McQuay VFD 009LA Installation Manual

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Page 1

Installation, Operation and Maintenance Manual

Variable Frequency Drives

Air-Cooled, LiquiFlo™ and LiquiFlo 2.0™

For Centrifugal Chillers

With MicroTech 200™ or MicroTech II™ Control

IOMM VFD-2

Group: Chiller

Part Number: 331375701 Effective: Sept. 2005 Supercedes: IOMM VFD

Page 2

Table of Contents

Introduction...........................................3

Environmental Conditions................................5

Harmonic Distortion.........................................5

General Description..............................6

Air-Cooled/LiquiFlo (LF ), Standard Features.6

LiquiFlo 2.0 (LF 2.0), Standard Features.........7

Codes/Standards...............................................7

Quality Assurance ............................................7

A-C/LiquiFlo, Nomenclature ...........................7

LiquiFlo 2.0, Nomenclature.............................7

Definition of Terms...............................9

Installation........................................... 11

Cooling Requirements for VFDs....................13

Separate Cooling Module (LF VFD 090, 120 and

all LF 2.0)....................................................15

Wiring, General..............................................21

Power Wiring.................................................21

Terminal Sizes................................................23

Optional Line Reactor Installation, Air-Cooled/LF

Only.............................................................25

VFD/Chiller Interconnection Wiring Diagram30

VFD Dimensions .................................32

Air-Cooled .....................................................32

LiquiFlo...........Error! Bookmark not defined.

LiquiFlo 2.0.....Error! Bookmark not defined.

MicroTech™ 200 VFD Control..........41

VFD Chiller Control States............................41

Control Sequence, MicroTech 200.................42

WDC/WCC, Dual Compressor VFD Operation43 MicroTech 200 Controller VFD Menu Screens43

MicroTech II™ VFD Control.............50

General Description: ......................................50

Sequence of Operation...................................50

Interface Panel Screens, MT II.......................52

Operation, Small A/C SP600 & LF 2.057

Using the Interface.........................................57

Using the LEDs..............................................59

About Alarms.................................................61

About Faults...................................................64

Troubleshooting.............................................73

Operation, Large A/C, PF700H.........77

Using the Interface.........................................77

Using the LEDs..............................................80

Faults and Alarms...........................................80

Troubleshooting.............................................87

Operation, LF .....................................90

Using the Interface.........................................90

Using the LEDs..............................................93

Troubleshooting.............................................95

Indices: Figures & Tables.................103

"Information and illustrations cover the McQuay International products at the time of publication and we reserve the right to make changes

“McQuay" is a registered trademark of McQuay International LiquiFlo and Reliance are trademarks of Rockwell Automation.

Manufactured in an ISO Certified facility

in design and construction at anytime without notice".

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DANGER

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 ma nual and other applicable manuals

in their entirety before proceeding. Failure to observe this precaution could result

in severe bodily injury or loss of life.

DANGER

DC bus capacitors re tain hazardous voltages after power has been disconnected.

After disconnecting input power to the unit, wait five (5) minutes for the DC bus

capacitors to discharge, and then check the voltage with a voltmeter to ensure the

DC capacitors are discharged before touching any internal components. Failure

to observe this precaution could result in severe bodily injury or loss of life.

CAUTION

The user is responsible for conforming to all applicable local, national and

international codes. Failure to observe this precaution could result in damage to,

or destruction of the equipment.

The drive contains printed circuit boards that are static-sensitive. Anyone who

touches the drive components should wear an anti-static wristband. Erratic

machine operation and damage to, or destruction of, equipment can result if this

Failure to observe this precaution can result in bodily injury.

Introduction

This manual covers Air-Cooled, LiquiFlo (LF ) and LiquiFlo 2.0 (LF 2.0) VFDs on centrifugal chillers with MicroTech 200™ or the newer MicroTech II™ controllers. Many issues are the same for both and are treated in common. Where differences occur, information will be designated as being for a specific VFD or controller model.

The above three types of VFDs have four family designations as show in Table 1 and Table

2. Each of these VFD families has a separate section in this manual. There is considerable overlap in programming methods and general operation of the drives, but they are in separate sections to avoid confusion. The beginning page number for each control section in the manual is noted in the tables.

WARNING

procedure is not followed.

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Table 1, Model Sizes, Air-Cooled/LiquiFlo

L=Shipped loose, M=Mounted, A=Air-cooled, W=Water-cooled

VFD Model

VFD 009LA 87 Air RC 100 VFD 009MA 87 Air RC 100 VFD 012LA 114 Air R1 130 VFD 012MA 114 Air R1 130 VFD 015LA 142 Air R2 160 VFD 015MA 142 Air R2 160 VFD 017LA 164 Air R3 200 VFD 017MA 164 Air R3 200 VFD 023LA 225 Air R4 250 VFD 023MA VFD 024LA 237 Air RY STD. VFD 024MA 237 Air RY STD. VFD 028LA 273 Air RY STD. VFD 028MA

VFD 047LW 414 Water RD 500

VFD 047MW 414 Water RD 500

VFD 060LW 500 Water R7 600

VFD 060MW 500 Water R7 600

VFD 072LW 643 Water R8 750

VFD 072MW 643 Water R8 750

VFD 090LW 890 Water RM 900

VFD120LW

VFD Family

Designation

SP 600 Page 57

PF700H Page 77

LF Page 90

Page

Location

Max.

Amps

225 Air R4 250

273 Air RY STD.

1157 Water R9 1200

Cooling

Optional Line Reactor

(Note 1)

Size Amp Rating

NOTES

1. Line reactors are optional on all sizes except Models VFD 024 and 028, where they are included as standard.

2. Electrical characteristics: 380/460 VAC ±10%, 3 phase, 50/60 Hertz, ±5 Hz.

3. Optional line reactors are 3% impedance.

Table 2, Model Sizes, LiquiFlo 2.0

VFD Model

VF 2037 368 Water VF 2055 VF 2080 809 Water VF 2110

VFD Family

Designation

LF 2.0, Frame 3

LF 2.0, Frame 4

Page

Location

Page 57

Max. Amps Cooling

553 Water

1105 Water

WSC and WDC single and dual compressor, and WCC dual compressor chillers can be equipped with Variable Frequency Drives (VFD). A VFD starts the compressor motor and then modulates the compressor speed in response to load, evaporator pressure, and condenser pressure, as sensed by the chiller microprocessor. Despite the small power penalty attributed to the VFD internal losses, a chiller can achieve outstanding overall efficiency by using a VFD. VFDs are effective when there is a reduced load, combined with a low compressor lift (lower condenser water temperatures), dominating the operating hours.

The traditional method of controlling centrifugal compressor capacity is by inlet guide vanes. Slowing down the compressor, thereby reducing the impeller tip speed, can also reduce capacity. However, sufficient impeller tip speed must always be maintained to meet the chiller’s discharge pressure requirements. The speed control method is more efficient than guide vanes by themselves.

In actual practice, a combination of the two techniques is used. The microprocessor slows the compressor (to a programmed minimum percent of full load speed) as much as possible,

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considering the need for sufficient tip speed, to make the required compressor lift. Then the guide vanes take over for further capacity reduction. This methodology provides the optimum efficiency under any operating condition.

Inlet guide vanes control compressor capacity based on a signal from the microprocessor, which is sensing changes in the leaving chilled water temperature. The guide vanes vary capacity by changing the angle and flow of the suction gas entering the impeller. The impeller takes a smaller “bite” of the gas. Reduced gas flow results in less capacity. Compressors start unloaded (guide vanes closed) in order to reduce the starting effort. A vane-closed switch (VC) signals the microprocessor that the compressor vanes are closed.

VFDs can be found on centrifugal chillers with the older MicroTech 200 controller (sometimes referred to as MicroTech I or just plain MicroTech) or the newer MicroTech II™ controller. The two MicroTech controller versions are easily differentiated as shown below. The MicroTech II panel shown below is the initial version known as Panel 1. Panel 2, shown on page 50, replaced it in mid-2005.

MicroTech 200 Control Panel

MicroTech II Operator Interface Panel 1

Operation and adjustment of the VFD involves settings on both the VFD itself and also to the chiller controller, either MicroTech 200 controller or MicroTech II controller. This manual consists of a section relating to VFD operation common to both chiller controllers and also separate sections for the settings specific to either of the chiller MicroTech controllers.

NOTE: VFDs are programmed differently in the factory for 50 and 60 hertz applications. It is prudent to verify this by checking the settings sticker in the unit and the actual unit settings using the Reliance manual shipped with the VFD unit as a reference.

Environmental Conditions

Operating Temperature (inside NEMA 1 enclosure) 32° to 131°F (0°C to 55°C) Ambient T em perature (outside NEMA 1 enclosure) 32° to 104°F (0°C to 40°C) Storage Temperature (Ambient) 32° to 131°F (0°C to 55°C) Humidity 5% to 95% (non-condensing) AC line distribution system capacity shall not exceed 85,000 amps symmetrical available fault

current.

Harmonic Distortion

Harmonic distortion, the effect that any variable frequency drive has on the electrical system supplying it power, is a consideration on most applications and is discussed in detail in Catalog Starter, which can be obtained from the local McQuay sales office or on www.mcquay.com.

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General Description

The VFD will not generate damaging voltage pulses at the motor terminals when applied within 500 feet of each other. The VFD drive complies with NEMA MG1 section

30.40.4.2, which specifies these limits at a maximum peak voltage of 600 volts and a minimum rise time of 0.1 microseconds.

All VFDs require cooling. Models VFD 019 and VFD 028, rated at 273 amps or less, are air-cooled. All others are water-cooled.

Factory-mounted, water-cooled VFDs have VFD cooling water combined in the factory with the compressor oil cooling system.

Freestanding water-cooled VFDs require field-installed chilled water supply and return piping for the VFD. Models VFD 090 and 120 and all LF 2.0 models have an intermediate cooling module, field installed, between the cooling source and the VFD.

Water-cooled VFD’s have a liquid-cooled heatsink assembly enabling liquid cooling of the drive though a single inlet and outlet connection point.

There is a temperature-regulating valve located in the drive. It must be set to maintain 95°F (35°C) leaving coolant temperature. This is necessary to prevent condensation from forming in the heatsink. Minimum entering coolent temperature is 40°F (4.4°C).

Air-Cooled/LiquiFlo (LF ), Standard Features

• Electronic overload circuit designed to protect an AC motor, operated by the VFD output, from extended overload operation on an inverse time basis. This electronic overload is UL and NEC recognized as adequate motor protection. No additional hardware, such as motor overload relays, or motor thermostats are required.

• An LED display that digitally indicates:

Frequency output Input kW DC bus voltage Voltage output Elapsed time Motor RPM Current output Time stamped fault indication

• The VFD is capable of maintaining operation through power dips up to 10 seconds without a controller trip, depending upon load and operating conditions. In this extended ride-through, the drive uses the energy generated by the load inertia of the motor as a power source for electronic circuits.

• An isolated 0-20mA, 4-20mA, or 0-4, 0-8, 0-10 V analog speed input follower.

• An isolated 0-10V or 4-20mA output signal proportional to speed or load.

• Standard I/O expansion interface card with the following features:

• Four isolated 24VDC programmable digital inputs

• One frequency input (0 to 200Hz) for digital control of speed or trim reference

• Four programmable isolated digital outputs (24 VDC rated)

• One Form A output relay rated at 250 VAC or 24VDC

• Two NO/NC programmable output relays rated at 250 VAC or 24 VDC

• The VFD includes the following standard protective circuit features:

• Output phase-to-phase short circuit condition

• Total ground fault under any operating condition

• High input line voltage

• Low input line voltage

• Loss of input or output phase

• External fault (This protective circuit will permit wiring to a remote normally

closed equipment protection contact to shut down the drive.)

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LiquiFlo 2.0 (LF 2.0), Standard Features

• NEMA 1 enclosure with hinged door.

• Package includes a circuit breaker with shunt trip with AIC rating of 65,000 amps.

• Full motor voltage is applied regardless of the input voltage.

• Efficiency at rated load and 60 hertz is 97%.

• Drive thermal overload is 110% for 60 seconds in volts per hertz mode and 150% for

five seconds in sensorless vector mode.

• Achieves IEEE519 using actively controlled IGBT front-end maximum of 5% THD.

• 0.99 power factor at full load and provides power factor correction at lighter loads.

• IGBT switching: 2kHz carrier frequency.

• The entire drive package is UL/CUL listed.

• Optional multi language LCD keypad.

• Power line dip ride through capability for up to 10 seconds.

• Adjustable auto restart (number of restarts and time delay between attempts are

selectable.) Display indicates when controller is attempting to restart.

• Control power transformer for chiller unit controls

Codes/Standards

• VFDs are UL 508 listed

• VFDs are designed to comply with the applicable requirements of the latest standards

of ANSI, NEMA, National Electric Code (NEC), NEPU-70, IEEE 519-1992, FCC Part 15 Subpart J, CE 96.

Quality A ssurance

• Every VFD is functionally tested under motor load. During this test the VFD is

monitored for correct phase current, phase voltages, and motor speed. Correct current limit operation is verified by simulating a motor overload.

• Scrolling through all parameters verifies proper factory presets. The computer port also

verifies that the proper factory settings are loaded into the drive.

• Every VFD’s heatsink is tested to verify proper embedding of the tubing for flow of

coolant liquid. Thermal tests are performed on the VFD to verify that the cooling occurs within the correct temperature range.

A-C/LiquiFlo, Nomenclature

VFD XXX M A

Variable Frequency Drive

2037 through 2110 (LF 2)

Model Number

009 through 120

Cooling Method A=Air-cooled W=Water-cooled

Mounting M=Factory-mounted L= Shipped Loose for Field Mounting

LiquiFlo 2.0, Nomenclature

Since all LF 2.0 models are field-mounted and water-cooled, there are no characters after the Model Number, typically VFD 2037.

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Figure 1, LiquiFlo, Internal Component s, Factory Mounted, Water-Cooled Model

Optional Meter Transformers (2)

Motor Terminals

Fuses

Disconnect Switch

Terminal Board

Motor Control Relays (MCR)

Control

Transformer

w/ Fuses

Drive Unit

Keyboard/Display

Cooling Water Lines

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Definition of Terms

Acc2 Active LEWT Setpoint Analog in loss Anig Cal Chksum Autotune AutoT MagRot AutoT Rs Stat CAN Bus Fit Command Speed DB Dec2 Decel Inhibit Demand Limit Dig in Conflict Drive OL

Esc/Prog

Flux Amps

Full Load

FVC HIM IGBT

IntDBResOvrHeat Lift Temperature Lift Temperature Control

Speed Low evap pressure inhibit

setpoint Manual Load Setpoint Maximum Pulldown Rate MCB MCR Minimum Amp Setpoint Minimum Rate Setpoint Minimum Speed Mod Net Network Setpoint NP Hz OIM PCB

Continued next page.

Acceleration time 2 The current Leaving Evaporator Water Temperature Setpoint Analog input loss Analog input calculation check sum, math function Set point adjustments made automatically, not used by McQuay Autotune rotate, not used by McQuay Autotune static, not used by McQuay Controlled area network bus fit The speed command issued by the MicroTech controller to the VFD Dynamic breaking (not used on McQuay units) Deceleration 2, not used by McQuay Deceleration inhibited The maximum amp draw as established by the Demand Limit setpoint Digital input conflict, contradictory instructions Drive overload Exit a menu, cancel a change to a parameter, or toggle between program and

process (user) display screens. Amount of current out of phase with the fundamental voltage component

The vane open switch closes and the speed output = 100%. Or

Load pulses exceed the full load setpoint timer (default 300 cumulative

seconds) and the speed output = 100%. Or % RLA is above or equal to Max Amp Limit or Demand Limit. Or The evaporator pressure is below the low evap. pressure inhibit setpoint.

Flux vector control Human interface module Insulated Gate Bi-polar Transistors Dynamic breaking resistor temp. exceeded setpoint(not used on McQuay

units) Saturated condenser refrigerant temperature minus saturated evaporator temperature. The minimum speed to maintain lift and avoid surge. The controller continuously calculates the minimum operating speed in all modes, based on the lift temperature.

The low evaporator pressure that inhibits any further compressor loading

MicroTech controller manual operation of the guide vanes for testing Maximum pulldown rate of chilled water in degrees per minute Main control board Motor control relay MicroTech controller minimum unloading setpoint Pulldown rate for MicroTech 200 controller The minimum speed allowed, usually set at 70% Module Network Chilled water setpoint from an external source

Operator interface module Printed circuit board

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Precharge PWM

Rapid Shutdown RLA

RMI Softloading

Speed Stage Delta

SVC

Parameters

Throughout this manual, you will see references to parameter names and numbers that identify them for the drive. This manual uses the same format that will be shown on the keypad/display to refer to parameters:

P.nnn H.nnn R.nnn

Where: nnn is a number P designates general parameters H designates Volts/Hertz parameters R designates optional RMI parameters

Precharge capacitors Pulse-width-modulated If there is a fault, the MicroTech switches the state to VFD OFF. This includes

changing the Unit Control Panel switch to OFF. Rated Load Amps, the maximum motor amps Remote meter interface, located in the VFD panel Extended ramp-up in capacity, set in the MicroTech controller Speed signal to the compressor motor from the variable frequency drive (VFD)

based on analog output (0 – 10 VDC) from the MicroTech controller. Multi compressor (or dual compressor unit) on/off cycling temperature delta-T Sensorless vector control

CAUTION

The original parameters values set by the McQuay startup technician must never be

changed by anyone not specifically trained and experienced with these VFDs. Damage

to the chiller or drive could occur.

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Installation

Mounting Arrangement s

Depending on size and type, VFDs may be factory-mounted with power and control wiring factory-installed or free-standing, requiring field mounting remote from the unit and fieldwiring of power and control wiring. Because of dimension restrictions for shipping, some “factory-mounted” VFDs for some large chillers are shipped separate from the unit. Mounting supports are on the unit and preassembled cable kits are provided. Mounting and wiring on site are the customer’s responsibility and can be subcontracted to McQuay Factory Service if desired.

Factory-Mounted (extra cost option):

The VFD is mounted on the chiller unit with the back of the VFD against the motor terminal box and wired directly to the motor. This arrangement is only available on WSC/WDC 063, 079, or 087 units and with LF.

On models WSC/WDC 048/050, the VFD (LF only) is factory-mounted on the front of the chiller unit and connected to the motor with conduit and cable.

Free-standing (standard):

Floor-mounted, separate from the chiller unit, and field wired to the compressor motor. This is available on all VFDs and is the only VFD arrangement available for WDC/WCC 100 and 126 dual compressor units.

Brackets and cable (extra cost option):

VFDs (LF only) for WSC 100 to 126 single compressor units may be shipped separately from the chiller unit and furnished with mounting brackets and interconnecting cables for field mounting and connection by others. This option must be clearly specified when chillers are ordered since brackets are welded onto the evaporator during its construction.

Table 3, VFD Mounting Arrangements

Chiller

Size

WSC/WDC 050 X X X

WSC/WDC 063 X X X

WSC/WDC 079 X X X

WSC/WDC 087 X X X

WSC 100 - 126 X X X WDC 100 – 126,

WCC 100 - 126

Factory- Mounted Free-Standing Brackets & Cables Free-Standing

X X

Air-Cooled/LiquiFlo LiquiFlo 2.0

Receiving

Since factory-mounted VFDs are mounted and wired at the factory, this section will only apply to free-standing units.

The unit should be inspected immediately after receipt for possible damage. All McQuay centrifugal VFDs are shipped FOB factory and all claims for handling and

shipping damage are the responsibility of the consignee.

Rigging

Extreme care must be used when rigging the equipment to prevent damage. See the certified dimension drawings included in the job submittal for the center of gravity of the unit. Consult the local McQuay sales office for assistance if the drawings are not available.

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Air-Cooled, The unit can be lifted by fastening the rigging hooks to the two lifting eyes located on the top of the unit.

LiquiFlo; The unit can be lifted by fastening the rigging hooks to the four lifting eyes located on the top of the unit.

LiquiFlo 2.0:

Figure 2, LF 2.0, Lifting Point s

Use the following procedure to lift and mount the LiquiFlo 2.0 drive:

Step 1. Using an overhead or portable hoist (minimum 2 ton rated capacity), attach a free-fall chain to the chain secured to the drive. Take up any vertical slack in the chain.

Step 2. Using the hoist, lift the drive from the horizontal shipping pallet. Step 3. Position the drive. Step 4. Machine or floor-mount the drive enclosure using 1/2-inch bolts, grade 5 or

better, with compression washers.

Location and Mounting

Location

Consider the following guidelines: •

• Verify that NEMA 1 enclosure drives can be kept clean and dry.

• The area chosen should allow the space required for proper air flow. A minimum of 6-

inch clearance is required wherever vents are located.

• Be sure that the NEMA 1 enclosure is installed away from oil, coolants, or other airborne contaminants.

• Do not install the drive above 1000 meters (3300 feet) without derating output power. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), derate the output current 1%.

• Verify that the drive location meets the environmental conditions specified on page 5.

• Floor-mounted units should be attached to the floor with the C-channel rails provided.

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Clearance

The VFDs must be mounted on a level concrete or steel base and must be located to provide adequate service. Local codes or the National Electric Code (NEC) can require more clearance in and around electrical components and must be checked.

Mounting

Make sure that the floor or structural support is adequate to support the weight of the unit shown on the dimension drawing.

Standard NEMA 1 and NEMA 12 VFDs must be installed indoors in an area that is not exposed to direct water spray. Do not install in areas where the ambient temperature falls below 32°F (0°C) or exceeds 104°F (40°C) enclosed, or 122°F (50°C) open unless this was noted at the time of order placement and special precautions were taken to protect against these abnormal temperatures.

Heatsink temperatures can run as high as 158°F (70°C) during normal operation. Do not mount the starter in contact with any material that cannot accept this heat. The VFD must be mounted with the heat sink fins oriented vertically in an area that will not experience excessive shock or vibration.

Grounding the Drive

Use the following steps to ground the drive:

Step 1. Open the door of the enclosure. Step 2. Run a suitable equipment grounding conductor unbroken from the drive

enclosure ground lug to earth ground. See figure 2.2. Tighten these grounding connections to the proper torque.

Step 3. Close the door of the enclosure.

Safety Precautions

Electrical codes require that all equipment (VFD, motor, operator station, etc.) be properly grounded. An incoming disconnect must be locked open before wiring or servicing the starter, motor, or other related equipment. The equipment must only be serviced by qualified personnel fully trained and familiar with the equipment.

The opening of the branch circuit protective device may be an indication that a fault current has been interrupted. To reduce the risk of electrical shock, current carrying parts and other components of the starter should be inspected and replaced if damaged.

Equipment is at line voltage when AC power is connected. Pressing the Stop push-button does not remove AC mains potential. All phases must be disconnected before it is safe to work on machinery or touch motor terminals and control equipment parts.

Cooling Requirements for VFDs

Air-cooled VFDs: all air-cooled have self-contained cooling systems and require no field work.

Water-cooleed, factory-mounted VFDs: VFD cooling water piping is factory-connected to the chiller’s oil cooling system. See Figure 3. Cooling water piping is to the normal chiller oil-cooling system connections.

Freestanding VFDs: VFD cooling water piping must be field connected on freestanding units. See Figure 4. Cooling water is connected directly to models 047LA through 072LW. Models 090LW and 120LW, and all LF 2.0 units, are always freestanding and have a separate cooling module that must be field piped to the cooling water supply and also interconnected to the VFD. See page 15 for detailed installation instructions.

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Figure 3, VFD 047 through 072, Cooling Water Piping for Factory-M ount ed VFD

CHILLED

WATER

PUMP

STOP

VALVE

STOP

VALVE

Field Supplied Piping Components

Field Piping Connection Point

BALANCING

VALV E

STRAINER

MAX. 40 MESH

CHILLER

VFD HEAT

EXCHANGER

SOLENOID

VALV E

(Factory Mounted)

SOLENOID

VALV E

(Factory Mounted)

DRAIN VALVE

OR PLUG

COMPRESSOR

OIL COOLER CIRCUIT

WATER

REGULATING

VALV E

(Factory Mounted)

STOP

VALVE

WATER

REGULATING

VALV E

(Factory Mounted)

STOP

VALV E

Figure 4, VFD 047 – 120 and all LF 2.0, Cooling Water Piping f or Free- Standing VFD

CHILLED

WATER

PUMP

STOP

VALV E

STOP

VALVE

Field Supplied Piping Components

Field Piping Connection Point

BALANCING

VALV E

STRAINER

MAX. 40 MESH

CHILLER

COMPRESSOR

OIL COOLER CIRCUIT

SOLENOID

VALV E

(Factory Mounted)

SOLENOID

VALV E

(Factory Mounted)

DRAIN VALVE

OR PLUG

VFD HEAT

EXCHANGER

WATER

REGULATING

VALV E

(Factory Mounted)

STOP

VALV E

WATER

REGULATING

VALV E

(Factory Mounted)

STOP

VALVE

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NOTE: In some cases, the “VFD HEAT EXCHANGER” may be a separate-mounted cooling module that is, in turn, connected

to the VFD.

Table 4, Cooling Requirements

Combined

McQuay

Drive Model

Number

VFD 009-028 N/A N/A Air N.A. 104 40 NA N/A

VFD 047 1.0 7/8 in. Water (1) 2.0 90 40 10 (2) 300 VFD 060 1.0 7/8 in. Water (1) 2.0 90 40 30 (2) 300 VFD 072 1.0 7/8 in. Water (1) 2.5 90 40 30 (2) 300 VFD 090 1 1/4 1.0 in. Water (1) (3) 7.0 90 40 30 (2) 300 VFD 120 1 1/4 1.0 in. Water (1) (3) 7.0 90 40 30 (2) 300

VF 2037 N/A 3/4 NPT Water (1) (3) 7.0 90 40 N.A. 180 VF 2055 N/A 3/4 NPT Water (1) (3) 7.0 90 40 N.A. 180 VF 2080 N/A 3/4 NPT Water (1) (3) 15.0 90 40 N.A. 180 VF 2110 N/A 3/4 NPT Water (1) (3) 15.0 90 40 N.A. 180

Notes:

1. Cooling water must be from the closed, chilled water circuit with corrosion inhibitors for steel and copper, and must be piped across the chilled water pump.

2. The pressure drop is given for the maximum coolant temperature (maximum flow). The water-regulating valve will reduce the flow when the coolant temperature is below the maximum in the table. The pressure drop includes the drop across the solenoid valve, heat exchanger and water regulating valve.

3. Models VFD 090and 120 and all LF 2.0 models have a separate self-contained cooling loop with a recirculating water pump and heat exchanger, but have the same cooling source water piping as all water-cooled VFDs.

Comp. Oil and

VFD Cooling Copper Tube

Size

VFD Cooling

Only, Copper

Tube Size

Type K or L

Coolant Method

Air-Cooled/LF

LF 2.0

Flow

(gpm)

Max.

Entering

Coolant

Temp. (° F)

Min.

Entering

Coolant

Temp(° F)

Pressure

Drop

(feet)

Max.

Pressure

(Water

Side) psi

Table 5, Chiller Cooling Water Connection Sizes

Chiller Unit

WDC/WCC 100/126 1 1/2 in. FPT ¾ in. MPT 1 1/2 in. FPT

WSC/WDC 050 Not Required Air-Cooled Not Required

All Others 1 in. FPT 3/4 in MPT 1 in. FPT

Free-Standing VFD, LF and LF 2.0 Factory-Mounted VFD, LF Only

To Oil Cooler To VFD Combined

Separate Cooling Module (LF VFD 090, 120 and all LF 2.0)

The cooling module for the LF models VDF 090 and 120 has a self-contained coolant temperature control system and no associated programming of the VDF is required. All cooling modules used with LF 2.0 VFD models are controlled by the VFD and require VFD programming as shown on page 19. This is done by McQuay at startup.

Closed loop cooling system operation

• A pump circulates a glycol/ water mixture (coolant) through the VFD heat sink, a coolant reservoir and a small plate heat exchanger. Heat is removed from the VFD heat sink and rejected to the plate heat exchanger.

• The pump and control valve are controlled by the VFD control system on LF 2.0 VFD models and self-contained on LF models.

• The plate heat exchanger is cooled by water from the chilled water system

Installation steps:

• Place cooling loop module in desired location.

• Attach coolant and chilled water piping. Seven to nine gpm of coolant will be circulated. A

40 mesh strainer is required at the drive inlet. Include service isolation valves in the coolant and chilled water inlet and outlet piping.

IOMM VFD-2 15

Page 16

• Wire according to the supplied wiring diagrams.

16 IOMM VFD-2

Page 17

The following is required from the customer's chilled water supply for the McQuay VFD cooling loop to perform properly.

Water Quality:

Water must be compatible with components supplied in the cooling loop; brass, copper, stainless steel and neoprene rubber seals. Supply water circulates through a copper brazed stainless steel, plate type heat exchanger by way of a stainless steel and brass ball valve and associated stainless steel, brass and copper piping.

Water Source:

Clean and non-corrosive chilled water must be used as the coolant.

Figure 5, Cooling Module Dimensions

Weights

Shipping weight: 300 lbs (136 kg) Dry weight: 250 lbs (114 kg) Operating weight: 270 lbs. (123 kg)

IOMM VFD-2 17

Page 18

Figure 6, LF 2.0 Remote Cooling Module Int erconnect i ng Wiring

TB2 is the terminal board located in the remote module. TB1 is a terminal board located in the VFD. Field Wiring:

• TB1-10 (DO NO2) to TB2-4 (OP, Open)

• TB1-13 (DO NO3) to TB2-5 (CL, Close)

• Wire 42 (Aux Relay) to TB2-3 (Neutral)

• Wire 42 (Aux Relay) to TB2-2 (LPN, Loop Pump Neutral)

• Aux Relay Terminal 7 to TB2-1 (LP, Loop Pump)

• GRD (PE) to Ground

18 IOMM VFD-2

Page 19

Maximum Static Pressure:

300 psi nominal limited by ball valve and piping pressure ratings.

Requirements for proper operation of the drive/ cooling module cooling loop.

Cooling Loop Liquid:

25% inhibited (corrosion protected) propylene glycol (DOWFROST or equivalent) concentration by volume with distilled water. Non-inhibited or silicate containing glycols may cause equipment damage.

Coolant Volume:

Approx. 1 gallon is required with side-by-side connection of cooling module to the drive cabinet. More coolant volume will be required if coolant loop is located up to 20 feet away from drive.

Coolant Maintenance:

The coolant liquid should be checked and refreshed as needed on a yearly basis. The pH should be maintained between 8.0 and 10.0. A 50% solution of sodium hydroxide or potassium hydroxide can be used to raise pH if falls below 8.0. Any time the coolant falls below a pH of 7.0 the loop should be flushed and coolant replaced. Any time the coolant appears other than water white it should be replaced.

Remote Mounted Cooling Loop:

The maximum distance the cooling loop can be installed away from the drive cabinet connections is 20 feet. Careful planning of remote mounting is required to minimize coolant flow restrictions introduced by piping connections.

Cooling Module Parameters Set in LF 2.0 VFD models

LF 2.0 drives control the operation of the cooling module. The parameters are set by McQuay at chiller commissioning.

How to Monitor Cooling Loop Operation FX-05 Screen Navigation (see Figure 7)

After power-up the process temperature will be displayed.

Alarms

When an alarm is present the alarm LED will blink fast and the error code will flash. The following is a list of the error code.

• E0: OK

• E1: Low Level Fault

• E2: Fluid Over-Temperature Fault

• E3: Fluid Under-Temperature Fault

• E4: Fluid Low Flow Fault

To acknowledge the alarms hold the φ key for 3 seconds. The alarm error code will be displayed and the reset led will light while the button is depressed. After the φ key is released the process temperature will be displayed.

To view the alarm summary hold both the ↵ ↓ keys for 3 seconds. To exit the alarm summary screen press the φ key or the screen will automatically time out after 10 seconds.

IOMM VFD-2 19

Page 20

Figure 7, FX05 Display Panel

ALARM RESET PUMP ON

Fx05

Operation

The FX controller controls to a fixed loop water setpoint.

20 IOMM VFD-2

Page 21

Wiring, General

Unit-Mounted: Unit mounted VFDs have factory-wired control wiring plus power wiring from the VFD to the compressor motor terminals. The VFDs only require a power supply. Cable entrance is shown on the dimension drawings beginning on page 32 for LF and page Error! Bookmark not defined. for LF 2.0 models. An exception is on models LF models 090 and 120 and all LF 2.0 models that require some interconnection control wiring from the VFD to the remote cooling module as described in the section beginning on page 15.

Freestanding: Freestanding units require both field control and power wiring from the VFD to the chiller and. some interconnection control wiring on models 090 and 120.

Wiring Diagram: The control and power wiring diagram is located on page 25.

Power Wiring

Wiring, fuse and wire size must be in accordance with local codes and the National Electric Code (NEC).

CAUTION

Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to

10 times the voltage unbalance per NEMA MG-1, 1998 Standard. This is an

important requirement to avoid excessive motor or drive heating.

WARNING

Qualified and licensed electricians must perform wiring. Shock hazard exists.

Power wiring to compressors must be in proper phase sequence. Motor rotation is set up for clockwise rotation facing the lead end with phase sequence of 1-2-3. Care must be taken that the proper phase sequence is carried through the VFD to the compressor. With the phase sequence of 1-2-3 and L1 connected to T1 and T6, L2 connected to T2 and T4, and L3 connected to T3 and T5, rotation is proper. See diagram in terminal box cover.

The McQuay start-up technician will check the phase sequence.

CAUTION

Connections to terminals must be made with copper lugs and copper wire.

Care must be taken when attaching leads to compressor terminals.

Note: Do not make final connections to motor terminals until wiring has been

checked and approved by a McQuay technician.

Under no circumstances should a compressor be brought up to speed unless proper sequence and rotation have been established. Serious damage can result if the compressor starts in the wrong direction. Such damage is not covered by product warranty.

Compressor Motor Terminal Insulation

It is the installing contractor's responsibility to insulate the compressor motor terminals (as described below) when the unit is installed in a high humidity location that could cause condensate to form on the motor terminals. The terminals are cooled to 45°F to 50°F as a result of the motor cooling. The required material can be ordered and shipped in as a kit (775123601).

IOMM VFD-2 21

Page 22

This is to be done after the McQuay start-up technician has checked for proper phase sequence and motor rotation.

Following this verification by the McQuay technician, the contractor should apply the following items.

Materials required:

1. Loctite® brand safety solvent (12 oz. package available as McQuay part number 350A263H72)

2. 3M™ Co. Scotchfil brand electrical insulation putty (available in a 60-inch roll as McQuay part number 350A263H81)

3. 3M Co. Scotchkote™ brand electrical coating (available in a 15 oz. can with brush as McQuay Part Number 350A263H16)

4. Vinyl plastic electrical tape

The above items are available at most electrical supply outlets.

Application procedure:

1. Disconnect and lock out the power source to the compressor motor.

2. Using the safety solvent, clean the motor terminals, motor barrel adjacent to the terminals, lead lugs, and electrical cables within the terminal 4OX to remove all dirt, grime, moisture and oil.

3. Wrap the terminal with Scotchfil putty, filling in all irregularities. The final result should be smooth and cylindrical.

4. Doing one terminal at a time, brush the Scotchkote coating on the motor barrel to a distance of up to '/2" around the terminal and on the wrapped terminal, the rubber insulation next to the terminal, and the lug and cable for approximately 10". Wrap additional Scotchfil insulation over the Scotchkote coating.

5. Tape the entire wrapped length with electrical tape to form a protective jacket.

6. Finally, brush on one more coat of Scotchkote coating to provide an extra moisture barrier.

22 IOMM VFD-2

Page 23

General Wiring Practice

1. Never connect input AC power to the motor output terminals T1/U, T2/V or T3/W.

2. Power wiring to the motor must have the maximum possible separation from all other wiring. Do not run control wiring in the same conduit; this separation reduces the possibility of coupling electrical noise between circuits. Minimum spacing between metallic conduits containing different wiring groups should be three inches (76 mm).

3. Minimum spacing between different wiring groups should be six inches (152

mm).

4. Wire runs outside of an enclosure should be run in metallic conduit or have shielding/armor with equivalent attenuation.

5. Different wire groups should cross at 90 degrees whenever power and control

wiring cross.

6. Different wire groups should be run in separate conduits.

7. Adhere to local electrical codes.

8. The National Electrical Code and Canadian Electrical Code requires that an approved circuit disconnecting device be installed in series with the incoming AC supply in a location readily accessible to personnel installing or servicing this equipment. If a disconnect switch is not supplied with the starter, one must be installed.

9. Supply lines and motor lines may enter the enclosure from the top, bottom or sides. Wire connections can be determined to best suit specific installations. Wire runs should be properly braced to handle both starting and fault currents. Size power cable per local electrical codes. Long lengths of cable to the motor of over 150 feet must be de-rated.

Terminal Sizes

Compressor Motor Terminals

Power wiring connections at the motor are “spark plug” type terminals with threaded copper bar, sized per the following table.

Table 6, Chiller Compressor Motor Terminal Sizes

Type/Size Comp. Size Terminal Size

Low Voltage to 275 A, to 575 V CE 050 0.375-16 UNC2A, 0.94 in. long Low Voltage to 750 A, to 575V CE 063-126 0.635-11 UNC-2A, 1.88 in. long

VFD Terminals

For field wiring freestanding VFDs, the outgoing terminals and incoming power block terminals are determined by the VFD size listed in Table 8. For factorymounted VFDs, the outgoing terminals are factory-connected to the compressor motor.

When wiring to a VFD with a disconnect switch or circuit breaker, the incoming lug size is determined by the device size as shown in Table 9.

IOMM VFD-2 23

Page 24

Table 7, LiquiFlo 2.0, Terminal Size Range

VFD Size

VF2037 VF2055 VF2080 VF2110

Incoming Terminals Outgoing

Terminals

Incoming connecti on is

to the standard circuit

breaker. See

Table 9.

(3) 1.5 inch wide tab

w/ 0.472 inch hole

(3) 2.25 inch wide tab

w/ 0.56 inch hole

Table 8, Air-Cooled/LiquiFlo, Outgoing, Incoming Power Block, Terminal Size Range

Incoming

VFD Size

Power Block

Terminals

VFD 009 SP600 #14 – 1/00 #14 – 1/00 VFD 012 SP600 #4 – 3/0 #4 – 3/0 VFD 015 SP600 #14 - 250 #14 - 250 VFD 017 SP600 #14 - 250 #14 - 250 VFD 023 SP600 #14 - 250 #14 - 250 VFD 024 PF700H 4/0 - 350 4/0 - 350 VFD 028 PF700H 4/0 - 350 4/0 - 350 VFD 047 LF (2) #4 - 500 (2) #6 - 300 VFD 060 LF (2) #4 - 500 (2) #4 - 350 VFD 072 LF (2) #4 - 500 (2) #4 - 350

VFD 090 LF (2) #4 - 500

VFD 120 LF (2) #4 - 500

Outgoing

Terminals

2 in. x 1/4 in. bus

(1) 9/16 in. hole

2 in. x 1/4 in. bus

(1) 9/16 in. hole

Table 9, Incoming Terminal Size Range, Disconnects & Circuit Breakers

Max

RLA

Size

74 100 (1) #6- 300 93 125 (1) #6- 300 148 200 (1) #6- 300 163 220 (1) 4/0 - 500 185 250 (2) 3/0 - 500 296 400 (2) 3/0 - 500 444 600 (3) 1/0 - 500 593 800 (4) 250 – 500 889 1200 (5) 300 – 600 1185 1600 (5) 300 - 600

NOTE: (X) is the number of terminals per phase.

Incoming Terminal, Disconnect

Switch or Circuit Breaker

24 IOMM VFD-2

Page 25

Optional Line Reactor Installation, Air-Cooled/LF Only

Mounting Options

Optional line reactors can be mounted in the VFD enclosure on free-standing units and must be field-mounted and wired when the VFD is factory-mounted. When the reactor is installed in the VFD enclosure, a much larger enclosure is required and it is too large to mount on the chiller.

VFD Line Harmonics

VFDs have many benefits, but care must be taken when applying VFDs due to the effect of line harmonics on the building electric system. VFDs cause distortion of the AC line because they are nonlinear loads, that is, they don't draw sinusoidal current from the line. They draw their current from only the peaks of the AC line, thereby flattening the top of the voltage waveform. Some other nonlinear loads are electronic ballasts and uninterruptible power supplies.

Reflected harmonic levels are dependent on the source impedance and the KVA of the of the power system to which the drive is connected. Generally, if the connected power source has a capacity greater than twice the drive’s rated amps (see Table 1 or Table 2 for rated amps), the installation will conform to IEEE Standard 519 with no additional attenuation. Presumably, the application on which this drive is applied has been checked for harmonic levels. If not, contact the local McQuay office.

The IEEE 519-1991 Standard

The Institute of Electrical and Electronics Engineers (IEEE) has developed a standard that defines acceptable limits of system current and voltage distortion. A simple form is available from McQuay that allows McQuay to determine compliance with IEEE 519-1991. Line harmonics and their associated distortion may be critical to AC drive users for three reasons:

1. Current harmonics can cause additional heating to transformers, conductors, and switchgear.

2. Voltage harmonics upset the smooth voltage sinusoidal waveform.

3. High-frequency components of voltage distortion can interfere with signals transmitted on the AC line for some control systems.

The harmonics of concern are the 5 by three, and high magnitude harmonics are usually not a problem.

Current Harmonics

An increase in reactive impedance in front of the VFD helps reduce the harmonic currents. Reactive impedance can be added in the following ways:

1. Mounting the drive far from the source transformer.

2. Adding line reactors.

3. Using an isolation transformer.

Voltage Harmonics

Voltage distortion is caused by the flow of harmonic currents through a source impedance. A reduction in source impedance to the point of common coupling (PCC) will result in a reduction in voltage harmonics. This may be done in the following ways:

1. Keep the point of common coupling (PCC) as far from the drives (close to the power source) as possible.

2. Increase the size (decrease the impedance) of the source transformer.

, 7th, 11th, and 13th. Even harmonics, harmonics divisible

IOMM VFD-2 25

Page 26

3. Increase the capacity of the busway or cables from the source to the PCC.

4. Make sure that added reactance is "downstream" (closer to the VFD than the source) from the PCC.

DANGER

High voltage is used in the operation of line/load reactors. Use Extreme caution to

avoid contact with high voltage when operating, installing or repairing equipment

containing line/load reactors.

INJURY OR DEATH MAY RESULT IF SAFETY PRECAUTIONS ARE NOT

OBSERVED

DANGER

Even if the upstream disconnect/protection device is open, a drive or inverter

down stream of the line/load reactor may feed back high voltage to the reactor.

The inverter or drive safety instructions must be followed.

INJURY OR DEATH MAY RESULT IF THE SAFETY PRECAUTIONS ARE NOT

OBSERVED

CAUTION

An upstream disconnect/protection device must be used as required by the

National Electrical Code

CAUTION

The frame of line/load reactors must be grounded at least at one of the reactor’s

mounting holes.

This section is intended for use by personnel experienced in the operation and maintenance of electronic drives, inverters and similar types of power electronic equipment. Because of the high voltages required by the equipment connected to line reactors and the potential dangers presented by rotating machinery, it is essential that all personnel involved in the operation and maintenance of line/load reactors know and practice the necessary safety precautions for this type of equipment. Personnel should read and understand the instructions contained in this section before installing, operating or servicing line/load reactors and the drive to which the reactor is connected

AGENCY A PPROVALS:

UL-508, File E180243 Component Recognized (1 amp – 2400 amps) UL-508, File E180243 UL Listed Nema 1 units (1 amp – 2400 amps) CSA C22.2, File LR29753-13 CSA Certified (1 amp – 1200 amps) Class H, 200 C, File E66214, Type 180-36, UL Recognized Insulation System CE

26 IOMM VFD-2

Page 27

Ambient Temperature

Maximum ambient temperature is 45°C (113°F).

Figure 8, Line Reactor Dimensions, Models VFD 009 - 017

Figure 9, Line Reactor Dimensions, Models VFD 047 - 072

Table 10, Line Reactor Data

VFD Model

009MA 13.2 (335) 13.2 (335) 13.2 (335) 86 (39) 6-0 6-4=45, 2-0=500

012MA–017MA 13.2 (335) 13.2 (335) 13.2 (335) 98 (44) 2-0000

023MA 17.0 (432) 17.0 (432) 24.0 (610) 151 (69) 00-500

024-028 See Note 3

047MW-060MW 17.0 (432) 17.0 (432) 24.0 (610) 225 (102) See Note 2

072MW 24 (610) 24 (610) 30 (762) 393 (178) See Note 2

090LW-120LW See Note 3 See Note 4

Width “A”

in. (mm)

NOTES:

1. Models 012MA through 023MA have box lugs, one wire per lug.

2. Models 047MW through 072MW have copper tabs with (1) 0.656 hole.

3. Models 024LA/MA through 028LA/MA have reactor as standard and it is mounted in VFD. Wiring required to incoming reactor terminals.

4. Models 090LW through 120LW have (2) 0.656 holes, and are always shipped loose with reactors factory-mounted in VFD. Wiring required to incoming terminals.

Depth “C”

in. (mm)

Height “B”

in. (mm)

Weight lbs (kg)

Wire

Range

Torque

In. lb.

2-1=150, 1/0-

2/0=180, 3/0-

4/0=250

00=180, 000-

0000=250

250-350=325,

500=375

IOMM VFD-2 27

Page 28

Mounting

NEMA 1 enclosures designed for floor mounting must be mounted with the enclosure base horizontal for proper ventilation. Wall mounting a floor mounted enclosure with the base against the wall will cause the reactor to over heat resulting in equipment damage.

Allow a minimum side, front, and back clearances of 12 inches (305 mm) and vertical clearances of 18 inches (457 mm) for proper heat dissipation and access. Do not locate the enclosure next to resistors or any other component with operating surface temperatures above 260°F (125°C).

Select a well ventilated, dust-free area away from direct sunlight, rain or moisture, where the ambient temperature does not exceed 45°C (113°F).

Do not install in or near a corrosive environment. Avoid locations where the reactor will be subjected to excessive vibrations. Where desirable, enclosures may be mounted on vibration isolating pads to reduce audible

noise. Standard vibration control pads made from neoprene or natural rubber and selected for the weight of the enclosed reactor are effective.

Reactor Power Wiring

WARNING

Input and output power wiring to the reactor must be performed

by authorized personnel in accordance with the NEC

and all local electrical codes and regulations.

Verify that the power source to which the reactor is to be connected is in agreement with the nameplate data on the reactor. A fused disconnect switch or circuit breaker should be installed between the reactor and its source of power in accordance with the requirements of the NEC and all local electrical codes and regulations. Refer to the drive, inverter, or other electrical equipment user manual for selection of the correct fuse rating and class.

The reactor is suitable for use on a circuit capable of delivering not more than 65,000 rms symmetrical amperes at 480 volts when protected by Bussman type JJS, KTK, KTK-R, PP or T class fuses.

Reactors are designed for use with copper conductors with a minimum temperature rating of 75°C. Table 10 lists the wire range for the power input and output connections by VFD model.

Refer to

Figure 10 for a typical electrical diagram of a reactor in its proper location, upstream of a VFD.

Where desirable, a flexible conduit connection to the reactor enclosure should be made to reduce audible noise.

28 IOMM VFD-2

Page 29

Failure to connect reactors supplied as a component part of a drive system or

other power electronic system according to the system interconnection diagram

supplied by the System Engineer will result in equipment damage, injury, or

death.

WARNING

If a line reactor or a line reactor and a load reactor are used with a drive equipped

with a bypass circuit, the reactors must be removed from the motor circuit in the

bypass mode. Damage to the motor and other equipment will result if this

warning is not observed.

Figure 10, Line Reactor Wiring

Grounding

A stud is provided in the reactor enclosure for grounding the enclosure. The enclosure must be grounded.

WARNING

The frame of line/load reactors must be grounded at the designated grounding

terminal or one of the reactor mounting holes if no designated grounding terminal

is provided. The enclosure of reactors supplied in enclosures must be grounded.

INJURY OR DEATH MAY RESULT IF SAFETY PRECAUTIONS ARE NOT

OBSERVED.

IOMM VFD-2 29

Page 30

VFD/Chiller Interconnection Wiring Diagram

Figure 11, Control and Power Wiring Diagram

MICROTECH CONTROL

BOX TERMINALS

(115V) (24V)

EP2

* COOLING

TOWER

FOURTH

STAGE

STARTER

* NOTE 10

GND

POWER

* NOTE 7

NEUTRAL

* COOLING

TOWER

THIRD

STAGE

STARTER

* COOLING

TOWER

SECONDH

STAGE

STARTER

* COOLING

TOWER

FIRST

STAGE

STARTER

* NOTE 10

COOLING TOWER

BYPASS VALVE

COOLING TOWER VFD

L1 L2 L3

COMPRESSOR

MOTOR

STARTER

(NOTE 1)

-LOAD-

COMMON

23(5A)

24(5)

11(6 )

1-10 VDC

CP1

CP2

POWER

COMPRESSOR CONTROL

NOTE 2

GND

NOTE 2

82(NO)

83(NC)

MICROTECH

BOX TERMINALS

115 VAC

See notes on following page.

T3-S

CTB1

LESS THAN 30V OR 24VAC

EP1

CP2

ALARM RELAY

(NOTE 4)

CP1

STARTER LOAD SIDE TERMINBALS

VFD

UV W

T4 T3 T5T1 T6 T2

COMPRESSOR TERMINALS

- COMPRESSOR CONTROL SCHEMATIC 330342201

- LEGEND: 330343001

* FIELD SUPPLIED ITEM

330387901-0A

30 IOMM VFD-2

Page 31

NOTES for Wiring Diagram

1. Compressor motor VFDs are either factory-mounted and wired, or shipped separate for field-mounting and wiring. VFDs must be provided by McQuay. All line and load side power conductors must be copper.

2. If VFDs are freestanding, then field control wiring between the starter and the control panel is required. Minimum wire size for 115 Vac is 12 GA for a maximum length of 50 feet. If greater than 50 feet, refer to McQuay for recommended wire size minimum. Wire size for 24 Vac is 18 GA. All wiring to be installed as NEC Class 1 wiring system and must be made with copper wire and copper lugs only. All 24 Vac wiring must be run in separate conduit from 115 Vac wiring.

3. Main power wiring between VFD and motor terminals is factory-installed when chillers are supplied with unit-mounted VFDs.

4. Six conductors are used between the VFD and the motor as shown in the wiring diagram. Wiring of free-standing VFDs must be in accordance with the NEC and connection to the compressor motor terminals must be made with copper wire and copper lugs only.

5. LF models VFD 090 and 120 and all LF 2.0 models require field wiring between the VFD

and the field mounted cooling module per instruction beginning on page 15.

IOMM VFD-2 31

Page 32

VFD Dimensions

6.0

8.0

Air-Cooled

Figure 12, VFD 009LA/023LA, Air-Cooled, Free-Standing

(203.2)

Power Wiring

(152.4)

Entry Panel

2.0

(50.8)

14.0

(355.6)

Removable Lifting Eyes

Note: Remove before drilling to prevent metal particles fro falling into drive components.

72.0

(1828.8)

36.0 (914.4)

19.1 (485.1)

Unit Weights

Model VFD 009 VFD 012 VFD 015 VFD 017 VFD 023

Operating Weight, lb (kg) 725 (329) 725 (329) 796 (361) 796 (361) 796 (361)

Shipping Weight, lb. (kg) 795 (361) 795 (361) 866 (393) 866 (393) 866 (393)

32 IOMM VFD-2

Page 33

Figure 13, VFD 024LA/028LA, Air-Cooled, Free-Standing

Unit Weights

Model VFD 024LA VFD 028LA

Operating Weight, lb. (kg) 1206 (548) 1206 (548)

Shipping Weight, lb (kg) 1326 (602) 1326 (602)

IOMM VFD-2 33

Page 34

Figure 14, VFD 009MA/028MA (Air-Cooled), Unit Mount ed

NOTE: Incoming cable entrance is top-left. Outgoing wiring is factory-installed.

34 IOMM VFD-2

Page 35

LiquiFlo

Figure 15, VFD 047LW, Water-Cooled, Free- Standing

NOTES: Power entry for unit-mounted VFD is on top, left hand.

Unit Weights

Model VFD 047LW

Operating Weight, lb. (kg) 982 (446)

Shipping Weight, lb (kg) 1070 (486)

IOMM VFD-2 35

Page 36

Figure 16, VFD 060LW/072LW, Water-Cooled, Free-Standing

12.0

6.0

(

)

3.0 (76.2)

12.0

(304.8)

(152.4)

(304.8)

POWER WIRING

ACCESS PANEL

12.0

(304.8)

POWER WIRING

ACCESS PANEL

15.0

(381)

3.0 (76.2)

12.0

(304.8)

Note: Remove before drilling to prevent metal particles from falling into drive components.

60.0

(1524)

9.0

(228.6)

72.0

(1828.8)

19.1

(485.1)

OUTLET VALVE

3/4 (19.1) NPT

3.5

(88.9)

7.5

190.5

INLET VALVE

3/4 (19.1) NP

18.6

(473.2)

NOTES: Power entry for unit-mounted VFD is on top, left hand.

Unit Weights

Model VFD 060 VFD 072

Weight lb. (kg) 1272 (577) 1272 (577)

36 IOMM VFD-2

Page 37

Figure 17, VFD 090LW/120LW, Water-Cooled, Free-Standing Only

3.38

(85.8)

TYP

16.0

(406.4)

72.0

(1828.8)

10.5

(266.7)

11. 9

(302.3)

24.3

(617.2)

LINE LEAD ACCESS

COVER PLATE

11. 9

(302.3)

78.2

(1986.3)

Note: Remove before drilling to prevent metal particles from falling into drive components.

MOTOR LEAD ACCESS COVER PLATE

POWER

DRIVE F

ULT

PUMPMOTOR

RUNNING

POWE

DRIVE

ULT

PUMP

MOTOR

RUNNING

(614.7)

24.2

FAN

AIR

FLOW

NOTE: T he shipped loose, field installed, closed loop cooling module is shown installed adjacent to the VFD. It can also be install separated from it. See page 15 for installation instructions.

Unit Weights

Model VFD 090 VFD 120

Weight lb. (kg) 1800 (817) 1800 (817)

IOMM VFD-2 37

Page 38

Figure 18, VFD 047MW-072MW, Water-Cooled, Unit Mounted

(

8.00

4.00

POWER WIRING

16.00

ENTRY PANEL

38.00

15.26

38.0

APPROX.)

OFF

72.00

SS1

SS2

38 IOMM VFD-2

Page 39

LiquiFlo 2.0

Figure 19, VF 2037-2055;Free Standing

NOTE: Closed loop cooling module is also required.

Unit Shipping Weights

Model VF 2037 VF 2055

Weight lb. (kg) 1600 (726) 1600 (726)

IOMM VFD-2 39

Page 40

Figure 20, VF 2080-2110, Free Standing

NOTE: Closed loop cooling module is also required.

Unit Shipping Weights

Model VF 2080 VF 2110

Weight lb. (kg) 2000 (908) 2000 (908)

40 IOMM VFD-2

Page 41

MicroTech™ 200 VFD Control

Figure 21, MicroTech 200 Control Panel

frequency drive to the MicroTech to indicate the speed of the motor. The actual percent motor speed is within 1% of the analog output signal from the MicroTech controller.

Digital Input, DI 10, is wired to a switch on the compressor that indicates when the vanes are 100% open (VO switch). If the switch is open, the status of the vanes is Not Open. If the switch is closed, the status of the vanes is Open.

The MicroTech 200™ unit controller has control wiring to the variable frequency drive instead of to a motor starter. The MicroTech controller provides the speed setpoint signal to a hardwired input on the VFD. The output on the MicroTech AOX (auxiliary output) board is configured (using jumpers) to provide a 010 VDC signal to a hard wired analog input on the VFD.

There is no feedback signal required from the variable

VFD Chiller Control States

There are seven VFD chiller control states viewable as shown below. They are based on the unit status. See Table 12 on page 45 for relationships.

MicroTech: Menu 1, Screen 2, States

MicroTech 200

VFD Off VFD Start VFD Running: Adjust Speed & Open Vanes VFD Running: Hold Minimum Speed & Adjust Vanes VFD Routine Shutdo wn VFD Locked Speed VFD Override Capacity Control

VFD Off: The VFD is turned off, the speed output is 0%, and the vanes are closed. VFD Start: The VFD is turned on, the speed output is minimum speed, and the vanes are

modulated to maintain the leaving evaporator setpoint. (VFD running, hold minimum speed, and adjust vanes mode.)

VFD Running Adjust Speed & Open Vanes: The VFD remains on, the speed output is modulated to maintain the leaving evaporator setpoint, and the vanes are pulsed to the open position. This mode drives the vanes open and uses the speed to control capacity based on the evaporator leaving water setpoint.

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VFD Running Hold Minimum Speed & Adjust Vanes: The VFD remains on, the speed output is held at Minimum Speed, and the vanes are modulated to maintain the evaporator leaving water setpoint. This mode occurs when the load (tons) can be satisfied with the vanes not fully open while at minimum speed. Decreasing speed can no longer reduce capacity, so the vanes maintain temperature control. When the load increases, the vanes will pulse open until the vane open switch shows that the vanes are full open. At this point, the MicroTech controller changes the mode to VFD Running: Adjust Speed and Open Va nes.

VFD Routine Shutdown: The VFD remains on, the speed output remains the same, dependent on the prior state, and the vanes are driven closed.

VFD Locked Speed: The MicroTech has a VFD LOCKED Speed Setpoint that can be selected either “ON” or “OFF” from the MicroTech controller keypad. When the VFD Locked Speed mode is set to ON, the VFD speed will be locked at the locked speed setpoint (keypad adjustable). The purpose of this mode is to allow proper setup (calibration, testing, etc.) of the chiller at a constant speed with constant conditions.

NOTE: Do not set the drive minimum speed above the factory setpoint to limit

reduced speed. A control incompatibility will result between the MicroTech controller and the drive.

Override Capacity Control: Any capacity override (see Capacity Overrides on page 48) that forces the VFD out of normal speed control. To return to normal speed control, the capacity override condition is corrected.

First level capacity overrides hold speed and vane position while waiting for the condition to correct.

If the override condition becomes critical (second level capacity override), speed and vane position will be modulated in an attempt to correct the critical condition.

Control Sequence, MicroTech 200

VFD Off: The VFD is turned off, the speed output is 0%, and the vanes are closed. If the

chiller is turned on and if there is a load, the chiller will go through its start sequence; and when the unit status reaches Motor Control Relay (MCR) Started, the VFD status (MicroTech II controller Menu 1 Screen 2) will switch to “VFD Start”.

VFD Start: The VFD is turned on, the speed output is minimum speed, and the vanes are

modulated to maintain the chilled water setpoint (Active Setpoint on keypad/display). At the same time, the minimum speed will continually be re-calculated based on the lift temperature.

In the start mode, capacity control is “Hold Minimum Speed & Adjust Vanes” to satisfy the Active Setpoint (leaving chilled water temperature). When the vanes have been pulsed to the full open position, the Vane Open (V.O) switch closes, the VFD mode changes to “VFD Running” adjust speed, open vanes”.

VFD Running Adjust Speed & Open Vanes: The VFD remains on, the speed

output is modulated to maintain the Active Setpoint, and the vanes are driven to the open position. As the load decreases; if the Speed equals the lift temperature control speed, and the Leaving Evaporator Water Temperature (LEWT) is less than the active setpoint minus one-half the control band, the mode switches to “VFD Running: Hold Minimum Speed & Adjust Vanes”. Otherwise, the controller stays in this mode.

If any capacity override exists, the VFD mode changes to the ”Override Capacity Control” mode (see Capacity Overrides on page 48).

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VFD Running Hold Minimum Speed & Adjust Vanes: The VFD remains on,

the command speed is held at Minimum Speed, and the vanes are modulated to maintain the Active Setpoint. As the load increases; if the vane open switch closes, and the LEWT is greater than the active setpoint plus ½ the control band, the mode switches to “VFD Running Adjust Speed & Open Vanes”. Otherwise, the controller stays in this mode with the speed at Minimum Speed and the vanes being controlled to satisfy the Active Setpoint. If any capacity override exists, the VFD mode changes to the “Override Capacity Control” mode.

VFD Routine Shutdown: The VFD remains on, the speed output remains constant,

and the vanes are driven closed. This state is used during a routine shutdown of the chiller. If there is a rapid shutdown cause by a fault alarm, the state switches to “VFD Off”.

Rapid Shutdown: If there is a fault alarm, the mode immediately switches to VFD

OFF. ”Rapid Shutdown” also occurs by changing the front panel “Stop/Auto” switch on the MicroTech to “Stop”.

WDC/WCC, Dual Compressor VFD Operation

The MicroTech 200 controller has the capability to control a dual compressor VFD chiller or two stand-alone VFD chillers with interconnecting network communications, including all lead/lag load balance functions.

The lead compressor starts and runs the same as a single VFD compressor, controlling speed and vane position based on Leaving Evaporator Water Temperature (LEWT). When the capacity of the lead compressor reaches an equivalent user defined speed, LEWT offset, and pull down rate, it indicates to the master control panel that it is time to enable the lag (second) compressor to satisfy additional cooling requirements.

When the master control panel sees the enable lag indication, it checks the LEWT and if it is greater than the active setpoint plus the lag Start UP (S/U) Delta T, it will start the lag delay timer (keypad adjustable). At this time, the MicroTech control will record the evaporator chilled water Delta T for reference to determine lag compressor shutdown.

NOTE: Operation assumes constant chilled water flow for dual compressor, VFD

units.

The MicroTech is constantly looking at the recorded startup evaporator Delta T, the user adjustable offset from the delta T, and the active setpoint. As the load decreases, and the evaporator Delta T drops below the recorded Startup Delta T minus the user adjustable offset, and the LEWT is below the active setpoint minus the control band plus user defined offset, the user adjustable lag compressor shutdown timer (same time as the lag start timer) is activated. When the timer times out, and the above conditions still exist, the lag compressor will be shut down.

MicroTech 200 Controller VFD Menu Screens

The MicroTech controller screens are modified from standard when VFD software is loaded into the microprocessor in the factory. VFDs require special software as described in this section. The screens are grouped by “menus” that are further broken down to screen numbers. Fields noted with an (*) are only active when a VFD is used. Arrows indicate that addition related screens are located above or below.

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Menu 1, Screen 2– Unit Status

This entire screen only appears when a VFD is used.

1.Unit Status hh:mm mon-dd-yy VFD:Off (etc) Cmnd VFD Speed= XXX%Vanes=Not Open(Open) Lift Ctl Speed= XXX%

Menu 2, Screen 2 – Water Temps and Flows

2. Water Temps/Flow hh:mm mon-dd-yy (*) PulldwnRate= X.X° /M Evap Flow= XXXgpm Ent Ht Rcvy=N/A °F Cond Flow= XXXgpm Lvg Ht Rcvy=N/A °F

Menu 3, Screen 2 – Refrigerant Temps/Press

3.Refrig Temps/Press hh:mm mon-dd-yy Lift Press= XX.Xpsi Lift Temp= XX.XºF (*) Calc Lift Speed= XXX%

Menu 9, Screen 1 – Network Status

9. Network Status hh:mm mon-dd-yy Master Command=Auto Compress Req. One Slave Command=Stop Status=Lead&Lag Off Lead Unit=Slave (*) LagShtdwnDT = XX°F

Menu 11, Screen 1 – Control Mode

11.Control Mode hh:mm mon-dd-yy Mode= Manual Off (etc)

(*) MinVFDSpeedSpt =XXX% (*) Max Speed Spt =XXX%

Menu 11, Screen 2 – Control Mode Setpoints

This entire screen only appears when a VFD is used.

11.Control Mode hh:mm mon-dd-yy Sample Time =XXSec Max Spd Step = XX% Mod Limit = X.XºF Lock VFD Speed Off (On) Deadband = X.XºF Lock Speed @ XXX%

Menu 13, Screen 1 – Motor Amp Setpoints

13. Motor Amp Spts hh:mm mon-dd-yy Amp Reset=No Reset Active Spt =XXX% Reset Signal=XX.Xma (*) Min Amp Spt =XXX% Network Spt =XXXA (*) Max Amp Spt =XXX%

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Menu 13, Screen 2 – Motor Amp Setpoints

13. Motor Amp Spts hh:mm mon-dd-yy Soft Load =Off (*) Dual Speed Spt = XXX% Begin Amp Lim= XX% (*)LagPDRateSpt = X.X°/M Ramp Time= XXMin

Menu 23, Screen 1 – Dual / Netw ork Set poi nts

23. Dual / Net Spts hh:mm mon-dd-yy Slave Address=01.01 Start-up=Unload LL Mode=Auto (*)LagStrtup DT=X.X°F LL SwOver=N/A 00:00 (*) LagShtdnOffst= X.X°

Menu 26, Screen 3 – Unit Setup

26. Unit Setup hh:mm Mon-dd-yy Full Load Amp = XX Hi Mtr Cur = Enable (*) Vane Open Switch Yes No Str Tran = Enable Low Mtr Cur = Enable Starter Flt = Enable

Table 11, MicroTech 200, VFD Setpoints

Item Default Setpoints Ranges MicroTech Keypad Menu

Sample Time 10 Sec. (1 to 63 Sec.) Menu 11 Screen 2 Deadband 0.5% (00.2 to 91%) Menu 11 Screen 2 Mod Limit 2.5ºF (1.0 to 10ºF) Menu 11 Screen 2 Maximum Speed Steps 2% (1 to 5%) Menu 11 Screen 2

Motor Current

Motor Current Threshold 5% (1 to 20%) Menu 22 Screen 3 Minimum Amp Setpoint 10% (5 to 100%) Menu 13 Screen 1

Maximum Amp Setpoint 100% (0 to 100%) Menu 13 Screen 1

Locked VFD Speed On for Start-up /set up (On / Off) Menu 11 Screen 2 Locked VFD Speed Off for VFD operation (On / Off) Menu 11 Screen 2 Locked Speed 100% for Start-up Set up NA Menu 11 Screen 2

NOTE: Setpoints shown above apply only to Menu 11, Screen 1, through Menu 26, Screen 3.

Set From Compressor

Nameplate RLA

NA Menu 26 Screen 3

Table 12, MicroTech Unit Status vs VFD Status

Unit Status: MicroTech Menu 1 Screen 1 VFD Status: MicroTech Menu 1 Screen 2

All Systems Off VFD Off Off: Alarm VFD Off Off: Ambient Lockout VFD Off Off: Front Panel Switch VFD Off Off: Manual VFD Off Off: Remote Contacts VFD Off Off: Remote Communications VFD Off Off: Time Schedule VFD Off Start Requested VFD Off Waiting: Low Sump Temperature VFD Off Evaporator Pump Off VFD Off Evaporator Pump On: Recirculate (used for chillers) VFD Off

Continued on next page.

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Unit Status: MicroTech Menu 1 Screen 1 VFD Status: MicroTech Menu 1 Screen 2

Evaporator Pump On: Cycle Timers (used for chillers) VFD Off Evaporator Pump On: Waiting For Load (used for chillers) VFD Off Condenser Pump Off VFD Off Oil Pump Off VFD Off Oil Pump On: Pre-Lubrication VFD Off Condenser Pump On: Waiting for Flow VFD Off Evaporator Pump On: Waiting for Flow VFD Off Startup Unloading VFD Off MCR Started VFD Start

Running OK

-OrRunning Capacity Override

Can have either VFD status shown to the right. MCR Off: Rapid Shutdown VFD Off Shutdown: Unloading VFD Routine Shutdown-Or-VFD Off MCR Off: Routine Shutdown VFD Off Condenser Pump Off: Shutdown VFD Off Evaporator Pump Off Shutdown VFD Off Post Lubrication VFD Off Shutdown: Oil Pump Off VFD Off

VFD Running; Hold Minimum Speed & Adjust Vanes

VFD Running; Adjust Speed & Open Vane

VFD Start Then,

VFD Running; Capacity Override

Or-

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Figure 22, MicroTech 200 VFD Speed Control State Diagram

VFD Off

Command Speed is held at 0%

Vanes closed

Motor Relay

closed

Motor Relay is closed AND Locked Speed

is ON

Command Speed starts at 70% full speed and

Vanes are

Full Open

Override corrects

Command Speed >

Minimum Speed

Command Speed and vane position held constant except if override becomes critical, then modualte

Command Speed always >= MinimumSpeed

VFD Running Adj. Speed

Open Vanes

Speed Modulating to chilled water

except when driven faster by MinSpeed

Vanes continuously pulsed Open

VFD Start

increases with Minimum Speed

Vanes modulating to chilled water

Capacity Overrides effect Vane modulations

VFDCapOverrides

Command Speed & Vane position

Any

Override

exists

Vanes

Open

AND

LEWT >

Spt + .5CB

Any Override

exists

VFD Running Hold Min

Command Speed equals Minimum Speed

Override Corrects Command Speed

equals

Minimum Speed

Speed Adj. Vanes

Vanes modulating to LEW T

Vane Closed

Switch is

Closed

UnitStatus

is Rapid

Shutdown

Unit Status

is any

Shutdown

Command Speed

Locked

Speed is

OFF

VFD locked speed

Command Speed equals Locked speed set point

except when driven faster by Minimum Speed

Vanes modulating to LEWT

LEWT leaving evap water temperature

CB Control Band

MinSpeed

AND LEWT < Spt- .5CB

Unit Status

is any

Shutdown

Unit Status

is any

Shutdown

Unit Status

is any

Shutdown

VFD Routine Shutdown

Command Speed held 0%

vanes continuosly pulsed closed

Vane Closed

Switch isOpen

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Capacity Overrides (Override Types Listed by Priority)

The following explains certain control functions and setpoints of interest.

NOTE: Stp = Setpoint

1. Max Amp Limit

If the motor current is greater than 100% RLA, Hold Command Speed, pulse vanes closed for two seconds once every two minutes.

If the motor current is greater than 105% RLA, If Command Speed is 10% greater than Minimum Speed, reduce Command Speed by 5%. If Command Speed is within 10% of Minimum Speed, reduce Command Speed by 2%. Close the vanes by one two-second pulse. Wait 15 seconds to see the if motor current corrects before repeating the process.

2. Manual Loading

Manual Load setpoint is adjustable from the keypad display. If Manual Loading is Enabled. Pulse vanes open OR closed to drive the motor current %RLA to the Manual Load

Setpoint.

3. Minimum Amp Limit

Minimum Amp setpoint is adjustable from the keypad display. Range 5% to 100% in 1% increments. Default value is 10%. If the motor current %RLA is less than Minimum Amp Setpoint, hold vane position and

command speed. If the motor current %RLA is 5% below the Minimum Amp Setpoint, open vanes and

hold command speed.

4. Manual Amp Limit

User defined capacity limit adjustable from the keypad display from 0% to 100%. If the motor current %RLA exceeds the Network setpoint, hold Command Speed and

vane position. If the motor current %RLA is 5% greater than the Network setpoint, reduce command

speed by 1% every five seconds. If the command speed should be reduced to minimum speed, close the vanes.

5. Network Capacity Limit

Network provided capacity limit setpoint. The setpoint is limited in the software from 0% to 100%.

If the motor current %RLA exceeds the Network setpoint, hold Command Speed and vane position.

If the motor current %RLA is 5% greater than the Network setpoint, reduce command speed by 1% every five seconds. When the command speed is reduced to minimum speed, close the vanes.

6. Max Pulldown Rate

Max Pull Down Rate setpoint is an adjustable setpoint (range 0.1 to 5.0°F/minute in 0.1°F increments, default is 1.0°F/minute) Pulldown rate = leaving evap. water temp one minute ago, minus leaving evap. water

temp now. If the Pulldown rate exceeds the setpoint, hold command speed and vane position.

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7. Demand Limit

Establishes a demand limit between 10 and 100% RLA based on a 4-20 mA signal input.

If the motor current %RLA is greater than the demand limit, hold command speed and vane position.

If the motor current %RLA is 5% greater than the demand limit, reduce command speed by 1% every five seconds. If the command speed is reduced to Minimum Speed, close the vanes.

8. Softloading

Establishes a soft load capacity limit between 10 and 100% RLA based on time from the first start of the day.

If the motor current %RLA is greater than the soft load capacity, limit hold command speed and vane position.

If the motor current %RLA is 5% greater than the soft load capacity, limit reduce command speed by 1% every five seconds. If Command Speed is reduced to Minimum Speed, close the vanes.

9. Low Evap. Pressure

If the evaporator refrigerant pressure is less than 38.0 psi (default), hold speed and vane position.

If the evaporator refrigerant pressure is less than 31.0 psi (default), hold speed and close vanes.

Low evaporator pressure shutdown alarm setpoint is 26.0 psi (default).

Note: The above pressures must be set at unit design conditions.

10. High Discharge Temperature

If the discharge temperature is higher than 170º F, pulse the load solenoid if the vanes are not fully open.

If the vanes are full open, increase command speed at the rate of 1% every five seconds.

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MicroTech II™ VFD Control

General Description:

Figure 23, MicroTech II Operator Interface Panel 1

Figure 24, MicroTech II Operator

Interface Panel 2

when the vanes are 100% open. If the switch is open, the status of the vanes is Not Open. If the switch is closed, the status of the vanes is Open.

The following describes the software for centrifugal chillers with variable speed drive and the MicroTech II controller. Complete information on the MicroTech II controller operation is contained in the Operating Manual OM CentrifMicro II.

Variable Frequency Drive (VFD) Control:

Digital output NO1, (terminal J12) on the compressor controller is wired to the CR relay (Compressor Relay). The CR relay energizes the MCR (Motor Control Relay) which enables the variable frequency drive instead of a standard motor. Analog output Y1 (terminal J4) on the compressor

controller provides the speed setpoint signal to the VFD. The output is a 0-10 VDC analog output signal, hard wired to the VFD.

There is no feedback signal required from the variable frequency drive to the MicroTech II controller to indicate the speed of the motor. The actual percent motor speed is within 1% of the analog output signal from the MicroTech II controller.

Digital Input ID9 (terminal J7) on the compressor controller is wired to the Vane Open switch (VO switch) that indicates

If the compressor controller pulses a load output for the vanes to load for a cumulative time of 300 seconds (user adjustable), the MicroTech II controller will assume the compressor is fully loaded the same as if the V.O. switch closed (one unload pulse will reset the timer).

Sequence of Operation

Compressor Off:

The VFD is turned off, the speed output is 0%, and the vanes are closed. If the chiller is turned on and if there is a load, the chiller will go through its start sequence. The MCR will be energized, the speed signal will be set to minimum speed, and the VFD will start the compressor. When the compressor starts, it will be in the VFD Running, hold speed, adjust vanes mode.

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VFD Running, Hold Minimum Speed, Adjust Vanes:

The VFD remains on, the command speed is held at Minimum Speed, and the vanes are modulated to maintain the Active LEWT Setpoint. As the load increases; if the vane open switch closes or the MicroTech II controller pulses the vanes open for a cumulative 300 seconds (default), and the LEWT is greater than the active setpoint, the mode switches to “VFD Running Adjust Speed, Open Vanes”. Otherwise, the controller stays in this mode with the speed at Minimum Speed and the vanes being controlled to satisfy the Active LEWT Setpoint.

VFD Running, Adjust Speed, Open Vanes:

The VFD remains on, the speed output is modulated to maintain the Active LEWT Setpoint, and the vanes are driven to the open position. As the load decreases, if the speed equals the lift temperature control speed and the LEWT is less than the active LEWT setpoint, the mode switches to “VFD Running, Hold Minimum Speed, Adjust Vanes”. Otherwise, the controller stays in this mode.

Compressor Shutdown:

The VFD remains on, the speed output remains constant, and the vanes are driven closed (shutdown unload state). This state is used during a routine shutdown of the chiller. If there is a rapid shutdown caused by a fault alarm, the MCR will be immediately deenergized, the speed signal will go to zero, and the compressor state will go directly to Postlube.

WDC, Dual Compressor VFD Operation

The MicroTech II controller has the capability to control a dual compressor VFD chiller or multiple stand alone VFD chillers with interconnecting network communications, including all compressor staging and load balance functions. (See OMCentrifMicro II for set up of multiple compressor staging).

General Dual Compressor VFD Operation

The first compressor starts and runs as a single VFD compressor controlling speed and vane position based on LEWT (L the first compressor reaches “Full Load” and LEWT is greater than stage delta, and the slope (pull down rate) is less than the user adjustable minimum rate setpoint, the next compressor will be enabled.

eaving Evaporator Water Temperature). When the capacity of

Dual Compressor Unit Stage Down

When “Compressor Capacity” exceeds calculated system load (internal algorithm), the “next off” compressor will be disabled. When the “next off” compressor is disabled, the controller will unload the compressor by closing the vanes (shutdown unload) to unload the compressor. The load balance function will make the other compressor follow. When the shutdown unload timer expires, or the vane close switch closes (which ever occurs first), the MCR will de-energized, and the controller will transition to the post lube sequence. At the end of the post lube timer, the oil pump will be turned off and the controller will transition to the off sequence.

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Interface Panel Screens, MT II

NOTE: This section contains the MicroTech II controller and Operator Interface Panel display screens. Figure 25 is the setpoint screen on the initial production panel (Panel 1). Figure 26 shows the screen used on the second issue panel (Panel 2) that went into production mid-2005.

Figure 25, MOTOR (VFD) Setpoint Screen, Panel 1

VFD related settings are #9 through #12. Password: T = Technician Level, M = Manager Level, O = Operator Level

Description No. Default Range Password Comments

Nominal Capacity 14 Design

Oil No Start Diff (above Evap Temp)

Lift @ Max Speed 12

Speed @ 0 Lift 11 50% 0 to 100% T

Minimum Speed 10 70% 60 to 100% T Min VFD speed, has priority over SPs 11 & 12 VFD 9 No No, Yes T VFD on unit or not

Maximum Rate 8

Minimum Rate 7

Soft Load Ramp 6 5 min 1 to 60 min M

Initial Soft Load Amp Limit

Soft Load Enable 4 OFF OFF, ON M Soft load on (using SP 5 and SP 6) or off

Maximum Amps 3 100% 40 to 100% T

Minimum Amps 2 40% 20 to 80% T % RLA below which unloading is inhibited Demand Limit

Enable

5 40% 20 to 100% M Initial amps as % of RLA. Used with SP 4 and SP 6

1 OFF OFF, ON O

40 °F 30 to 60 °F

0.5 °F/min

0.1 °F/min

NOTE: Shaded settings are VFD related.

0 to 9999

Tons

0.1 to 5.0

°F/min

0.0 to 5.0

°F/min

Determines when to shut off a compressor

Minimum Delta-T between oil sump temperature and saturated evaporator temperature Temp lift at 100 % speed (cond sat – evap sat temp) Lift @ min speed as a % of 100 % lift. SP 10 has priority over this setting.

Inhibits loading if LWT change exceed the setpoint value.

Additional compressor can start if LWT change is below setpoint. Time period to go from initial load point (% RLA) set in SP 5 to 100% RLA

% RLA above which loading is inhibited (Load Limit) Unloading is forced at 5% above this value.

ON sets %RLA at 0% for 4 mA external signal and at 100% RLA for 20 mA signal

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Figure 26, MOTOR (VFD) Setpoint Screen, Panel 2

Table 13, MOTOR Setpoint Settings

VFD related settings are #12 through #15. Password: T = Technician Level, M = Manager Level, O = Operator Level

Description No. Default Range Password Comments

Lift @ Max VFD Speed

VFD Speed @ 0 Lift 14 50% 0 to 100% T

VFD Minimum Speed 13 70% 60 to 100% T Min VFD speed, has priority over SPs 11 & 12 VFD 12 No No, Yes T VFD on unit or not Oil No Start Diff

(above Evap Temp)

Nominal Capacity 10 Design

Maximum LWT Rate 9

Minimum LWT Rate 8

Soft Load Ramp Time 7 5 min 1 to 60 min M

Initial Soft Load Amp Limit

Soft Load Enable 5 OFF OFF, ON M Soft load on (using SP 5 and SP 6) or off Nameplate RLA 4 N.A. N.A. N.A. Not used on these chillers

Maximum Amps 3 100% 40 to 100% T

Minimum Amps 2 40% 20 to 80% T % RLA below which unloading is inhibited

Demand Limit Enable 1 OFF OFF, ON O

6 40% 20 to 100% M Initial amps as % of RLA. Used with SP 4 and SP 6

40 °F 30 to 60 °F

0 to 9999

Tons

0.5 °F/min

0.1 °F/min

0.1 to 5.0

°F/min

0.0 to 5.0

°F/min

T Temp lift at 100 % speed (cond sat – evap sat temp)

Lift @ min speed as a % of 100 % lift. SP 10 has priority over this setting.

Minimum Delta-T between oil sump temperature and saturated evaporator temperature Determines when to shut off a compressor, factory set Inhibits loading if LWT change exceed the setpoint value.

Additional compressor can start if LWT change is below setpoint. Time period to go from initial load point (% RLA) set in SP 5 to 100% RLA

% RLA above which loading is inhibited (Load Limit) Unloading is forced at 5% above this value.

ON sets %RLA at 0% for 4 mA external signal and at 100% RLA for 20 mA signal

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Setpoint 11 on Panel 1 (setpoint 14 on Panel 2) sets the % speed at 0 degrees F Lift, point A in Figure 25.

Setpoint 12 on Panel 1 (setpoint 15 on Panel 2) sets the lift in degrees F at the 100 % speed point, point B in Figure 26.

Figure 27, Operating Envelope, Setpoint s 11 and 12 Settings

Typical Variable Frequency Drive Operating Envelope

120

110

100

Minimum Speed

Percent Speed

“A”

Operating Envelope

Lift Temperature Control Speed

Maximum Speed

“B”

0 1020304050607080

Saturated Temperature Difference (°F)

(Condenser Saturation Temperature Minus Evaporator Saturation Temperature)

Figure 28, View I/O Screen

The MicroTech II controller View I/O Screen, shown to the right, displays the compressor motor speed, as controlled by the VFD, at the bottom of the screen. This is information only and no settings are made on this screen.

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Table 14, MicroTech II, Settings and Ranges (Single Compressor)

MicroTech II VFD Default Setpoint Range

Motor Current Comp. Nameplate RLA N.A. UC-SC-(4) N/A

Motor Current Threshold (1) 5% 1 to 20% UC-SA-(4)

Minimum Amp Setpoint (2) 10% 5 to 100% UC-SC-(1) Set -Motor-(2)

Maximum Amp Setpoint 100% 0 to 100% UC-SC-(1) Set -Motor-(3)

VFD Yes yes/no UC-SU-(10) Set -Motor-(9)

Minimum Speed 70% 70 to 100% UC-SU-(10)

Setpoint 11 on

Panel 1 (setpoint

14 on Panel 2)

Speed 50% (@ 0°F lift, “Y” axis

Lift

NOTES:

1. Motor Current Threshold, current at which a low current fault occurs.

2. Minimum Amp Setpoint, Minimum unloading amp setpoint.

3. The OITS is the preferred place t o adju st setpo ints. The unit contro ller is th e second choice and the compressor controller should never be used.

40°F (@100% speed, X

axis

sets the % speed

at 0 degrees F

Lift, point A in

Figure 25.

Setpoint 12 on

Panel 1 (setpoint

15 on Panel 2)

sets the lift in

degrees F at the

100 % speed

point, point B in

Figure 26.

Keypad

Location

UC-SU-(10)

OITS

Locations

Set-Alarms-

(12)

Set -Motor-

(10)

Set -Motor-

(11)

Set -Motor-

(12)

Table 15, MicroTech II, Settings and Ranges (Multiple Compressor Includes

Duals)

MicroTech II VFD Default Setpoints Range Keypad OITS Locations

Max Comp. On 2 for Dual 1 to 16 UC-SC-(2) Modes-(9)

Stage Delta 1°F 0.5 to 5.0°F UC-SC-(3) Water-(6)

Nominal Capacity Unit Design Tons N.A. UC-SC-(5) Motor-(14)

Unload Timer (1) 030 sec

Min LWT Rate 0.1°F 0.0 to 5.0°F UC-SU-(7 Motor-(7)

NOTE: 1. This must be set longer than the mech. vane speed to unload the compressor.

10 to 240

sec.

UC-SC-(6) Timers-(6)

Code: UC = Unit Controller CC = Compressor Controller OITS = Operator Interface Touch Screen V = View Menu Keypad or OITS Screen A = Alarm Menu Keypad Or OITS Screen S = Set Menu Keypad or OITS Screen C = Compressor Menus U = Unit Menus

Example:

Setpoint location for VFD Minimum speed = UC-SU-(10). The location would be the U C

ontroller, Set Unit Setpoints Menu, Screen 10. OITS locations are S = Setpoint screen,

nit

“Alarms” or “Motor”, and the number of the setpoint on the screen. Additional Setpoints, the following two setpoints are at Technician level and are located at

UC-SC-(8) and not on the OITS. They are for exclusive use of factory trained service technicians.

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VFD Mode = Auto (auto/manual), this allows the VFD speed output signal to be manually

controlled for testing, or to be automatic for normal operation. The MicroTech II controller will not allow the speed signal to go below the calculated lift control speed.

VFD Speed Manual Setpoint = 100%,

when the unit is started for the first time, and set up for design, or to check the operation and performance of the unit, it is necessary to run the unit at a constant fixed speed of 100%. To accomplish this, set the VFD Minimum Speed to 100% [UC-SU-(10) or OITS-S-Motor-(10)], then set up and adjust the unit. When testing is complete, set the minimum speed back to the original setpoint. Do not set the drive minimum speed to 100% to set up or test the unit at full speed, as the controller will not know that the drive will not respond to it’s speed signal. The controller will try to control the LEWT setpoint with speed and a control conflict will result.

Figure 29, MicroTech II VFD Speed Control State Diagram

OFF Manual Switch AUTO Remot e Switch Shutdown Manual Switch

VanesOpen

Switch Closed or

Loading continuously Full Vanes L oad timer

expired (5min.) and

reached Min.

SpeedLine

VFD Running,Adj. Speed While holding Open Vanes

Speed Mod ulating to chilled water

Vanes Loaded continuously

Capacity Override s- Corrective action

applies to Speed

COMPRESSOR STATE

RUN-Load Speed RUN-Unlo ad Speed RUN-Hold Speed

RUN-Unlo ad Speed- Evap Pre ss RUN-Hold Speed-Ev ap Press RUN-Hold Speed-Pu ll-dow n Rate RUN-Unlo ad Speed -Max Amps RUN-Hold Speed-Max Amps

Compressor OFF

Compressor MotorRelays

CR & LR are off, and VFD Speed 0%

Vanes closed

Dual Compressor Transition States

Startup Tr ansition

Loads Vanes to LEWT control and

reduces speed at a fixed rate to Min.

Speed Line

The starting and running compressor arebum ped

to 100% speed.

Startup Unloading

Speed is locked the vanes are unloaded

totheUnloadtimer.

Full loadflag set and

over Stage DeltaT .

and More thatone

Compressor set.

Vanes Open

Switch

Closed or

continuously

Full Vanes Load timer

expired (5min.)

VFDSpeed

MinSpeed

AND LEWT < Spt

Unit Status

is any

Shutdown

VFDSpeed

MinSpeed

Full load flag setand over

Stage Delta T.

Likely Capcity override

limited and More than one

Compr set.

VFD Running, Hold Min

Speed, Ad

VFD Speed equals Minimum Speed

Vanes modulating to LEWT

CapacityOverrides- Corrective action

applies to Vanes

Motor Relayis

closed & VF D

Speed = Min

Speed %

. Vanes

Unit Status

is any

Shutdown

COMPRESSOR STATE (BOX)

OFF-Unit State or OFF-Manual Switch OFF-Evap FlowRecirculate(30sec.) OFF-Low Oil Sump Temp OFF-Staging (Next ON) OFF-Awaiting Load PRELUBE Vanes Open PRELUBE-Timer = 30(30 sec.) PRELUBE ( 6 sec.)

Vane Closed

Switch is

Closed

UnitStatus

is Rapid

Shutdown

COMPRESSOR STATE

RUN-Load Vanes RUN-Unload Vanes RUN-Hold Vanes

RUN-Hold Vanes-Pu ll-do wn Rate RUN-Unload Vanes-Max Amps RUN-Hold Vanes-Max Amps RUN-Unload Vanes-Evap Press RUN-Hol d Vanes-E vap Pres s

COMPRESSOR STATE

SHUTDOWN Unload POSTLUBE Timer=30 (30sec.)

LEW T leaving evap water temper ature

CB Control Band

Compressor Shutdown

Command Speed held 0%

vanes continuosly pulsedclosed

Vane Closed

Switch isOpen

Notes:

1. The above pressures must be set at unit design conditions.

2. Low evaporator pressure shutdown alarm setpoint is 26.0 psi (default)

3. If the discharge temperature is higher than 170º F, pulse the load solenoid if the vanes are not fully open.

56 IOMM VFD-2

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Operation, Small A/C SP600 & LF 2.0

The SP600 and LF 2.0 VFDs share the same interface modules and their operation is the same except for some differences in parameters, (which are outside the purview of this manual) and differences in some faults and alarms. The faults and alarms are given separately later in this section.

Warning

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 ma nual and other applicable manuals in

their entirety before proceeding. Failure to observe this precaution could result in

severe bodily injury or loss of life.

The status of the drive can be viewed on the Operator Interface Module (OIM) or on various LEDs.

Using the Interface

The LCD Operator Interface Module is a keypad/display that enables programming, monitoring, and controlling the drive.

Figure 30, Operator Interface Module

Refer to Figure 31 fo

display description.

Refer to Table 16 fo

key descriptions.

CAUTION

Stop and start keys are

never used to start or stop the drive/compressor. These functions are controlled by the chiller MicroTech II only.

Powering Up and Adjusting the LCD OIM

• The first time the LCD OIM is powered up, you will be prompted to select a language for the display text. If the Start-Up routine has not been completed, the Start-Up menu is displayed immediately following the language selection screen.

Selecting the Fast Power Up Feature

• The fast power up feature bypasses the initialization screen at power up, and the Main

Menu is displayed immediately. To select this feature, select Fast PwrUp Mode from the Display menu.

Adjusting the Screen Contrast

• To adjust the screen contrast, select Contrast from the Display menu.

IOMM VFD-2 57

Page 58

Resetting the Display

• Do not reset the display to “factory settings” as these may be the display manufacturer’s

settings and not the McQuay factory settings.

Figure 31, Display Description

Table 16, Key Descriptions

Key Function

Scroll through options or user function keys, move cursor to the left.

Scroll through options or user functions keys, move cursor to the right.

Scroll through options, increase a value, or toggle a bit.

Scroll through options, decrease a value, or toggle a bit.

ESC/PROG

HAND

AUTO

Exit a menu, cancel a change to a parameter, or toggle between program and process (user) display screens.

Enter a menu, select an option, or save changes to parameter value

Enable Hand (manual) reference control.

Release Hand (manual) reference control.

Stop the drive. Clear a fault if the OIM is the control source.

Start the drive if the OIM is the control source.

F1 though F4: Predefined or user-configured functions. The definition of each key is shown directly above the key on the display. See item in figure B.3.

From the main menu, use the

or keys to scroll through the sub menus. The

Diagnostics menu is if primary interest to the operator. When selected, press the Enter key,

58 IOMM VFD-2

Page 59

to select it. Then use the scroll keys, up, down, right, or left, to select the item of

interest.

Using the LEDs

Determining Precharge Board Status Using the LED Indicators (Frames 5 & 6 Only)

Precharge is an internal function that is used automatically when powering up the control. There is no operator function required. Precharge LEDs give the status of the board. They are located above the Line Type jumper shown in Figure 32.

In addition to the LED signal, a fault in the precharge function will also show on the display.

Figure 32,

Location of Precharge Status LED

Table 17, Precharge Board LED Indicators

Name Color State Description

Power ON Green Steady Indicates when pre-charge board power supply is operational

Indicates one of the following alarms occurred causing the pre-charge to momentarily stop firing: • Line Loss • Low Phase

Alarm Yellow Steady

Fault Red Steady

(single-phase dropped below 80% of line voltage) • Input

frequency out of range (momentarily) Note: An alarm

condition automatically resets when the condition no longer exists Indicates one of the following faults: • DC Bus short • DC Bus not charged • Input frequency out of range • Overtemperature

Note: A fault indicates a malfunction that needs to be

corrected prior to restarting. A fault condition is only reset after cycling power.

LED Drive Status

Figure 33, Location of the Ready LED

IOMM VFD-2 59

Page 60

Table 18, Ready LED Status Functions

Color State Description

Green

Yellow

Red

Flashing Drive ready, but not running and no faults are present. Steady Drive running, no faults are present. Flashing The drive is not ready. Check parameter 214 (Start Inhibits).

Steady

Flashing

Steady A fault has occurred.

Determining Drive Status Using the Status LEDs

Two status LEDs are located on the DPI Communications Interface board on the front of the power module. The LEDs indicate of the status of the inverter and the rectifier. Note that if the LEDs are off, it indicates it is not receiving power.

An alarm condition exists. Check parameters 211 (Drive Alarm 1) and 212 (Drive Alarm 2). An alarm condition exists. Check parameters 211 (Drive Alarm 1) and 212 (Drive Alarm 2).

Table 19, Status LED Definitions

Color State Description

60 IOMM VFD-2

Page 61

Green

Yellow

Red

Flashing Drive ready, but not running and no faults are present. Steady Drive running, no faults are present. Flashing The drive is not ready. Check parameter 214 (Start Inhibits).

Steady

Flashing A fault has occurred Steady A non-resettable fault has occurred.

An alarm condition exists. Check parameters 211 (Drive Alarm 1) and 212 (Drive Alarm 2).

About A larms

Alarms indicate conditions that may affect drive operation or application performance. There are two alarm types, as described in Table 20. Alarms do not shut down a unit, but often lead to a :fault that will.

Table 20, Types of Alarms

Type Alarm Description

User-

Configurable

Non-

Configurable

The drive indicates alarm conditions in the following ways:

These alarms alert the operator of conditions that, if left untreated, may lead to a fault condition. The drive continues to operate during the alarm condition. The alarms are enabled or disabled using Alarm Config 1 (259). The status of these alarms is shown in Drive Alarm 1 (211). These alarms alert the operator of conditions caused by improper programming and prevent the drive from starting until the problem is resolved. These alarms are always enabled. The status of these alarms is shown in Drive Alarm 2 (212).

• Yellow LED visible from the front of the drive.

• Ready LED on the drive cover (see Table 18).

• Alarm name and bell graphic on the LCD OIM. The alarm is displayed as long as

the condition exists. The drive automatically clears the alarm when the condition causing it is removed.

• Alarm status parameters. Two 16-bit parameters, Drive Alarm 1 (211) and Drive Alarm 2 (212), indicate the status of type 1 and type 2 alarms, respectively.

• No external signal is available for alarms.

About the Alarm Queue

The drive automatically retains a history of alarms that have occurred in the alarm queue. The alarm queue is accessed using the OIM or PC software.

The alarm queue holds the eight most recent alarms. The last alarm to occur is indicated in queue entry #1. As new alarms are logged into the queue, existing alarm entries are shifted (for example, entry #1 will move to entry #2). Once the queue is full, older alarms are discarded from the queue as new alarms occur.

All entries in the alarm queue are retained if power is lost. Alarms are automatically cleared when the alarm condition goes away.

The alarm queue can be cleared using the OIM by selecting “Clr Alarm Queue”, or by using a PC software tool.

IOMM VFD-2 61

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Alarm Descriptions

Table 21, Alarm Descriptions, SP600

Alarm Type Description

Analog In Loss

Bipolar Conflict

Decel Inhibit

Dig In ConflictA

Dig In ConflictB

Dig In ConflictC

DigIn Bad Value

Drive OL Level 1

Drive OL Level 2

Flux Amps Ref Rang

IntDBRes OvrHeat

IR Volts Range

Ixo Vlt Rang

MaxFreq Conflict

Continued on next page.

An analog input is configured for alarm on signal loss and signal loss has

occurred. Parameter 190 (Direction Mode) is set to Bipolar or Reverse Dis and one of

more of the following digital input functions is configured: Fwd/Rev or Run Fwd. Note that the default is Reverse Dis.

The drive is being inhibited from decelerating.

Digital input functions are in conflict. Combinations marked with an (X) will

cause an alarm. Acc2 / Dec2 Accel 2 Decel 2 Fwd / Rev

Acc2 / Dec2

Accel 2

Decel 2

Fwd / Rev

Digital input functions are in conflict. Combinations marked with an (X) will

cause an alarm Start Stop–CF Run Run Fwd Fwd/Rev

Start

Stop–CF

Run

Run Fwd

Fwd / Rev More than one physical input has been configured to the same input function.

Multiple configurations are not allowed for the following input functions:

Forward/Reverse Run Bus Regulation Mode B

Speed Select 1 Stop Mode B Acc2 / Dec2

Speed Select 2 OIM Control Accel 2

Speed Select 3 Stop Mode B Decel 2

Run Forward

2 Unsupported function selected in Digital In”x” Sel parameters (361-366).

The calculated IGBT temperature requires a reduction in PWM carrier

frequency. If Drive OL Mode (150) is disabled and the load is not reduced, an overload fault will eventually occur. The calculated IGBT temperature requires a reduction in Current Limit. If Drive

OL Mode (150) is disabled and the load is not reduced, an overload fault will eventually occur.

2 Result of autotune procedure (61).

The drive has temporarily disabled the dynamic braking regulator because the

resistor temperature has exceeded a predetermined value. The drive autotuning default is Calculate and the value calculated for IR Drop

Volts is not in the range of acceptable values. This alarm should clear when all motor nameplate data is properly entered.

Motor leakage inductance is out of range.

The sum of Maximum Speed (82) and Overspeed Limit (83) exceeds Maximum Freq (55). Raise Maximum Freq (55) or lower Maximum Speed (82) and/or

Overspeed Limit (83) so that the sum is less than or equal to Maximum Freq (55).

X X X X

X X

X X X X X

62 IOMM VFD-2

Page 63

Alarm Type Description

Motor Type (40) has been set to Sync Prm Mag or Sync Reluc, and one or Motor Type Cflct

more DC functions (for example, DC Boost, DC Brake, etc.) have been

activated. DC injection functions are imcompatible with synchronous motors

and may demagnetize them. NP Hz

Conflict Power

Loss Prechrg

Actv

Fan/pump mode is selected in Torq Perf Mode (53), and the ratio of Motor NP

Hertz (43) to Maximum Freq (55) is greater than 26.

1 Drive has sensed a power line loss.

1 Drive is in the initial DC bus precharge state.

Sleep/Wake configuration error. When Sleep-Wake Mode [178] = Direct, Sleep Config

possible causes include: - Drive is stopped and Wake Level [180] < Sleep

Level [182] - Digital Inx Sel [361 to 366] is not set to one of the following:

Stop=CF, Run, Run Forward, or Run Reverse. Speed Ref

Cflct Under-

Voltage

VHz Neg Slope

Waking

2 Speed Ref A Sel (90) or PI Reference Sel (126) is set to Reserved.

The bus voltage has dropped below a predetermined value.

Custom V/Hz mode has been selected in Torq Perf Mode (53) and the V/Hz

slope is negative.

The wake timer is counting toward a value that will start the drive.

Table 22, Alarm Descriptions (LF 2.0

NOTE: Ty pe, 1=Auto-resettable 2=Non-resettable 3=User-configurable

Alarm Type Description

Analog In Loss 1

Bipolar Conflict 2

Dig In ConflictA 2

Dig In ConflictB 2

An analog input is configured for alarm on signal loss and signal loss has occurred. Parameter 190 (Direction Mode) is set to Bipolar or Reverse Dis and one of more of the following digital input functions is configured: Fwd/Rev, Run Fwd, Run Rev, Jog Fwd, or Jog Rev.

Digital input functions are in conflict. Combinations marked with a will cause an

Acc2/Dec2

Accel2

Cecel2

Jog

Jog Fwd

Jog Rev

Fwd/Rev

Digital input functions are in conflict. Combinations marked with a will x cause an

Start

Stop-CF

Run

Run Fwd

Run Rev

Jog

Jog Fwd

Jog Rev

Fwd/Rev

Acc2/

Dec2

x x x x x

x x x x x x x x x x x x x

x x x x x x

x x

Accel2 Cecel2 Jog

x x x x

x x

Stop

-CF

Run

alarm.

Run Fwd

Continued next page.

Run Rev

Jog

Fwd

Jog

Fwd

Jog

Rev

Jog Rev

Fwd/R

Fwd/

Rev

IOMM VFD-2 63

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Alarm Type Description

More than one physical input has been configured to the same input function.

Multiple configurations are not allowed for the following input functions:

Forward/Reverse Run Reverse

Dig In ConflictC 2

Drive OL Level 1 1

Drive OL Level 2 1

Flux Amps Ref

Rang

IntDBRes OvrHeat 1

IR Volts Range 2

MaxFreq Conflict 2

Motor Type Cflct 2

NP Hz Conflict 2

Power Loss 1 Drive has sensed a power line loss.

Prechrg Actv 1 Drive is in the initial DC bus precharge state.

Speed Ref Cflct 2 Speed Ref x Sel or PI Reference Sel is set to “Reserved”.

Under-Voltage 1 The bus voltage has dropped below a predetermined value.

VHz Neg Slope 2

2 Result of autotune procedure (61).

Speed Select 1 Jog Forward Acc2 / Dec2

Speed Select 2 Jog Reverse Accel 2

Speed Select 3 OIM Control Decel 2

Run Forward Stop Mode B Run

The calculated IGBT temperature requires a reduction in PW M carrier frequency. If Drive OL Mode (150) is disabled and the load is not reduced, an overload fault will eventually occur.

The calculated IGBT temperature requires a reduction in Current Limit. If Drive OL Mode (150) is disabled and the load is not reduced, an overload fault will eventually occur.

The drive has temporarily disabled the dynamic braking regulator because the resistor temperature has exceeded a predetermined value.

The drive autotuning default is Calculate and the value calculated for IR Drop Volts is not in the range of acceptable values. This alarm should clear when all motor nameplate data is properly entered.

The sum of Maximum Speed (82) and Overspeed Limit (83) exceeds Maximum Freq (55). Raise Maximum Freq (55) or lower Maximum Speed (82) and/or Overspeed Limit (83) so that the sum is less than or equal to Maximum Freq (55).

Motor Type (90) has been set to Sync Prm Mag or Sync Reluc, and one or more DC functions (for example, DC Boost, DC Brake, etc.) have been activated. DC injection functions are incompatible with synchronous motors and may demagnetize them.

Fan/pump mode is selected in Torq Perf Mode (53), and the ratio of Motor NP

Hertz (43) to Maximum Freq (55) is greater than 26.

Custom V/Hz mode has been selected in Torq Perf Mode (53) and the V/Hz slope

is negative.

Bus Regulation Mode

About Faults

Faults indicate conditions within the drive that require immediate attention. The drive responds to a fault by initiating a coast-to-stop sequence and turning off power to the motor.

A flashing red LED indicates a fault has occurred and a fault signal will appear in the chiller touchscreen. A steady red LED indicates that it is non-resettable.

Table 23, Fault Types

Type Fault Description

If the drive is running when this type of fault occurs, and Auto Rstrt AutoReset/Run

(Not used on McQuay units)

Non-

Resettable

User-

Configurable

Tries (174) is set to a value greater than 0, a user-configurable timer,

Auto Rstrt Delay (175) begins. When the timer reaches zero, the drive

attempts to automatically reset the fault. If the condition that caused the

fault is no longer present, the fault will be reset and the drive will be

restarted.

This type of fault normally requires drive or motor repair. The cause of

the fault must be corrected before the fault can be cleared. The fault will

be reset on power up after repair.

These faults can be enabled/disabled to either annunciate or ignore a

fault condition using Fault Config 1 (238).

64 IOMM VFD-2

Page 65

The drive indicates faults in the following ways:

• Ready LED on the drive cover (see section 12.3).

• Drive status parameters Drive Status 1 (209) and Drive Status 2 (210).

• Entries in the fault queue (see section 12.5.1).

• Pop-up screen on the LCD OIM. See figure 12.4. The screen displays:

• Fault number

• Fault name

• Time that has elapsed since fault occurred.

Figure 34, Sample Fault Screen

NOTES:

1. Press any F Key to acknowledge the fault

2. The fault screen is displayed until it is acknowledged by pressing any F-key or cleared in the drive by other means.

on the LCD OIM

About the Fault Queue

The drive automatically retains a history of faults that have occurred in the fault queue. The fault queue is accessed using the OIM or VS Utilities software.

The fault queue holds the eight most recent faults. The last fault to occur is indicated in queue entry #1. As new faults are logged into the queue, existing fault entries are shifted (for example, entry #1 will move to entry #2). Once the queue is full, older faults are discarded from the queue as new faults occur.

All entries in the fault queue are retained if power is lost. The Time Stamp For each entry in the fault queue, the system also displays a fault code and time stamp

value. The time stamp value is the value of an internal drive-under-power timer at the time of the fault. The value of this timer is copied to PowerUp Marker (242) when the drive powers up. The fault queue time stamp can then be compared to the value in PowerUp Marker to determine when the fault occurred relative to the last drive power up.

The time stamp is cleared when the fault queue is cleared.

IOMM VFD-2 65

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Clearing Faults

A fault condition can be cleared by the following: Step 1. Press the ESC/Prog key or any F-Key to acknowledge the fault and remove the

fault pop-up from the LCD OIM screen.

Step 2. Address the condition that caused the fault. The cause must be corrected before the

fault can be cleared.

Step 3. After corrective action has been taken, clear the fault using one of the following:

• Setting Fault Clear (240) to Clear Faults (1).

• Press F1 (Cflt) from the fault queue screen.

• Issuing a Stop-Clear Faults command from the control source.

Resetting faults will clear the faulted status indication. If any fault condition still exists, the fault will be latched, and another entry made in the fault queue.

Note that performing a fault reset does not clear the fault queue. Clearing the fault queue is a separate action. See the Fault Clear (240) parameter description.

The table beginning on the following page, describes drive faults and corrective actions. It also indicates the fault type as:

1 Auto-resettable 2 Non-resettable 3 User-configurable

Table 24, SP600 Fault Descriptions and Corrective Actions

Fault No. Type Description Action

Analog In Loss

Anlg Cal Chksum

Auto Rstrt Tries

AutoTune Aborted DB Resistance

Decel Inhibit 24 3

Drive OverLoad

Excessive Load

FluxAmpsRef Rang

29 1,2

108 2

33 3

An analog input is configured to fault on signal loss. A signal loss has occurred. Configure with Anlg In 1, 2 Loss (324, 327). The checksum read from the analog calibration data does not match the checksum calculated. Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of Auto Rstrt Tries (174). Enable/disable with Fault Config 1 (238). The autotune procedure was canceled by the user. Resistance of the internal DB resistor is out of range.

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

Drive rating of 110% for 1 minute or 150% for 3 seconds has been exceeded. Motor did not come up to speed in the allotted time. The value for flux amps determined by the autotune procedure exceeds the programmed Motor NP FLA (42).

1. Check parameters. 2. Check for broken/loose connections at inputs.

Replace drive.

Correct the cause of the fault and manually clear.

Restart procedure.

Replace resistor.

1. Verify input voltage is within drive specified limits. 2. Verify system ground impedance follows proper grounding techniques. 3. Disable bus regulation and/or add dynamic brake resistor and/or extend deceleration time.

Reduce load or extend Accel Time (140).

1. Uncouple load from motor. 2. Repeat Autotune (61).

1. Reprogram Motor NP FLA (42) with the correct motor nameplate value. 2. Repeat Autotune (61).

Continued next page.

Fault No. Type Description Action

66 IOMM VFD-2

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Function Loss

Ground Fault

Heatsink OvrTemp

HW Over Current

Incompat MCB-PB

I/O Comm Loss I/O Board Fail

I/O Mismatch

IR Volts Range

Motor Overload

Over Speed Limit

Over Voltage

Parameter Chksum

2 1 Function loss input is open. Check remote wiring.

13 1

8 1

12 1

106 2

121 2

122 Board failure.

120 Incorrect I/O board identified.

7 1, 3

25 1

5 1

100 2

Continued next page.

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

Heatsink temperature exceeds a predefined value of 90°C (195°F).

The drive output current has exceeded the hardware current limit.

Drive rating information stored on the power board is incompatible with the Main Control board. Loss of communication to I/O board.

The drive autotuning default is Calculate and the value calculated for IR Drop Volts is not in the range of acceptable values.

Internal electronic overload trip. Enable/disable with Fault Config 1 (238).

Functions such as slip compensation or bus regulation have attempted to add an output frequency adjustment greater than that programmed in Overspeed Limit (83).

DC bus voltage exceeded maximum value.

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

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

1. Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded 40°C (104°F) NEMA Type 1 installations or 50°C (122°F) for Open type installations. 2. Check fan. Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current. Motor dynamics cannot be accommodated by autotuning. Manual tuning of the current loop required. Consult technical support.

Load compatible version files into drive.

Cycle power.

1. Cycle power. 2. If fault repeats, replace I/O board Restore I/O board to original configuration, or If new configuration is desired, reset fault.

Re-enter motor nameplate data.

An excessive motor load exists. Reduce load so drive output current does not exceed the current set by Motor NP FLA (42).

Remove excessive load or overhauling conditions or increase Overspeed Limit (83).

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the ecal time or install dynamic brake option.

1. Restore defaults. 2. Reload user set if used.

IOMM VFD-2 67

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Fault No. Type Description Action

1. Clear the fault or cycle power to the drive. 2. Program the drive parameters as needed.

Clear fault.

1. Check the wiring between the drive and motor. 2. Check motor for grounded phase. 3. Replace drive.

1. Check the motor and drive output terminal wiring for a shorted condition. 2. Replace drive.

1. If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, adapters, Main Control board or complete drive as required.

2. Check OIM connection.

1. Check communication adapter board for proper connection to external network. 2. Check external wiring to adapter on port. 3. Verify external network fault.

Monitor the incoming AC line for low voltage or line power interruption.

1. Check for damaged output transistors. 2. Replace drive.

Clear the fault or cycle power to the drive.

1. Cycle power to the drive. 2. If problem persists, replace drive.

1. Restore defaults. 2. Reprogram parameters.

Check load requirements and Current Lmt Val (148) setting.

Params Defaulted

Phase Imbalance

Phase U to Grnd Phase V to Grnd Phase W to Grnd Phase UV Short Phase VW Short Phase UW Short

Port 1-6 DPI Loss

Port 1-6 Net Loss

Power Loss 3 1, 3

Power Unit 70

Pwr Brd Chksum1

Pwr Brd Chksum2

Replaced MCB-PB

Shear Pin 63 3

8186

7176

104

105 2

107 2

The drive was commanded to write default values to EEPROM.

Phase current displayed in Imbalance Display (221) > percentage set in Imbalance Limit (49) for time set in Imbalance Time (50).

A phase-to-ground fault has been detected between the drive and motor in this phase.

Excessive current has been detected between these two output terminals.

The network card connected to DPI port stopped communicating. The fault code indicates the offending port number (71 = port 1, etc.)

DC bus voltage remained below 85% of nominal for longer than Power Loss Time (185). Enable/disable with Fault Config 1 (238). One or more of the output transistors were operating in the active region instead of desaturation. This can be caused by excessive transistor current or insufficient base drive voltage. The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data. The checksum read from the board does not match the checksum calculated. Main Control board was replaced and parameters were not programmed. Programmed Current Lmt Val (148) has been exceeded. Enabled/disable with Fault Config 1 (238).

68 IOMM VFD-2

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Fault No. Type Description Action

SW Over Current

Trnsistr OvrTemp

Under Voltage

UserSet1 Chksum UserSet2 Chksum UserSet3 Chksum

36 1

9 1

4 1, 3

101 2

102 2

103 2

The drive output current has exceeded the software current.

Output transistors have exceeded their maximum operating temperature.

DC bus voltage fell below the minimum value of 160V DC at 200/240V input, 300V DC at 400/480V input or 375V DC at 575V input. Enable/disable with Fault Config 1(233).

The checksum read from the user set does not match the checksum calculated.

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

1. Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded 40°C (104°F) for NEMA Type 1 installations or 50°C (122°F) for Open type installations. 2. Check fan.

Monitor the incoming AC line for low voltage or power interruption.

Re-save user set.

Table 25, LF 2.0 Fault Descriptions and Corrective Actions

Fault No. Type Description Action

1. Verify proper input voltage.

2. Check line sync board and

AC Line Lost 227 Input power Lost

An analog input is configured

Analog In

Loss

Auto Rstrt

Tries

AutoTune

Aborted

Auxiliary Input 2 1 Input is open. Check remote wiring.

Decel Inhibit 24 3

Drive

OverLoad

Excessive

Load

29 1 3

33 1

to fault on signal loss. A signal loss has occurred. Configure with Anlg In 1, 2 Loss (324, 327). Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of Auto Rstrt Tries (174). Enable/disable with Fault Config 1 (238). The autotune procedure was canceled by the user.

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

Drive rating of 110% for 1 minute or 150% for 3 seconds has been exceeded. Motor did not come up to speed in the allotted time.

Continued next page.

fuse.

3. Check AC line I/O board.

4. 4. Verify connection between boards.

1. Check parameters.

2. 2. Check for broken/loose connections at inputs.

Correct the cause of the fault and manually clear.

Restart procedure.

1. Verify input voltage is within drive specified limits.

2. Verify system ground impedance follows proper grounding techniques.

3. Disable bus regulation and/or add dynamic brake resistor and/or extend deceleration time.

Reduce load or extend Accel Time (140).

1. Uncouple load from motor.

2. Repeat Autotune (61).

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Fault No. Type Description Action

The value for flux amps

FluxAmpsRe

f Rang

Ground Fault 13 1

High AC Line 222 Input line voltage is too high.

OverCurrent

I/O Board

Comm Loss

I/O Board

Fail

I/O Board Mismatch

Incompat

MCB-PB

Input Amp Imbalance

Input Volt

Imbalance

Inverter Dsat

U, V, W

Inverter

OverCurrent

U, V, W

Invtr Base

Temp

Invtr Gate

Kill

Invtr IGBT

Temp

IR Volts

Range

Line

Frequency

Low DC Bus 223 The bus voltage is too low. Verify proper input voltage.

Motor I

Imbalance

Motor

Overload

12 1

121 2

122 Board failure.

120

106 2

225

226

200 201 202 203 204 205

8 1

207

9 1

228

7 1 3

determined by the autotune procedure exceeds the programmed Motor NP FLA (42). A current path to earth ground in excess of 7% of drive rated amps has been detected at one or more of the drive output terminals.

The drive output current has exceeded the hardware current limit.

Loss of communication to I/O board.

Incorrect I/O board identified.

Drive rating information stored on the power board is incompatible with the Main Control board. Input phase current imbalance exceeded limits. Input voltage imbalance exceeded limits.

High current was detected in an IGBT.

Base temperature exceeded limit. Inverter gate kill contact is open. Output transistors have exceeded their maximum operating temperature. The drive autotuning default is Calculate, and the value calculated for IR Drop Volts is not in the range of acceptable values. Line frequency not in the range of 47-63 Hz.

Phase current displayed in Imbalance Display (221) > percentage set in Imbalance Limit (49) for time set in Imbalance Time (50).

Internal electronic overload trip. Enable/disable with Fault Config 1 (238).

1. Reprogram Motor NP FLA (42) with the correct motor nameplate value.

2. Repeat Autotune (61).

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

Reduce input voltage to meet specification of 480 ±10%. Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current.

Cycle power.

1. Cycle power.

2. If fault repeats, replace I/O

board Restore I/O board to original configuration, or If new configuration is desired, reset fault.

Load compatible version files into drive.

Check for loose connection in input power wiring. Check for problem in input power distribution.

1. Check for loose connection in IGBT wire harness.

2. Check IGBTs.

1. Verify proper motor data is entered.

2. Reduce current limit.

Check for proper temperature and flow rate of coolant.

Close gate kill contact.

Check for proper temperature and flow rate of coolant.

Re-enter motor nameplate data.

Verify connection between AC Line Sync and AC Line I/O boards.

Clear fault.

An excessive motor load exists. Reduce load so drive output current does not exceed the current set by Motor NP FLA (42).

70 IOMM VFD-2

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OverSpeed

Limit

OverVoltage 5 1

Parameter

Chksum

Params

Defaulted

Phase U to

Grnd Ph V

To Grnd

Phase W to

Grnd

Phase UV

Short

Phase VW

Short

Phase UW

Short

Port 1-5 DPI

Loss

Port 1-5 Net

Loss

Power Loss 3

Precharge

closed

Precharge

open

25 1

100 2

81 85

71 75

233

234

Functions such as slip compensation or bus regulation have attempted to add an output frequency adjustment greater than that programmed in Overspeed Limit (83).

DC bus voltage exceeded maximum value.

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

The drive was commanded to write default values to EEPROM.

A phase-to-ground fault has been detected between the drive and motor in this phase.

Excessive current has been detected between these two output terminals.

DPI port stopped communicating. An attached peripheral with control capabilities via Logic Source Sel (89) (or OIM control) was removed. The fault code indicates the offending port number (81 = port 1, etc.) The network card connected to DPI port stopped communicating. The fault code indicates the offending port number (71 = port 1, etc.) DC bus voltage remained below 85% of nominal for

longer than Power Loss

Time (185). Enable/disable with Fault Config 1 (238).

Precharge was closed when it should be open.

Precharge was open when it should be closed.

Remove excessive load or overhauling conditions or increase Overspeed Limit (83).

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the ecal time or install dynamic brake option.

1. Restore defaults.

2. Reload user set if used.

1. Clear the fault or cycle power to the drive.

2. Program the drive parameters as needed.

1. Check the wiring between the drive and motor.

2. Check motor for grounded phase.

3. Replace drive.

1. Check the motor and drive output terminal wiring for a shorted condition.

2. Replace drive.

1. If module was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, modules, Main Control board or complete drive as required.

2. Check OIM connection.

1. Check communication board for proper connection to external network.

2. Check external wiring to module on port.

3. Verify external network fault.

Monitor the incoming AC line for low voltage or line power interruption.

1. Check AUX contacts on precharge.

2. Check input bit 0 in rectifier parameter 216 to view status of input.

3. Check wiring.

1. Check AUX contacts on precharge.

2. Check input bit 0 in rectifier parameter 216 to view status of input.

3. Check wiring.

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Pwr Brd Chksum1

104

The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data.

Clear the fault or cycle power to the drive.

Pwr Brd Chksum2

Rctfr I/O Board

Rctfr Not OK 232

Rctfr Over Volt

Rctfr Pwr Board

Rectifier Base Temp

Rectifier Dsat U, V, W

Rectifier Ground Fault Rectifier IGBT Temp

Rectifier IOC U, V, W

Rectifier Checksum

Reactor Temp

Rectifier IT Overload

Rectifier I2T Overload

Replaced MCB-PB

Ride Thru Abort

105 2

236

224 The bus voltage is too high.

235

217

208 209 210

216

218

211 212 213

229

214

219

220

107 2

221 Input power loss timed out.

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

Loss of communication to I/O board.

Board failure.

A fault was detected in the rectifier other than one specifically decoded.

Drive rating information stored on the power board is incompatible with the Main Control board.

The checksum read from the board does not match the checksum calculated. Excessive rectifier temperature measured.

Rectifier overcurrent

High current was detected in an IGBT.

Excessive ground current measured. Excessive calculated IGBT temperature.

The checksum read from the board does not match the checksum calculated. Temperature switch in reactor opened.

Short-term current rating of rectifier exceeded.

Long-term current rating of rectifier exceeded.

Main Control board was replaced and parameters were not programmed.

1. Cycle power to the drive.

2. If problem persists, replace drive.

Cycle power.

1. Cycle power.

2. 2. If fault repeats, replace I/O board

Look at rectifier parameter 243 to see fault code.

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. Load compatible version files into drive.

1. Cycle power to the drive.

2. If problem persists, replace drive. Check for proper temperature and flow rate of coolant.

1. Check for loose connection in IGBT wire harness.

2. Check IGBTs.

Check for grounded input wiring.

Check for proper temperature and flow rate of coolant.

1. Verify proper motor data is entered.

2. Reduce current limit.

1. Restore defaults.

2. Reload user set if used.

Check for proper temperature and fan operation. Low input voltage can result in increased current load. Provide proper input voltage to the drive. Low input voltage can result in increased current load. Provide proper input voltage to the drive.

1. Restore defaults.

2. Reprogram parameters.

1. Verify input power and connections.

2. Check Line Sync board.

3. Check AC Line I/O board.

Continued next page.

Fault No. Type Description Action

Shear Pin 63 3 Programmed Current Lmt Check load requirements and

72 IOMM VFD-2

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SW OverCurrent

UnderVoltage 4 1 3

UserSet1

Chksum

Set2 102 2

Set3 103 2

36 1

101 2

Troubleshooting

Val (148) has been exceeded. Enabled/disable with Fault Config 1 (238). The drive output current has exceeded the software current. DC bus voltage fell below the minimum value of 407V DC at 400/480V input or 204V DC at 200/240V input.

Enable/disable with Fault Config 1(233).

The checksum read from the user set does not match the checksum calculated.

Current Lmt Val (148) setting.

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

Monitor the incoming AC line for low voltage or power interruption.

Re-save user set.

Common Symptoms and Corrective Actions

Table 26, No Start From Terminal Block Logic

Indication(s) Cause(s) Corrective Action

Clear fault: • Press OIM stop key if

that OIM is control source. •Cycle Flashing red Ready LED.

Incorrect operation from the terminal block.

Continued next page.

Drive is faulted.

Incorrect input wiring. • 2-wire control requires Run, Run Forward, or Run Reverse input(s).

• 3-wire control requires Start and Stop inputs • Jumper from terminal 7 to 8 is required. Incorrect digital input programming. • Mutually exclusive choices have been made. • 2-wire and 3-wire programming may be conflicting. • Exclusive functions (i.e, direction control) may have multiple inputs configured. • Stop if factory default and is not wired or is open. • Start or Run programming may be missing. Logic Source Sel is not set to Terminal Blk.

power. • Set Fault Clear (240) to 1. •

Toggle terminal block stop or

terminal block reset digital input if

terminal block is the control source.

Wire inputs correctly and/or install

jumper.

Program Digital In”x” Sel (361-366)

for correct inputs.

Set Logic Source Sel to Terminal

Blk.

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Table 27, No Start From Terminal Block Logic (Continued)

Indication(s) Cause(s) Corrective Action

Incorrect digital input programming.

Flashing yellow Ready LED and DigIn CflctB indication on LCD OIM.

Drive Status 2. (210) shows type 2 alarm(s).

• Mutually exclusive choices

have been made.

• 2-wire and 3-wire

programming may be conflicting.

• Exclusive functions (i.e,

direction control) may have multiple inputs configured.

• Stop if factory default and is

not wired or is open.

• Start or Run programming

may be missing.

Program Digital In”x” Sel (361-366) to resolve conflicts.

Remove multiple selections for the same function

Install stop button to apply a signal at stop terminal.

Table 28, No Start From OIM

Indication Cause(s) Corrective Action

Drive is programmed for 2-wire control and Logic Source Sel (89)

None

Flashing or steady red Ready LED.

Flashing yellow Ready LED.

Drive Status 1 (209) indicates logic control source.

= All Ports. OIM start and network start are disabled for 2-wire control.

Active fault. Reset fault.

Enable input is open. Close terminal block enable input. The terminal block stop input is

open and control source is set to All Ports.

Start inhibit bits are set. Check status in Start Inhibits (214). Logic Source Sel (89) is not equal

to the desired OIM (Local OIM, DPI Port 2, or DPI Port 3). DPI Port 2 is required for remote OIM.

If 2-wire control is required, no action is necessary. If 3-wire control is required, program Digital Inx Sel (361-366) for correct inputs.

Close terminal block stop input.

Verify setting of Logic Source Sel (89). The OIM Control digital input effectively sets the control source to the lowest attached OIM port.

Table 29, No Response to Changes in Speed Command

Indication Cause(s) Corrective Action

LCD OIM Status Line indicates “At Speed” and output is 0 Hz.

None

Speed reference from analog input

No value is coming from the source of the command.

Incorrect reference source has been programmed.

Incorrect reference source is being selected via remote device or digital inputs.

Improper reference common signal wiring.

1. If the source is an analog input, check wiring and use a meter to check for presence of signal. 2. Check Commanded Freq (2) for correct source.

1. Check Speed Ref Source (213) for the source of the speed reference. 2. Reprogram Speed Ref A Sel (90) for correct source.

1. Check Drive Status 1 (209), bits 12 - 15 for unexpected source selections. 2. Check Dig In Status (216) to see if inputs are selecting an alternate source. 3. Reprogram digital inputs to correct Speed Sel x option.

1. Verify that common is properly connected to AnlgIn(-) terminal.

74 IOMM VFD-2

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Table 30, Motor Will Not Accelerate to Commanded Speed

Indication Cause(s) Corrective Action

Acceleration time is excessive. Drive is forced into current limit, slowing or stopping acceleration. Speed command source or value is not as expected. Programming is preventing the drive output from exceeding limiting values.

Incorrect value in Accel Time “x” (140, 141).

Excess load or short acceleration time.

Improper speed command.

Incorrect programming.

Reprogram Accel Time “x” (140,

141). Check Drive Status 2 (210), bit 10 to see if the drive is in current limit. Remove excess load or reprogram Accel Time “x” (140, 141). Check for the proper speed command using steps 1 through 7 in table 12.11.

Check Maximum Speed (82) and Maximum Freq (55) to insure that speed is not limited by programming.

Table 31, Motor Operation is Unstable

Indication Cause(s) Corrective Action

Motor data was incorrectly

None

entered or autotune was not performed.

Table 32, Stopping the Drive Results in a Decel Inhibit Fault

1. Correctly enter motor nameplate data. 2. Perform static or rotate autotune procedure (61).

Indication Cause(s) Corrective Action

Decel Inhibit fault screen. LCD status line indicates Faulted.

The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage. Excess bus voltage is normally due to excessive regenerated energy or unstable AC line input voltages.

Internal timer has halted drive operation.

1. Reprogram bus regulation (parameters161 and 162) to eliminate any Adjust Freq selection.

2. Disable bus regulation (parameters 161 and162) and add a dynamic brake.

3. Correct AC input line instability or add an isolation transformer.

4. Reset drive

Troubleshooting the Drive w/ the LCD OIM

The LCD OIM provides immediate visual notification of alarm or fault conditions as well as the following diagnostic information:

• Entries in the fault queue

• Fault parameters

• Drive status parameters

• Selected device version and status information

• OIM version information

Accessing the Fault Queue

The drive automatically retains a history of the last eight faults that have occurred in the fault queue.

To access the fault queue, press the F4 key at the process display screen, or see Figure 35 to access the fault queue from the Main Menu.

IOMM VFD-2 75

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Figure 35, Accessing the Fault Queue

Figure 36, Sample Fault Queue Entry

The drive can be reset (as if the power were cycled) by pressing the F3 (Dres) function key while in the "View Fault Queue" screens. The reset function is active only while the drive is stopped. During a reset, drive communication with peripheral devices will stop until the reset function completes.

CAUTION:

Pressing F3 (Dres) will immediately cause the drive to be reset. This may result

in communication errors in other devices attached to the drive which could

result in machine damage.

76 IOMM VFD-2

Page 77

Operation, Large A/C, PF700H

The status of the drive can be viewed on the Human Interface Module (HIM) or on various LEDs.

Using the Interface

Figure 37, Human Interface Module (HIM)

The interface module can be removed to provide security against tampering with the control. To do so, first press the ALT key, release it and then press the left arrow (REMOVE) key, This procedure allows the module to be removed without causing a fault. Then press the tab on top of the module and slide the module upwards and out.

One function of the module is to program the various parameters that control the VFD/chiller operation. Programming is to be done only by service technicians who are factory trained and authorized to work on VFDs.

The module is used by the operator to troubleshoot the drive by viewing faults, and to clear faults after corrective action has been taken, as explained later in this section.

IOMM VFD-2 77

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Figure 38, LCD Display, Main Menu

LEDs

Illumination of a yellow LED indicates the presence of an alarm, a red LED indicated a fault.

Viewing Faults and Alarms

The primary area of interest to the operator is viewing drive alarms and faults. Alarms are problems that do not shut down the drive/compressor. They may eventually turn into faults, which do stop the compressor.

From the main menu, use the Up or Down arrows, Figure 38. Press the Enter key,

to select this menu. Then use these navigating keys to

reach a desired menu as shown in Figure 39.

or ,to select Diagnostics. See

78 IOMM VFD-2

Page 79

Figure 39, HIM Menu Structure

IOMM VFD-2 79

Page 80

Using the LEDs

Drive LEDs

Figure 40, Front Panel LED Indications

# Name Color State Description

PWR

(Power)

PORT(1) Green –

MOD(1) Yellow –

NET A(1) Red –

Green Steady

NET B(1) Red –

Illuminates when power is applied to the drive. Status of DPI port internal communications (if present). Status of communications module (when installed).

Status of network (if

Status of secondary network (if connected).

connected).

This section provides information to guide you in troubleshooting the PF 700H control family. Included is a listing and description of drive faults (with possible solutions, when applicable) and alarms.

Faults and Alarms

A fault is a condition that stops the drive. There are three fault types:

Table 33, Fault Types

Type Fault Description

When this type of fault occurs, and [Auto Rstrt Tries] is set to a value

Auto-Reset

Run

Non-

Resettable

User

Configurable

An alarm is a condition that, if left untreated, may stop the drive. There are two alarm types:

greater than “0,” a user-configurable timer, [Auto Rstrt Delay] begins. When the timer reaches zero, the drive attempts to automatically reset the fault. If the condition that caused the fault is no longer present, the fault will be reset and the drive will be restarted. This type of fault normally requires drive or motor repair. The cause of the fault must be corrected before the fault can be cleared. The fault will be reset on power up after repair These faults can be enabled/disabled to annunciate or ignore a fault condition.

Table 34, Alarm Types

Type Alarm Description

User

Configurable

Non-

Configurable

These alarms can be enabled or disabled through [Alarm Config 1]. It is recommended that factory setting not be changed.

These alarms are always enabled.

Drive Status

The condition or state of the drive is constantly monitored. Any changes will be indicated through the LEDs and/or the Human Interface module (HIM).

Clearing Alarms

Alarms clear automatically when the condition that caused the alarm is no longer present.

80 IOMM VFD-2

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HIM Indication

The LCD HIM also provides visual notification of a fault or alarm condition on the top line.

Manually Clearing Faults

Table 35, Fault/Alarm Types, Description and Actions

NOTE: See Table 33 and Table 34 for definition of fault/alarm types.

No. Name

1 PrechargeActv 1

2 Auxiliary In 1 Auxiliary input interlock is open. Check remote wiring.

3 Power Loss 1, 3 1

Fault

Alarm

Drive received a start command while in the DC bus precharge state.

DC bus voltage remained below [Power Loss Volts] for longer than [Power Loss Time]. Enable/Disable with [Fault Config 1]

Continued next page.

Description Action (if appropriate)

Monitor the incoming AC line for low voltage or line power interruption.

IOMM VFD-2 81

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No. Name

4 UnderVoltage 1, 3 1

5 OverVoltage 1

6 Motor Stall 1

7 MotorOverload 1, 3

8 HeatsinkOvrTp 2 1

9 IGBT OverTemp 1

10 System Fault 2

12 OverCurrent 1

13 Ground Fault 1

14 InverterFault 2

15 Load Loss 3 1

16 Motor Therm 3 1

17 Input Phase 3 1

21 OutPhasMissng 2

22 NP Hz Cnflct 2

23 MaxFreqCnflct 2

Fault

Alarm

Description Action (if appropriate)

DC bus voltage fell below the minimum value of 333V for 400/480V drives and 461V for 600/ 690V drives. Enable/ Disable with [Fault Config 1]

DC bus voltage exceeded maximum value.

Motor is operating at high current and low frequency and is not accelerating.

Internal electronic overload trip. Enable/Disable with [Fault Config 1).

Heatsink temperature exceeds maximum allowable value. 85 degrees C = Alarm 90 degrees C = Fault

Output transistors have exceeded their maximum operating temperature due to excessive load.

Hardware problem exists in the power structure.

The drive output current has exceeded the hardware current limit.

A current path to earth ground greater than 25% of drive rating. Ground fault level is 50% of the drive's heavy duty current rating. The current must appear for 800ms before the drive will fault.

Hardware problem in the power structure.

Option board thermistor input is greater than limit.

One input line phase missing.

Zero current in one output motor phase.

Fan/pump mode is selected in [Motor Cntl Sel] and the ratio of [Motor NP Hertz] to [Maximum Freq] is greater than 26.

The sum of [Maximum Speed] and [Overspeed Limit] exceeds [Maximum Freq]. Raise [Maximum Freq] or lower [Maximum Speed] and/or [Overspeed Limit] so that the sum is less than or equal to [Maximum Freq].

Monitor the incoming AC line for low voltage or power interruption.

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option.

1. Run Autotune 2. Reduce Load

1. Run Autotune 2. Verify settings of [Motor Overload Factor] and [Motor Overload Frequency]. 3. Reduce load so drive output current does not exceed the current set by [Motor NP FLA].

1. Verify that maximum ambient temperature has not been exceeded. 2. Check fan. 3. Check for excess load. 4. Check carrier frequency

1. Verify that maximum ambient temperature has not been exceeded. 2. Check fan. 3. Check for excess load.

1. Cycle power. 2. Replace drive.

Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current. Check for shorted motor leads or shorted motor.

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

1. Cycle power. 2. Replace drive.

1. Check user-supplied fuses 2. Check AC input line voltage.

1. Check motor wiring. 2. Check motor for open phase.

Continued on next page.

82 IOMM VFD-2

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No. Name

24 Decel Inhibit 3 1

25 OverSpd Limit 1

26 VHz Neg Slope 2 [Motor Cntl Sel] = “Custom V/Hz” & the V/Hz slope is negative.

27 SpdRef Cnflct 2 [Speed Ref x Sel] or [PI Reference Sel] is set to “Reserved”.

28 BrakResMissing 2 No brake resistor detected.

Fault

Alarm

Drive cannot follow commanded decel due to bus limiting.

Functions such as Slip Compensation or Bus Regulation have attempted to add an output frequency adjustment greater than that programmed in [Overspeed Limit].

Description Action (if appropriate)

1. Verify that input voltage is within specified limits. 2. Verify that system ground impedance follows proper grounding techniques. 3. Disable bus regulation and/or add dynamic brake resistor and/or extend deceleration time.

Remove excessive load or overhauling conditions or increase [Overspeed Limit].

1. Program [Bus Reg Mode x] to not use brake. 2. Install brake resistor.

An analog input is configured

29 Anlg In Loss 1, 3 1

30 MicroWatchdog 2 1

32 Fan Cooling 3

33 AutoReset Lim 2

34 CAN Bus Flt 1

37 HeatsinkUndTp 1

44 Device Change 2

45 Device Add 2 New option board added. Clear fault.

47 NvsReadChksum 2

to fault on signal loss. A signal loss has occurred. Configure with [Anlg In 1, 2 Loss]

Microprocessor watchdog timeout.

Fan is not energized at start command.

Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of [Flt RstRun Tries]. Enable/Disable with [Fault Config 1]

Sent message not acknowledged.

Ambient temperature is too low.

New power unit or option board installed of different type.

Error reading [Elapsed MWh] and [Elapsed Run Time] from EEPROM.

1. Check parameters. 2. Check for broken/loose connections at inputs.

1. Cycle Power. 2. Replace control.

Correct the cause of the fault and manually clear.

1. Cycle Power. 2. Replace control.

Raise ambient temperature.

Clear fault and reset drive to factory defaults.

48 ParamsDefault 2

50 MotorCalcData 2

54 Zero Divide 2

The drive was commanded to write default values to EEPROM.

Incorrect motor nameplate data.

This event called from arithmetical functions if divider is zero.

1. Clear the fault or cycle power to the drive. 2. Program the drive parameters as needed.

Check motor nameplate data.

1. Cycle Power. 2. Replace control.

Continued on next page.

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No. Name

63 Shear Pin 3

65 I/O Removed 2 Option board removed.

70 Power Unit 2

71 Periph Loss 2

81 Port DPI Loss 2

Fault

Alarm

Programmed [Current Lmt Val] has been exceeded. Enable/Disable with [Fault Config 1]

One or more of the output transistors were operating in the active region instead of desaturation. This can be caused by excessive transistor current or insufficient base drive voltage.

The communications card has a fault on the network side.

DPI port stopped communicating. A SCANport device was connected to a drive operating DPI devices at 500k baud.

Description Action (if appropriate)

Check load requirements and [Current Lmt Val] setting.

1. Clear fault.

1. Check DPI device event queue and corresponding fault information for the device.

1. If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, adapters, Main Control Board or complete drive as required. 2. Check HIM connection. 3. If an adapter was intentionally disconnected and the [Logic Mask] bit for that adapter is set to “1”, this fault will occur. To disable this fault, set the [Logic Mask] bit for the adapter to “0.”

94 Hardware Enbl

95 AutoT Rs Stat 2 Autotune Rs Static Test failed.

96 AutoT Lm Rot 2 Autotune Lm rotate test failed.

97 AutoT MagRot 2

98 AutoT Saturat 2

99 UserSet Timer 2

100 Param Chksum 2

104 PwrBrd Chksum 2

Enable signal missing from control terminal block.

Autotune magnetizing current rotate test failed.

Autotune saturation curve test failed.

User Set load or save not completed in less than 5 sec.

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

The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data.

Continued next page.

1. Check control wiring. 2. Check position of hardware enable jumper. 3. Check digital input programming.

1. Verify that motor is not rotating when autotune is enabled. 2. Check motor connections.

1. Check motor nameplate data. 2. Check motor connections. 3. Verify that Accel Time < (Base Speed/40) x 33 sec. Note: 33 sec. = time limit to bring motor to 40 Hz.

1. Check motor nameplate data. 2. Check motor connections. 3. Verify that Accel Time < (Base Speed/40) x 33 sec. (see above).

1. Check motor nameplate data. 2. Check motor connections.

Replace main control.

1. Restore defaults. 2. Cycle power. 3. Reload User Set if used.

1. Cycle power. 2. Replace drive.

84 IOMM VFD-2

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No. Name

Fault

Alarm

Description Action (if appropriate)

Drive rating information stored

106 MCB-PB Config 2

on the power board is incompatible with the main

1. Reset fault or cycle power. 2. Replace control board.

control board.

107 New IO Option 2

New option board added to control.

1. Restore defaults. 2. Reprogram parameters.

113 Fatal App 2 Fatal Application error. 1. Replace control board.

114 AutoT Enable 2

Autotune enabled but not started.

Press the Start key within 20 seconds of enabing autotune

120 I/O Change 2 Option board replaced. Reset Fault.

121 I/O Comm Loss 2

.I/O Board lost communications with the Main Control Board.

Check connector. Check for induced noise. Replace I/O board or Main Control Board.

Digital input functions are in conflict. Combinations marked with a “X” will

133 DigIn CnflctA 2

cause an alarm. * Jog 1 and Jog 2

Acc2/ Dec2

Acc2 Dece2

Acc2/ Dec2

Acc2 Dece2 Jog*

X X X X

Jog

Fwd

Rev

Fwd/ Rev

134

DigIn CnflctB 2

135 DigIn CnflctC 2

Continued on next page.

Jog* Jog

Fwd Jog Rev Fwd/ Rev

X X

.A digital Start input has been configured without a Stop input or other functions are in conflict. combinations that conflict are marked with a “X ” and will cause an alarm.

Stop

Start

Stop

-CF

Run

Run Fwd

Run Rev

Jog*

Jog Fwd

Jog Rev

Fwd/ Rev

-CF

X X X X X

X X X X X X X X X

X X X X

X X

X X X X

X X

* Jog1 and Jog 2

Run

Fwd

Run Rev

Jog*

Jog Fwd

Jog Rev

Fwd/ Rev

More than one physical input has been configured to the same input function. Multiple configurations are not allowed for the following inputs

Forward/Reverse Run Reverse Bus Regulation Mode B Speed Select 1 Jog Forward Acc2 / Dec2 Speed Select 2 Jog Reverse Accel 2 Speed Select 3 Run Decel 2

Run Forward Stop Mode B

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No. Name

136 BipolarCnflct . 2

143 TB Man Conflict 2

147 Start AtPwrUp 1

148 IntDB OvrHeat 1

149 Waking 1 The W ake timer is counting toward a value that will start the drive.

150 Sleep Config 2

Fault

Alarm

Parameter 190 [Direction Mode] is set to “Bipolar” or “Reverse Dis” and one or more of the following digital input functions is configured: “Fwd/Reverse,” “Run Forward,” “Run Reverse,” “Jog Forward” or “Jog Reverse.”

[TB Man Ref Sel] is using an analog input that is programmed for another function.

[Start At PowerUp] is enabled. Drive may start at any time within 10 seconds of drive powerup.

The drive has temporarily disabled the DB regulator because the resistor temperature has exceeded a predetermined value.

Sleep/Wake configuration error. With [Sleep-Wake Mode] = “Direct,”

possible causes include: drive is stopped and [Wake Level] < [Sleep

Level].“Stop=CF,” “Run,” “Run Forward,” or “Run Reverse.” is not configured in [Digital Inx Sel].

Description Action (if appropriate)

Check parameter settings to avoid problem.

Table 36, Fault/Alarm Cross Reference

Name No. Fault Alarm Name No. Fault Alarm

Anlg In Loss 29 X X MCB-PB Config 106 X AutoReset Lim 33 X MicroWatchdog 30 X

AutoT Enable 114

AutoT Lm Rot 96

AutoT MagRot 97

AutoT Rs Stat 95

AutoT Saturat 98

Auxiliary In 2

BipolarCnflct 136 BrakResMissng 28 X OutPhasMissng 21 X

CAN Bus Flt 34

Decel Inhibit 24

Device Add 45

Device Change 44

DigIn CnflctA 133

DigIn CnflctB 134 DigIn CnflctC 135 X Port DPI Loss 81 X

Fan Cooling 32

Fatal App 113

Ground Fault 13

Hardware Enbl 94

HeatsinkOvrTp 8

HeatsinkUndTp 37 I/O Change 120 X SpdRef Cnflct 27 X

I/O Comm Loss 121

I/O Removed 65

IGBT OverTemp 9 Input Phase 17 X X UnderVoltage 4 X X

IntDB OvrHeat 148 InverterFault 14 X VHz Neg Slope 26 X Load Loss 15 X X Waking 149 X

MaxFreqCnflct 23

X X X X X X

X X X X

X X

X X X

Motor Stall 6

Motor Therm 16

MotorCalcData 50

MotorOverload 7

New IO Option 107

NP Hz Cnflct 22

NvsReadChksum 47

OverCurrent 12

OverSpd Limit 25

OverVoltage 5

Param Chksum 100

ParamsDefault 48

Periph Loss 71

Power Loss 3

Power Unit 70

PrechargeActv 1

PwrBrd Chksum 104

Shear Pin 63

Sleep Config 150

Start AtPwrUp 147

System Fault 10

TB Man Conflict 143

UserSet Timer 99

Zero Divide 54

X X X X X X

X X

X X X

X X

86 IOMM VFD-2

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Troubleshooting

Table 37, No Start

Drive does not Start from Start or Run Inputs wired to the terminal block.

Cause(s) Indication Corrective Action

Clear fault. • Press Stop • Cycle

Drive is Faulted Flashing red status light

Incorrect input wiring. See Installation Manual for wiring examples.

• 2 wire control requires Run, Run Forward, Run Reverse or Jog input.

• 3 wire control requires Start and Stop inputs.

• Jumper from terminal 25 to 26 is required.

Incorrect digital input programming.

• Mutually exclusive choices have been made (i.e., Jog and Jog Forward).

• 2 wire and 3 wire programming may be conflicting.

• Exclusive functions (i.e, direction control) may have multiple inputs configured.

• Stop is factory default and is not wired.

None

Flashing yellow status light and “DigIn CflctB” indication on LCD HIM. [Drive Status 2] shows type 2 alarm(s).

power • Set [Fault Clear] to 1 • “Clear Faults” on the HIM Diagnostic menu.

Wire inputs correctly and/or install jumper.

Program [Digital Inx Sel] for correct inputsStart or Run programming may be missing.

Program [Digital Inx Sel] to resolve conflicts Remove multiple selections for the same function. Install stop button to apply a signal at stop terminal.

Table 38, No Start from HIM

Drive does not Start from HIM.

Cause(s) Indication Corrective Action

Drive is programmed for 2 wire control. HIM Start button is disabled for 2 wire control.

None

Table 39, No Speed Change

Drive does not respond to changes in speed command.

Cause(s) Indication Corrective Action

LCD HIM

Status Line No value is coming from the source of the command.

Incorrect reference source has been programmed.

Incorrect Reference source is being selected via remote device or digital inputs.

indicates

“At Speed”

and output

is 0 Hz.

None

If 2 wire control is required, no action needed.

If 3 wire control is required, program [Digital Inx Sel] for correct inputs

1. If the source is an analog input, check wiring and use a meter to check for presence of signal.

2. Check [Commanded Speed] for correct source

3. Check [Speed Ref Source] for the source of the speed reference.

4. Reprogram [Speed Ref A Sel] for correct source.

5. Check [Drive Status 1], bits 12 and 13 for unexpected source selections.

6. Check [Dig In Statusto see if inputs are selecting an alternate source.

7. 7. Reprogram digital inputs to correct “Speed Sel x” option.

Table 40, No Acceleration

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Motor and/or drive will not accelerate to commanded speed

Cause(s) Indication Corrective Action

Acceleration time is excessive. None Reprogram [Accel Time x]. Excess load or short acceleration times

force the drive into current limit, slowing or stopping acceleration.

Speed command source or value is not as expected.

Programming is preventing the drive output from exceeding limiting values.

None Check [Drive Status 2], bit 10 to see if

the drive is in Current Limit. Remove excess load or reprogram [Accel Time x].

None Check for the proper Speed Command

using Steps 1 through 7 above.

None Check [Maximum Speed and [Maximum

Freq] to assure that speed is not limited by programming.

Table 41, Unstable Operation

Motor operation is unstable.

Cause(s) Indication Corrective Action

Motor data was incorrectly entered or Autotune was not performed.

None

1. Correctly enter motor nameplate data.

2. Perform “Static” or “Rotate” Autotune procedure

3. Set gain parameters to default values.

Table 42, Stopping Gives Decel Fault

Stopping the drive results in a Decel Inhibit fault.

Cause(s) Indication Corrective Action

Decel Inhibit fault screen

LCD Status Line indicates “Faulted”.

1. See Attention statement

2. Reprogram parameters 161/162 to eliminate any “Adjust Freq” selection.

3.Disable bus regulation (parameters 161 &162) and add a dynamic brake

4. Correct AC input line instability or add an isolation transformer.

5. Reset drive.

The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage.

Excess bus voltage is normally due to excessive regenerated energy or unstable AC line input voltages.

Internal timer has halted drive operation

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Diagnostics Menu

When a fault trips the drive, use this menu to access detailed data about the drive.

Table 43, Fault menu

Option Description

Faults View fault queue or fault information, clear faults or reset drive. Status Info View parameters that display status information about the drive. Device Version View the firmware version and hardware series of components. HIM Version View the firmware version and hardware series of the HIM.

Parameter Menu

Refer to Viewing and Editing Parameters

Device Select Menu

Use this menu to access parameters in connected peripheral devices.

Memory Storage Menu

Drive data can be saved to, or recalled from, User and HIM sets. User sets are files stored in permanent nonvolatile drive memory. HIM sets are files stored in permanent nonvolatile HIM memory.

Table 44, Memory Storage

Option Description

HIM Copycat Device -> HIM Device <- HIM

Device User Sets Reset To Defaults Restore the drive to its factory-default settings

Save data to a HIM set, load data from a HIM set to active drive memory or delete a HIM set

Save data to a User set, load data from a User set to active drive memory or name a User set.

Preferences Menu

The HIM and drive have features that you can customize.

Option Description

Drive Identity Change Password

User Dspy Lines User Dspy Time Set the wait time for the User Display or enable/disable it.

User Dspy Video Reset User Dspy

Add text to identify the drive. Enable/disable or modify the password.

Select the display, parameter, scale and text for the User Display. The User Display is two lines of user-defined data that appears when the HIM is not being used for programming.

Select Reverse or Normal video for the Frequency and User Display lines Return all the options for the User Display to factory default values.

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Operation, LF

The status of the drive can be viewed on the Operator Interface Module (OIM) or on various LEDs.

Using the Interface

Figure 41, Keypad/Display

The front-panel keypad/display is used to monitor the drive. The functions available at the keypad depend on what mode the keypad/display is in and what is selected as the drive control source. It operates in two modes:

1. Monitor Mode (the default mode), used to monitor specific drive outputs as well as enter the speed or frequency reference for the drive.

2. Program Mode, used to view and adjust drive parameter values, and examine the error log.

Regardless of the control source selection, the keypad/display can be used to stop the drive and reset drive faults.

See Table 46 for a description of the Drive status LEDs.

Note: The STOP/RESET key can be disabled by parameter R055. This must be done so that only the chiller MicroTech II controller can stop or start the drive/compressor.

Monitor Mode

Monitor mode is the keypad/display’s default mode during drive operation, or it is entered by pressing the PROGRAM key until the PROGRAM LED turns off. The following output data can be displayed in monitor mode:

• Speed

• Volts

• Amps

• Hz

90 IOMM VFD-2

• kW

• Torque (vector regulation only)

• Selected reference (speed or torque)

Page 91

To select a value to monitor, press the ENTER key until the LED turns on next to the desired display item. Pressing the ENTER key advances you through each of the displays.

Note: All of the LEDs turn on to indicate the selected reference display.

Figure 42, Example of a Monitor Mode Displ ay

Displaying the Selected Reference

In monitor mode, you can display the speed reference (speed and frequency), or the torque reference the drive is using while it is running, (RUNNING LED is on, JOG LED is off). Follow these steps to display the selected reference:

Step 1 If you are not already in monitor mode, access it by pressing the PROGRAM key

until the PROGRAM LED turns off.

Step 2 Press the ENTER key repeatedly to advance through each of the monitor mode

LEDs. All of the monitor mode LEDs will then turn on at once and the reference will be displayed. Note that the displayed speed reference value is scaled based on P.028. The torque reference value is displayed in percent.

If the selected reference is negative, and its value is greater than 999, the SPEED LED will flash.

The Display

The display portion of the keypad/display is a four-character, seven-segment LED. At drive power-up, SELF is displayed as the drive performs power-up self diagnostics. During drive operation, the display indicates parameter numbers, parameter values, fault or alarm codes, and drive output values.

Display Range

Normally, a minus (-) sign is used as one of the four characters in the display to indicate a negative value. If a value (including the minus sign) exceeds four characters, the display will drop the minus sign and display four digits. In this case, the SPEED LED will flash to indicate that the displayed value is a negative number. Refer to the examples in the following table.

A decimal point to the right of the last digit in the display indicates there is further resolution (examples A and E below), unless a decimal point already appears as part of the number displayed (example G below). In either case, the system uses the full resolution of the number for drive control, not the displayed value.

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Table 45, Display Range Examples

Example If the actual number is …

A 1000.5 1000 Not Flash

B -999 -999 Not Flash

C -1000 1000 Flash

D -99.9 -99.9 Not Flash

E -1000.5 1000 Flash

F -9.99 -9.99 Not Flash

G -100.25 100.2 Flash

H -9.999 9.999 Flash

It will appear on the

display as …

And the SPEED LED will …

This does not apply for the speed display. For the speed display, the FORWARD REVERSE LEDs indicate actual speed reference polarity.

The Keypad

The drive’s keypad has nine membrane keys that are used to monitor, program, and control the drive.

Use the AUTO/MAN key to switch between the auto speed reference and

AUTO

MAN

the manual speed reference as shown below.

AUTO/MAN

Status

AUTO Selected

Control Source (P.000)

Local keypad/display

(P.000=LOCL)

Terminal Strip Remote

Inputs (P.000=rE)

Option Port (P.000=OP) Network

Serial Port

(P.000=SerL)

Speed Reference

Source

Terminal Strip

Note: Manual speed reference is not allowed on McQuay Centrifugal Chillers.

Use the ▲ and ▼ keys to:

• Step through the drive parameter menus and error log when the

▲ ▼

ENTER

keypad/display is in program mode.

• Increase (or decrease) a numeric value (such as the reference or a

parameter value).

Hold down these keys to increase the scroll speed.

Use the ENTER key to:

• Display a parameter (or a selection) value in program mode.

• Save a value.

• Move through each monitor display item when in monitor mode.

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Use the FORWARD/REVERSE key to select the direction of motor

FORWARD

REVERSE

rotation when the control source is local (REMOTE LED is off). This key is ignored if the control source is not local (REMOTE LED is on). See the FORWARD and REVERSE LED descriptions for more information.

Note: Local control source is not allowed on McQuay Centrifugal Chillers.

Use the PROGRAM key to move between program and monitor modes.

PROGRAM

RUN JOG

The PROGRAM LED turns on when the keypad/display is in program mode and turns off when the keypad/display is in monitor mode.

Use the RUN/JOG key to toggle between run and jog when in local control (REMOTE LED is off). When run is selected, pressing the START key results in continuous drive operation. When JOG is selected, pressing the START key results in drive operation only until the START key is released.

Note: Do not run in local control. Do not JOG. Compressor may run without lubrication.

This key is ignored if the control source is not local (REMOTE LED is on). See the RUN and JOG LED descriptions for more information.

Use the START key to apply power to the motor in local control

START

(REMOTE LED is off). See the RUNNING LED description for more information.

Note: Local control is not allowed on McQuay Centrifugal Chillers. Compressor may run without lubrication.

STOP

RESET

If the drive is running (RUNNING LED is on), the STOP/RESET key stops the drive. If the drive is not running (RUNNING LED is off), pressing this key resets drive faults.

Using the LEDs

The keypad contains eight LEDs that show the present drive status. The following table describes what each drive status LED means.

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Table 46, Drive Status LEDs

LED

RUNNING

REMOTE

JOG

AUTO

FORWARD

REVERSE

PROGRAM

PASSWORD

LED

Status

On Output power is being applied to the motor. Off Output power is not being applied to the motor.

The drive is being controlled (START, RUN/JOG,

Off The drive is being controlled from the keypad. (Not Allowed) Flashing The network connection is lost.

On Off

Off

Flashing

On The motor is running in the forward direction. Off The motor direction is not forward.

Flashing On Off

On The keypad/display is in program mode. Off The keypad/display is in monitor mode.

Off Parameters can be modified from the keypad.

FORWARD/REVERSE, speed reference) from a source other than the keypad.

(Not Allowed)

The drive is receiving its speed reference from the terminal strip input or network option.

The drive is receiving its speed reference from the local keypad or serial port (OIM or CS3000), i.e., using a manual reference. (Not Allowed)

The requested motor direction is forward; the actual motor direction is reverse (REVERSE LED is on).

(Not Allowed)

Parameters cannot be modified from the keypad without entering the correct password into P.051 (Programming Disable).

Note that disabling program changes by means of P.051 does not prevent parameter changes being made from the serial port or the network.

Meaning

Table 47 describes the values that will be displayed when the corresponding monitor mode LED is on.

Table 47, Monitor Mode LEDs

Monitor Mode LED Corresponding Display When LED Is On (Actual Values)

SPEED Motor speed is displayed. VOLTS Drive output volts are displayed. This value is not DC bus volts.

AMPS Drive output amps are displayed.

Hz Drive output frequency in hertz is displayed.

Output power of the drive in kilowatts is displayed. Note that this

TORQUE

ALL LEDs Selected speed reference or torque reference (in %) is displayed.

is intended for display purposes as a general indication of kilowatt output and should not be used for control or exact metering purposes.

Motor output torque is displayed in percent. (Valid only for vector regulation).

94 IOMM VFD-2

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Troubleshooting

DANGER

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 death.

The drive can display two kinds of error codes; alarms and faults, to signal a problem detected during self-tuning or drive operation. Fault and alarm codes are shown in Table 48 and Table 49. A special type of fault code, which occurs rarely, is the fatal fault code.

Alarm Codes

An alarm condition is signified by a two- or three-letter code flashing on the display. The drive will continue to operate during the alarm condition. The cause of the alarm should be investigated to check that it does not lead to a fault condition. The alarm code remains on the display as long as the alarm condition exists and clears when the condition causing it is corrected.

Fault Codes

A fault condition is also signified by a two- or three-letter code flashing on the display. If a fault occurs, the drive coasts to stop and the RUNNING LED turns off. The first fault detected is maintained flashing on the display, regardless of whether other faults occur after it. The fault code remains on the display until it is cleared by the operator using the STOP/RESET key or using the fault reset input from the selected control source.

Error Log

The drive automatically stores all fault codes for faults that have occurred in the system error log. The error log is accessible through the keypad or the OIM. There is no visual indication that there are faults in the log. You must access the error log to view the faults.

The error log holds the 10 most recent faults that have occurred. The last fault to occur is the first one to appear on the display when you access the error log. The faults in the log are numbered sequentially. The most recent fault is identified with the highest number (up to 9). Once the log is full, older faults are discarded from the log as new faults occur.

For each entry in the error log, the system also displays the day and time that the fault occurred. The day data is based on a relative 247-day counter (rolls over after 247.55). Scrolling through the error screens will give the day, for example, 117, which would be 117 days from the 0 day.

The time is based on a 24-hour clock. The first digits of the clock data represent hours. The last two digits represent minutes. For example, 10:17 PM would be 22.17. The clock can be reset using R030 (Elapsed Time Meter Reset).

See page 46 for details on adjusting the time stamp. All entries in the error log and the day and time data are retained if power is lost.

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Identifying Alarm Codes and Corrections

VFD drive alarm codes are shown in Table 48. Note that the alarm code will only be displayed for as long as the problem exists. Once the problem has been corrected, the alarm code will disappear from the display.

Table 48, List of Alarm Codes

Code

Hldc High DC bus

I-Ac V/Hz identification

I-En V/Hz identification

LIL Low AC input line AC input line is low. For

S-Ac Vector self-tuning

S-En Vector self-tuning

Alarm

Description

voltage

procedure active

procedure enabled

active

enabled

Alarm Cause Correction Action

The DC bus is charged above the trip threshold. (If U.018 > 415, DC bus is above 741 VDC. If U.018 ≤ 415, DC bus is above 669 VDC.)

V/Hz identification procedure is enabled and in progress.

H.020 = On; V/Hz identification procedure has been enabled but not started.

SVC, indicates DC bus is being regulated. No corrective action is required.

Vector self-tuning is enabled and in progress.

U.008 = On; vector selftuning has been enabled but not started.

Increase the deceleration time in P.0002, P.018.

Install optional snubber resistor braking kit.

Verify that the AC input is within specification. Install an isolation transformer if required.

Check the actual line voltage against U.018.

Allow identification procedure to finish.

Press keypad STOP/RESET to cancel identification procedure if desired.

Proceed with V/Hz identification procedure, start drive and allow procedure to begin. Display will change to I-Ac when drive is started.

Change H.020 to OFF to cancel identification and clear I-En if desired.

Adjust line voltage parameter (H.021 or U.018) to match actual Ac line voltage.

Allow vector self-tuning procedure to finish.

Press keypad STOP/RESET to cancel vector self-tuning procedure if desired.

Proceed with vector self-tuning, start drive and allow self-tuning procedure to begin. Display will change to S-Ac when drive is started.

Change U-008 to OFF to cancel selftuning and clear S-En if desired.

Note: Only properly trained and qualified service personnel should change the program or

operating parameters.

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Identifying Fault Codes and Recovering

DANGER

DC bus capacitors retain hazardous voltages after input power has been

disconnected. After disconnecting input power, wait five 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 death.

VFD drive fault codes are shown in Table 49. To clear a single fault that has occurred so that the drive can be started again, correct any problems indicated by the fault code and press the STOP/RESET key on the keypad, or assert the fault reset from the selected control source (P000). Because multiple faults can occur and only the first will be displayed, you must access the error log repeatedly in order to view all of the faults that have occurred and correct them.

Table 49, List of Fault Codes

Code Alarm Description Fault Cause Correction Action

Aln

bYC

CHS

EEr

EL Encoder loss

FL Function loss

Hld

HIL High line voltage

HU High Dc bus voltage

Analog input signal loss

DC bus charging bypass contactor

Default parameter restore (check sum error)

Earth current failure (ground fault)

Non-volatile memory write failure

High time identification aborted

Continued on next page.

P.011 = 4 or 5 and 4 to 20 mA analog input is below 1 mA.

Charging bypass contactor did not close or contact closure was not sensed by the system.

During drive operation: Regulator board failure.

After: Regulator board replacement.

Unintentional grounding.

Failure to write on non-volatile memory.

Drive is not detecting feedback from the encoder.

Function loss input on control terminal is opened.

Identification process for B/Hz has been aborted.

Input voltage more than 15% above nominal.

DC bus voltage too high (capacitor protection).

Deceleration time too short.

Verify that P.011 is set correctly. Check that the analog input source supply ≥ 1 mA.

Check operation of the bypass contactor. Verify the contactor is closing when the proper bus voltage is applied. Replace contactor.

Contact McQuay or replace regulator board.

Contact McQuay.

Check isolation between ground and output terminals. Possible leakage, current sensor defects; replace sensor.

Connect CS3000 software to upload parameters or record by hand. Then replace regulator board. Parameter values will be lost when power is cycled.

Check the connection between the encoder and the drive. Check the encoder/motor coupling.

Check external interlocks at terminals 16,

20.

See H.019 for identification result.

Check actual line voltage against U.018 or H.021.

Check input line voltage; if necessary, add transformer.

Increase deceleration time P.002/P.018/P.023 versus Maximum Speed/Hz (P.004). Install DB option with resistors.

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Code Alarm Description Fault Cause Correction Action

Verify that proper voltage is being applied to the drive. Check all phases.

Voltage ripple on DC bus due to missing input phase or an

IPL Input phase loss

LU Low DC bus voltage Input rectifier diodes defective.

NCL Network comm loss

Nld

OCA

Ocb

OCd

Identification request not yet performed (V/Hz only)

Overcurrent (steady state) – Trips between 185 and 200% load (based on inverter type current) check power module rating

Overcurrent (at acceleration)

Overcurrent (at DC braking)

Overcurrent (at deceleration)

imbalance between phases.

DC bus voltage too low. Line dip too long (P.042).

Communications with the AutoMax network have been lost.

Drive started but Identification Result = Zero.

Output phase-to-phase short.

Bus voltage line-to-line.

Ground fault.

Momentary overload.

Bad motor.

Torque boost / V/Hz too high (V/Hz).

Motor unknown to regulator (V/Hz

Parameter settings (vector).

Encoder wired incorrectly, wrong PPR.

Overcurrent condition occurred while accelerating. Acceleration time too short.

DC voltage too high. Check parameters H.006, H.007.

Overcurrent condition occurred while decelerating. Deceleration time too short.

Check input voltage, line fuses. If necessary, add transformer. Check value of Ride Through Time (R042), Line Voltage (H.021, U.018). Check DC bus voltage. If incorrect, replace diode set.

Check network cabling from network master to network option board. Check that network master is operating properly.

Reset fault. Perform Identification Request. Restart drive.

Check isolation between each output line.

Check transistor modules for correct output. If incorrect, possible board defect; replace. Possible Hall effect current sensor defective; replace.

Check isolation between ground and output terminals. Possible leakage current sensor defect; replace sensor.

Check for motor overload; reduce load on motor.

Check motor for correct operation.

Check parameters H.001, H.002, and/or H.003. Enable Identification Request (H.020)

Check that regulator was updated with actual motor characteristics via Identification Request (H.020).

Check Encoder PPR (U.001), Motor Poles (U.002), Base Frequency (U.003), Motor Nameplate Amps (U.004), Magnetizing Current (U.006), Speed Regulator Prop. Gain (U.012).

Check encoder wiring. Perform vector self-tuning.

See OC fault corrective actions. Increase acceleration time (P00l, P017, P021).

See OC fault corrective actions. Increase deceleration time (P002, P018, P022).

Continued on next page.

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Code Alarm Description Fault Cause Correction Action

Vector: Check parameters Encoder PPR (U.001), Motor Poles (U.002), Base Frequency (U.003).

V/Hz: Check DC bus voltage; increase decelerating time. Check values Max Speed (P004) Overfreq. (H.022). Check slip compensation (H.004). If H.016 ON, check motor size versus Power Module size, recheck setting of P005 (too high).

Check ambient temperature, cooling fan, minimum clearances around drive.

Vector: Check actual/Motor Rated Nameplate Amps (U.004)

V/Hz: Check actual current/Torque Boost (H.003).

Check that Power Module is sized correctly.

Reduce load on motor (for example, at low frequency).

Check that Power Module is sized correctly. Reduce load on motor (e.g., at low frequency).

Check output lines to the motor.

Check connections and cable of all 3 phases and motor windings. Replace any damaged cable.

Check Encoder PPR (U.001), Motor Poles (U.002), Base Frequency (U.003), Motor Nameplate RPM Speed (U.005). Check Reg. Proportional (U.01 2) Integral Gain (U.01 3)

Check cables between Regulator board and Power Module.

Power Module must be configured by Reliance service personnel.

Check load to Power Module. Check Power Module sizing versus application. Check DC Braking Current value (H.007). Check Torque Boost (H.003).

Check connection cable and communication port setup.

OF Overfrequency

OL Motor overload

OPL

OSP

PUc

PUn

PUo

SrL

UAr

UbS

Drive overtemperature

Motor output phase loss

Overspeed (vector only)

Missing power module ID connector

Power module not Identified

Drive power electronic overload

Self-tuning status (Vector only)

Communication loss between regulator/PC/OIM

Spurious host PC comm interrupt

Asymmetrical bus charge

Drive has exceeded maximum allowable output frequency. Regenerating energy is too high. Stability or slip compensation circuit adds frequency reference. If H.016 ON, searching current is too high. Motor is too small.

Cooling fan failure.

Excess motor current. V/Hz: Torque boost too high, therm. overload level too low.

Excess load on motor, for example, at too low speeds.

Loss of phase connection.

Phase lost between drive and motor.

RPM above 130% Maximum Speed (P.004), speed regulator response not optimized.

Bad or disconnected cable between Regulator and Power Module.

Drive parameters have been restored to power-up defaults. Regulator has not been configured to match Power Module.

Power Module overloaded. Too high DC Braking Current (H.007) or Torque Boost (H.003).

See parameter U.009

Serial Port communication cable, PC or OIM communication port setup.

Regulator board failure. Replace Regulator board.

Bad Power Module. Contact McQuay.

Note: If extensive troubleshooting or corrective actions are necessary, only properly trained and

qualified technicians should be used.

IOMM VFD-2 99

Page 100

Accessing, Reading, and Clearing the Faults in the Error Log

The following procedure shows how to access and clear the error log. Note that you cannot clear a single entry from the error log. The entire log, including all of the fault codes, and the day and time stamp of each fault, will be cleared simultaneously using this procedure.

Step 1. Press the PROGRAM key.

The First Menu General parameters are displayed. The PROGRAM LED will turn on.

Step 2. Press the ▼key until Err is displayed.

Step 3. Press the ENTER key.

If no faults have occurred, Err will be displayed again. If only one fault has occurred, the fault code will be displayed as the first entry in the log. If more than one fault has occurred, the first entry is the latest fault that occurred.

100 IOMM VFD-2

McQuay VFD 009LA Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual