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Start-Up and Service Instructions
Centrifugal liquid chillers are designed to provide safe and
reliable service when operated within design specifica-
tions. When operating this equipment, use good judgment
and safety precautions to avoid damage to equipment and
property or injury to personnel.
Be sure you understand and follow the procedures and
safety precautions contained in the chiller instructions as
well as those listed in this guide.
DANGER
ONLY QUALIFIED Electrical Personnel familiar with the construction
and operation of this equipment and the hazards involved should install,
adjust, operate, or service this equipment.
READ AND UNDERSTAND this manual and other applicable manuals in
their entirety before proceeding. Failure to observe this precaution could
result in severe bodily injury or loss of life.
DO NOT install modification kits with power applied to the drive. Discon-
nect and lock out incoming power before attempting such installation or
removal. Failure to observe this precaution could result in severe bodily
injury or loss of life
UNUSED WIRES in conduit must be grounded at both ends to avoid a
possible shock hazard caused by induced voltages. Also, if a drive sharing
a conduit is being serviced or installed; all drives using this conduit should
be disabled to eliminate the possible shock hazard from cross-coupled
motor leads. Failure to observe these precautions could result in bodily
injury.
DO NOT VENT refrigerant relief valves within a building. Outlet from
rupture disc or relief valve must be vented outdoors in accordance with the
latest edition of ANSI/ASHRAE 15 (American National Standards Insti-
tute/American Society of Heating, Refrigerating, and Air Conditioning
Engineers). The accumulation of refrigerant in an enclosed space can dis-
place oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,
especially for enclosed and low overhead spaces. Inhalation of high con-
centrations of vapor is harmful and may cause heart irregularities, uncon-
sciousness, or death. Misuse can be fatal. Vapor is heavier than air and
reduces the amount of oxygen available for breathing. Product causes eye
and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any
purpose. Oxygen gas reacts violently with oil, grease, and other common
substances.
NEVER EXCEED specified test pressures, VERIFY the allowable test
pressure by checking the instruction literature and the design pressures on
the equipment nameplate.
DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and func-
tioning before operating any chiller.
THERE IS A RISK OF INJURY OR DEATH by electrocution. High volt-
age may be present on the motor leads even though the motor is not run-
ning. Open the power supply disconnect before touching motor leads or
terminals.
WARNING
DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all
refrigerant (liquid and vapor) has been removed from chiller. Traces of
vapor should be displaced with dry air or nitrogen and the work area
should be well ventilated. Refrigerant in contact with an open flame pro-
duces toxic gases.
DO NOT work on high-voltage equipment unless you are a qualified elec-
trician.
DO NOT WORK ON electrical components, including control panels,
switches, VFD, or oil heater until you are sure ALL POWER IS OFF and
no residual voltage can leak from capacitors or solid-state components.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190012-01
Rockwell PowerFlex 755 VFD Option
SAFETY CONSIDERATIONS
Printed in U.S.A.
Form 19XRV-3SS
with PIC III Controls
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS
INTERRUPTED, confirm that all circuits are deenergized before resuming
work.
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes.
USE SAFETY GOGGLES. Wash any spills from the skin with soap and
water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES
with water and consult a physician.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller is
under pressure or while chiller is running. Be sure pressure is at 0 psig (0
kPa) before breaking any refrigerant connection.
CAUTION
TO AVOID an electric shock hazard, verify that the voltage on the bus
capacitors has discharged completely before servicing. Check the DC bus
voltage at the Power Terminal Block by measuring between the +DC and -
DC terminals, between the +DC terminal and the chassis, and between the
-DC terminal and the chassis. The voltage must be zero for all three mea-
surements.
THE USER is responsible to conform with all applicable local, national,
and international codes. Failure to observe this precaution could result in
damage to, or destruction of, the equipment.
THIS DRIVE contains ESD (Electrostatic Discharge) sensitive parts and
assemblies. Static control precautions are required when installing, testing,
servicing or repairing this assembly. Component damage may result if
ESD control procedures are not followed. For static control procedures,
reference Rockwell publication Guarding Against Electrostatic Damage, or
any other applicable ESD protection handbook.
DO NOT alter the setting of any jumper. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.
USE OF power correction capacitors on the output of the drive can result
in erratic operation of the motor, nuisance tripping, and/or permanent dam-
age to the drive. Remove power correction capacitors before proceeding.
Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
MOST CODES require that upstream branch circuit protection be pro-
vided to protect input power wiring. If fuses are chosen as the protection
method, refer to the PowerFlex 750 user manual. Failure to observe this
precaution could result in damage to, or destruction of, the equipment.
DO NOT route signal and control wiring with power wiring in the same
conduit. This can cause interference with drive operation. Failure to
observe this precaution could result in damage to, or destruction of, the
equipment.
DISTRIBUTION SYSTEM short circuit capacity shall not exceed the rat-
ing of the drive. Failure to observe this precaution could result in damage
to, or destruction of, the equipment.
DO NOT STEP on refrigerant lines. Broken lines can whip about and
release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow
safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move
inspection covers or other heavy components. Even if components are
light, use mechanical equipment when there is a risk of slipping or losing
your balance.
BE AWARE that certain automatic start arrangements CAN ENGAGE
THE VFD, TOWER FAN, OR PUMPS. Open the disconnect ahead of the
VFD, tower fans, or pumps.
USE only repair or replacement parts that meet the code requirements of
the original equipment.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion,
rust, leaks, or damage.
Pg 1
19XRV
711
3-11
Replaces: New

Summary of Contents

  • Page 1

    USE only repair or replacement parts that meet the code requirements of the original equipment. PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage. Printed in U.S.A. Form 19XRV-3SS 19XRV with PIC III Controls CAUTION Pg 1...

  • Page 2: Table Of Contents

    COMMUNICATIONS WIRING ....32-38 INTRODUCTION The Carrier VFD option Start-Up and Service Manual is in- tended for trained and qualified service personnel, and is to be used during start up, operation, and maintenance of Rockwell/ Allen-Bradley PF755L drive.

  • Page 3: Opening The Vfd Access Door, Drive Assembly Catalog Number, Components And Physical Data

    Components and Physical Data — Bradley PF755 Frame 6 drive is used for the 230-amp rated ap- plication (carrier Part No. 19XRV0230...). See Fig. 5. The Allen-Bradley PF755 Frame 7 drive is used for the 335-amp and 445-amp rated application (Carrier Part No.

  • Page 4

    LEGEND NAME DESCRIPTION Power Terminals R/L1, S/L2, T/L3, U/T1, V/T2, W/T3 PE Grounding Studs Terminating point to chassis ground for incoming motor shield DC Bus and Brake +DC, -DC, BR1, BR2 Terminals PE-A and PE-B MOV and CMC Jumper Wires DC+ and DC- Bus Voltage Test Points Fig.

  • Page 5: Start-up, Alternate Wire Lugs, Verify Installation, Allen-bradley Serial Number

    Model or Cat. Number b. Serial Number 4. From the ICVC control panel screen: a. Carrier Part Number and Revision b. ICVC Software Number Rockwell PowerFlex 750 drive start-up must be registered on the Rockwell website. Rockwell Registration site URL: http://www.automation.rockwell.com/warp/default.asp...

  • Page 6: Configure The Vfd, Commissioning The Unit

    ICVC screens. A complete set of configurations is transmit- ted to the VFD each time the controls are powered up. The following is from the 19XRV PIC III ICVC screen. Pa- rameters in italics are to be entered or confirmed at start-up. Pa- rameters in bold are to be changed only after consulting with Carrier service engineering.

  • Page 7: Check Internal Jumpers

    Vmax = Maximum measured phase-to-phase voltage (A to B, B to C, C to A) Vmin = Minimum measured phase-to-phase voltage Imbalance Calculation Formula (VAB + VBC + VCA) Vavg (Vmax – Vmin) x 100 Imbalance % Vavg 8. Take a final thermal measurement of the capacitor bank and power after finalizing the installation to ensure all connections are good.

  • Page 8: Service, Start-up, Service, Troubleshooting The Drive, Icvc Alert Codes, Icvc Alarm Codes

    ICVC called the Alert and Alarm codes. These codes signal a problem detected during self tuning or drive operation. Alert and Alarm codes are locat- ed in the 19XRV Start-Up, Operation and Maintenance Instruc- tions. Note the following differences between Carrier and Allen-Bradley terminology: •...

  • Page 9

    Table 3 NAME COLOR Green Flashing Steady Yellow Flashing Steady Flashing STS (Status) Steady Red/Yellow Flashing Alternately Green/Red Flashing Alternately None (Unlit) Flashing Steady ENET Red/Green Flashing Alternately Green Flashing Steady None (Unlit) LINK Green Flashing Steady NOTES: 1. A Type 1 alarm indicates that a condition exists. Type 1 alarms are user configurable.

  • Page 10

    DPI PORT 02 (COMPUTER PORT) DIGITAL INPUT TERMINAL BLOCKS (SLOTS 04 & 05) ETHERNET/IP ADDRESS SWITCHES DIGITAL OUTPUT TERMINAL BLOCKS (SLOTS 04 & 05) EMBEDDED ETHERNET/IP PORT MCB I/O TERMINALS (AUX FAULT / HIGH PRESSURE FAULT / ENABLE INPUT) Fig. 14 — MCB (Main Control Board) Components *Located outside of starter;...

  • Page 11

    PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is necessary. ICVC FAULT PRIMARY SECONDARY STATE MESSAGE MESSAGE PRESTART STARTS LIMIT ALERT EXCEEDED PRESTART HIGH BEARING ALERT TEMPERATURE PRESTART HIGH MOTOR ALERT TEMPERATURE PRESTART HIGH...

  • Page 12

    NORMAL RUN WITH OVERRIDES ICVC FAULT PRIMARY STATE MESSAGE RUN CAPACITY HIGH CONDENSER LIMITED PRESSURE RUN CAPACITY HIGH MOTOR LIMITED TEMPERATURE RUN CAPACITY LOW EVAP REFRIG LIMITED TEMP RUN CAPACITY HIGH COMPRESSOR LIMITED LIFT RUN CAPACITY MANUAL GUIDE VANE LIMITED TARGET RUN CAPACITY LOW DISCHARGE...

  • Page 13

    CHILLER ALERTS ICVC FAULT PRIMARY STATE MESSAGE SENSOR ALERT LEAVING COND WATER TEMP SENSOR ALERT ENTERING COND WATER TEMP LOW OIL CHECK OIL FILTER PRESSURE ALERT AUTORESTART LINE CURRENT PENDING IMBALANCE AUTORESTART LINE VOLTAGE PENDING DROP OUT AUTORESTART HIGH LINE VOLTAGE PENDING AUTORESTART LOW LINE VOLTAGE...

  • Page 14

    CHILLER ALERTS (cont) ICVC FAULT PRIMARY STATE MESSAGE SENSOR ALERT SPARE TEMPERATURE LOSS OF WITH WSM COMMUNICATION SENSOR ALERT EVAPORATOR APPROACH SENSOR ALERT CONDENSER APPROACH 163Condenser Approach VFD SPEED ALERT LOW VFD SPEED AUTORESTART LOW DC BUS VOLTAGE PENDING AUTORESTART HIGH DC BUS VOLTAGE PENDING SYSTEM ALERT...

  • Page 15

    219VFD Inverter Temp Exceeded: Check Cooling and VFD Config. ADDITIONAL CAUSE/REMEDY Malfunction within VFD Power Module. Call Carrier Service. Malfunction within VFD Power Module. Call Carrier Service. Check main circuit breaker for trip. Increase Current % Imbalance in VFD_CONF screen.

  • Page 16

    Check for condensation on motor terminals. Check motor power leads for phase to phase or phase to ground shorts. Disconnect motor from VFD and megger motor. Call Carrier Service. If operating from a generator, check generator size and speed. Check utility power supply.

  • Page 17

    ICVC is powered up if it was downloaded with software when it was not connected to a CCM. Call Carrier Service. Check for oil loss or excessive refrigerant. If oil level is low, refrigerant charge may be too low resulting in ineffective oil reclaim.

  • Page 18

    CHILLER PROTECTIVE LIMIT FAULTS (cont) ICVC FAULT PRIMARY STATE MESSAGE PROTECTIVE LIMIT HIGH VFD SPEED PROTECTIVE LIMIT INVALID DIFFUSER CONFIG. PROTECTIVE LIMIT DIFFUSER POSITION FAULT PROTECTIVE LIMIT SPARE TEMPERATURE PROTECTIVE LIMIT SPARE TEMPERATURE UNUSED UNUSED PROTECTIVE LIMIT VFD CONFIG CONFLICT PROTECTIVE LIMIT VFD CONFIG CONFLICT PROTECTIVE LIMIT GUIDE VANE CALIBRATION...

  • Page 19

    55-62 Hz if LINE FREQ=60Hz? is set to YES (60 Hz). VFD Gateway and VFD software versions are not compatible. Call Carrier Service. VFD Gateway and ICVC software versions are not compatible. Call Carrier Service. Check for high entering water temperature or low condenser water flow.

  • Page 20

    Temporary loss of voltage. Disable Single Cycle Dropout in VFD_CONF sceen. Verify phase-to-phase and phase-to-ground line voltage. VFD Circuit Board malfunction. Call Carrier Service. Verify phase to phase and phase to ground line voltage. Monitor AC line for high transient voltage conditions.

  • Page 21

    Table 6 Powerflex 755 Fault Code Descriptions and Corrective Actions (cont) — FAULT ICVC CODE FAULT FAULT TYPE ON VFD STATE HIST SCREEN Phase U to Gnd Phase V to Gnd Phase W to Gnd Phase UV Short Phase VW Short Phase WU Short Phase UNot Phase VNot ToGnd...

  • Page 22: With Input Power Off

    Table 6 Powerflex 755 Fault Code Descriptions and Corrective Actions (cont) — FAULT ICVC CODE FAULT FAULT TYPE ON VFD STATE HIST SCREEN HeatSinkUnder- HW En Jumper Safety Brd Fault Safety Jumper In HSFan Lifwe InFan Life MtrBrg Life MtrBrg Lube MachBrg life MachBrg Lube Excess Psn Error...

  • Page 23: Servicing The Drive, Removing The Drive, Rigging The Enclosure

    Servicing the Drive WARNING To guard against possible personal injury and/or equipment damage: 1. Inspect all lifting hardware for proper attachment be- fore lifting drive. 2. Do not allow any part of the drive or lifting mecha- nism to make contact with electrically charged con- ductors or components.

  • Page 24

    DRIVE RIGGING ACCESS DRIVE WIDTH + 4 IN. FRONT VIEW 2 IN. 2 IN. DRIVE RIGGING ACCESS SUPPORT FROM BELOW SIDE VIEW Fig. 19 — Enclosure Access for Removing Drive a19-1817 <45° > 1 / 2 A Fig. 20A — Rigging the Enclosure, Frame 6 >...

  • Page 25

    0.45-0.67 N-m (4.0-6.0 lb.-in.) 3 PLACES RIBBON CABLE Fig. 21 — COMM Card Fig. 22 — Mount COMM Card Plate to Drive  CHILL PLATE FAN AND INTERNAL FAN REPLACE- MENT — The following are the steps to replace the chill plate fan and internal fan in Frames 6 and 7.

  • Page 26: Parts Identification And Location

    Frame 7: 1. Disconnect power to the drive. Before removing the en- closure, open the access door on the front of the drive. See Fig. 16. 2. Check to be sure that the voltage between DC+ and DC- and from each DC terminal to the chassis is zero before proceeding.

  • Page 27

    a19-1848 NOTE: When replacing the Main Control Board (Item No. 1) the jumper marked “J1 ENABLE” must be removed and the jumper marked “J1 SAFETY” must be left in place. LEGEND 1 — Slot for Gateway (Gateway Not Shown) 2 — PF750 Series, Backplane Interface 3 —...

  • Page 28: Appendix A — Wiring Schematics

    APPENDIX A — WIRING SCHEMATICS (SHIELD) AUTO DEMAND LIMIT 4-20mA (OPTIONAL) (1-5vdc) AUTO CHILLED WATER 4-20mA RESET (OPTIONAL) (1-5vdc) (RED) EVAP ENT WATER TEMP (BLK) SWITCH POSITION (RED) SW "ON" = EXT 4-20mA EVAP LVG WATER TEMP SW "OFF" = EXT 1-5Vdc (BLK) 1 "OFF"...

  • Page 29

    APPENDIX A — WIRING SCHEMATICS (cont) CHILLER CONTROL SCHEMATIC (cont) TO TB-G ** 230V 115V (BLK) (BLK) (WHT) (WHT) COMP'R OIL HEATER (WHT) (BLK) (YEL) (RED) (ORN) (BRN) (BLK) TO VFD (CLR) (BLK) (RED) (SHIELD) (RED) (BLK) (CLR) (BLK) (BRN) COMP'R OIL PUMP MOTOR WINDING HIGH TEMPERATURE (WHT)

  • Page 30

    APPENDIX A — WIRING SCHEMATICS (cont)  ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) a19-1966 CONTINUED ON FACING PAGE USED USED...

  • Page 31

    I/O Card Mounting Slot Board — Remote — Relay Output Common SHLD — Shield — Terminal Block * Located outside of starter; connected by field wiring. DETAIL DETAIL B POWER PANEL POWER CARRIER PANEL FACTORY WIRING DETAIL A CARRIER FACTORY WIRING a19-1967...

  • Page 32: Communications Wiring

    APPENDIX B Optional BACnet* Communications Wiring — The following section is used to configure the UPC Open con- troller which is used when the BACnet communications option is selected. The UPC Open controller is mounted in a separate enclosure below the main control box. TO ADDRESS THE UPC OPEN CONTROLLER —...

  • Page 33

    EIA-485 and 2W. The example in Fig. C shows the BAS Port DIP Switches set for 76.8k (Carrier default) and MS/TP. Set the BAS Port DIP Switches DS2 and DS1 for the appro- priate communications speed of the MS/TP network (9600, 19.2k, 38.4k, or 76.8k bps).

  • Page 34

    APPENDIX B To install a BT485 terminator, push the BT485 terminator on to the BT485 connector located near the BACnet connector. NOTE: The BT485 terminator has no polarity associated with To order a BT485 terminator, consult Commercial Products i-Vu Open Control System Master Prices. MS/TP WIRING RECOMMENDATIONS —...

  • Page 35

    Navigation: BACview→CCN Home: Element Comm Stat Element: 1 Bus: 0 TROUBLESHOOTING — If there are problems wiring or addressing the UPC Open controller, contact Carrier Technical Support. Fig. F — BACview Device Connection RECOMMENDED VENDORS AND PART NUMBERS Connect Air...

  • Page 36

    APPENDIX B COMMUNICATION LEDS — The LEDs indicate if the controller is communicating with the devices on the network. See Tables E and F. The LEDs should reflect communication traffic based on the baud rate set. The higher the baud rate the more solid the LEDs become.

  • Page 37

    APPENDIX B POINT DESCRIPTION POINT NAME 1st Current Alarm State ALARM_01 Active Demand Limit DEM_LIM Actual Guide Vane Position GV_POS Actual VFD Speed VFD_ACT Calc Evap Sat Temp Chilled Water Deadband CWDB Chilled Water Delta P CHWPD Chilled Water Delta T CHW_DT Chilled Water Pump CHLP...

  • Page 38

    APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) POINT DESCRIPTION POINT NAME System Cooling Demand Level System Demand Limiting Target Guide Vane Position GV_TRG Target VFD Speed VFD_OUT Tower Fan Relay High TFR_HIGH Tower Fan Relay Low TFR_LOW User Defined Analog 1 User Defined Analog 2 User Defined Analog 3 User Defined Analog 4...

  • Page 40

    Copyright 2011 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53190012-01 Printed in U.S.A. Form 19XRV-3SS Pg 40 3-11 Replaces: New...

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