices to indicate that this function is enabled and the drive may start at any moment. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: If P.062 (Option Port: Communication Loss Response) = 2 and P.054 (Level Sense Start Enable) = ON and network communication is lost while the drive is running, the terminal strip stop input will function as a STOP/RUN input. If the terminal strip stop input is opened, the drive will stop. If the terminal strip stop input is closed, the drive will re-start. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: When starting with search enabled (H.016 is set to any value but OFF), there will be a several second delay, and the motor may drift in the forward and reverse direction, before the motor begins operating in the desired direction even if reverse has been disabled in P.027. Stay clear of rotating machinery. Failure to observe this precaution could result in bodily injury.

ATTENTION: When connected to a non-regenerative common DC bus, regeneration may cause a rise in DC bus voltage. Be aware that other drives on the bus may experience an unexpected

speed increase due to the high bus voltage. Failure to observe this precaution may result in bodily injury.

ATTENTION: The motor shaft can rotate in either direction by up to one (1) revolution, providing minimum torque immediately after the identification procedure (initiated in H.020) has been started. Stay clear of rotating machinery. Failure to observe this precaution could result in bodily injury.

ATTENTION: In V/Hz regulation, if P.000 (Control Source) is set to OP (Option Port), and P.062 is set to 1 (Hold Last Reference), and the drive loses communication with the network, the drive will maintain the last frequency command sent to it. Ensure that driven machinery, all drive-train mechanisms, and application material are capable of safe operation at the maximum operating speed of the drive. Failure to observe this precaution could result in bodily injury.

ATTENTION: Carrier Frequency (P.047) and Current Limit (P.005) must be set correctly before activating the identification procedure (H.020) to avoid motor overloading and/or overheating. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: The motor can rotate in the reverse direction during the identification procedure (H.020) even if reverse disable has been selected in P.027. Uncouple the motor from any driven machinery that could be damaged by reverse rotation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Chapter 1

Chapter 2

Chapter 3

CONTENTS

Using This Manual

1.1 Required Publications ...................................................................................... 1-1

1.2 Getting Assistance from Reliance Electric....................................................... 1-1

Identifying Drive Components Using Reference Drawings and Parts Lists

2.1 VFD Chiller Installation Drawing (500A and 643A VFD) ................................. 2-1

2.2 Front View of 500 and 643 Amp VFD with Parts List

(19XV04000601 rev 4.0) ................................................................................. 2-3

2.3 500 Amp and 643 Amp 19XRV Drive Module Component

Locations and Parts List .................................................................................. 2-4

2.4 Front View of 414 Amp VFD with Parts List (19XV04003001 rev 2.0) ............ 2-5

2.5 414 Amp 19XRV Drive Module Component Locations and Parts List............. 2-6

2.6 414 Amp 19XRV Drive Wiring Diagrams ......................................................... 2-7

2.7 VFD System Wiring Diagram (19XV05007901 rev A) ..................................... 2-9

2.8 500 Amp and 643 Amp 19XRV Drive Wiring Diagrams ................................ 2-14

Using the Keypad/Display to Program, Monitor, and Control the Drive..............3-1

Chapter 4

Chapter 5

Chapter 6

Identifying Parameter Defaults For Carrier Drives...............................................4-1

Verifying the Installation ......................................... ...............................................5-1

Troubleshooting the Drive

6.1 Test Equipment Needed To Troubleshoot....................................................... 6-1

6.2 Verifying That DC Bus Capacitors Are Discharged ......................................... 6-1

6.3 Checking the Power Modules and Motor with Input Power Off ....................... 6-4

6.4 Troubleshooting the Drive Using Error Codes ................................................. 6-6

6.4.1 Identifying Alarm Codes and Recovering .............................................. 6-7

6.4.2 Identifying Fault Codes and Recovering ............................................... 6-8

6.4.3 Accessing, Reading, and Clearing the Faults in the Error Log............ 6-11

6.5 Identifying Fatal Fault Codes and Recovering............................................... 6-14

6.6 Indentifying PMC Board Fault Codes and Recovering .................................. 6-15

6.7 Resetting a Checksum (CHS) Fault .............................................................. 6-15

Contents

Carrier VFD Quick Reference

The Carrier VFD Quick Reference is intended for qualified Carrier service personnel, and is to be used during start up, operation, and maintenance of the variable speed drive.

1.1 Required Publications

The Carrier VFD Quick Reference must be used with the following manuals:

CHAPTER 1

Using This Manual

• D2-3410

• D2-3411

• D2-3341

• D2-3448

• 531-982

(19XR-5SS)

LiquiFlo AC General Purpose (Volts/Hertz) and Vector Duty Drive Software Start-Up and Reference Manual

LiquiFlo AC Power Modules Hardware Reference, Installation, and Troubleshooting

Super Remote Meter Interface (RMI) Board for GV3000 and LiquiFlo AC Drives

Control and Configuration Software

19XR, XRV Start-Up, Operation, and Maintenance Instructions

1.2 Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this manual, contact your local Reliance Electric sales office. For technical assistance, call 1-864-284-5444.

Before calling, have the following information available (from the Reliance label):

• Reliance model number

• Carrier part number

• Serial number

Using This Manual

• Carrier drawing number and revision

1-1

1-2

Carrier VFD Quick Reference

Identifying Drive Components Using

Reference Drawings and Parts Lists

Replace with 2.fm (11 X 17 Z-fold)

CHAPTER 2

Identifying Drive Components Using Reference Drawings and Parts Lists

2-1

2-2

Carrier VFD Quick Reference

+ 26 hidden pages