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Troubleshooting
Related Manuals for McQuay RVSS14
Summary of Contents for McQuay RVSS14
- Page 1 Installation, Operation and Maintenance Manual IOMM Starter Group: Chiller Part Number: 331375501 Effective: Sept. 2005 Supercedes: New Starters for Centrifugal Chillers Low Voltage, Solid State and Wye-Delta Medium/High Voltage, Solid State and Across-the-Line...
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Page 2: Table Of Contents
"McQuay" is a registered trademark of McQuay International © 2005 McQuay International "Illustrations and data cover McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice". IOMM Starter... -
Page 3: General
Metering Option” has been ordered. See page 27 for details. Medium and high voltage (2300-7200 volts) starters share common software known as “Micro II Control”, not to be confused with the McQuay MicroTech II™ chiller control system. Figure 1, Wye-Delta Starter... -
Page 4: Variable Frequency Drives
VFDs also perform starting and motor protection functions. They are only available for 3/60/460-480 service. VFDs are available only from McQuay and when purchased as part of the original chiller purchase. Installation and operation are covered in McQuay manual IOMM VFD. -
Page 5: Installation
Open transition: A reduced voltage starter characteristic occurring when the motor is temporarily disconnected from power at the time the starter changes from the starting mode to the final running mode. A second smaller inrush spike will occur. McQuay does not recommend use of this type of starter. -
Page 6: Receiving And Setting
The unit should be inspected immediately after receipt for possible damage. All McQuay centrifugal starters are shipped FOB factory and all claims for handling and shipping damage are the responsibility of the consignee. Extreme care must be used when rigging the starter to prevent damage. See the certified dimension drawings included in the job submittal for the center of gravity of the unit. - Page 7 Safety Precautions Electrical codes require that all equipment (starter, 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 familiar with the equipment.
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Page 8: Power Wiring
T3 and T5, rotation is proper. See diagram in terminal box cover. The McQuay start-up technician will check the phase sequence. Note: Do not make final connections to motor terminals until wiring has been checked and approved by a McQuay technician. - Page 9 (775123601) placed in the motor terminal box on all medium and high voltage units. It can be ordered for high humidity applications. This is to be done after the McQuay start-up technician has checked for proper phase sequence and motor rotation.
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Page 10: Connection Sizes
Table 2, Solid State Connection Sizes, Power Block Starter Incoming Outgoing Model No. Connection to Connection Size (Note 1) Power Block (Note 2) RVSS14 2/C #6-300 NOTES: RVSS17 2/C #6-300 Data is the same for unit-mounted RVSS20 2/C #6-300 starters, RVST14, etc. RVSS27 2/C #6-300 Outgoing are NEMA 1 hole pattern. -
Page 11: Table 3, Solid State, Connection Sizes, Disconnect & Circuit Breaker
Table 3, Solid State, Connection Sizes, Disconnect & Circuit Breaker 50/60 HZ Incoming Size Incoming Size Max RLA Disc. Switch Circuit Breaker #6- 350 #6- 350 #6- 350 #6- 350 #6- 350 #6- 350 #6- 350 #6- 350 2/C 3/0 - 500 2/C 3/0 - 500 2/C 3/0 - 500 2/C 3/0 - 500... -
Page 12: Table 5, Wye-Delta Connection Size, Disconnects & Circuit Breakers
Table 5, Wye-Delta Connection Size, Disconnects & Circuit Breakers 50/60 HZ Incoming Size Incoming Size Max RLA Disc. Switch Circuit Breaker #6- 350 #6- 350 #6- 350 #6- 350 #6- 350 #6- 350 #6- 350 #6- 350 2/C 3/0 - 500 2/C 3/0 - 500 2/C 3/0 - 500 2/C 3/0 - 500... -
Page 13: Control Wiring
16. Low voltage starters may have additional control wiring as shown on Figure 4 if the optional full metering package is ordered with the unit. The control circuit on the McQuay centrifugal packaged chiller is designed for 115-volts. Control power can be supplied from three different sources: •... -
Page 14: Low Voltage Starters
Separate Power Source Chiller control power usually comes from a control transformer located in the starter and factory or field wired to the chiller control panel. In the event a separate transformer supplies control voltage, it must be rated at 3 KVA, with an inrush rating of 12 KVA minimum at 80% power factor and 95% secondary voltage. -
Page 15: Medium/High Voltage Starters
Figure 4, Field Wiring for Optional D3 Communication NOTES. 1. See Figure 3 for Starter connection location. 2. The compressor controller serial card location is in the lower-center of the compressor controller, under the operating buttons. 3. The bias block is located on the rail, just to the left of the compressor controller. 4. -
Page 16: Figure 5, Control And Power Field Wiring
Figure 5, Control and Power Field Wiring MICROTECH CONTROL BOX TERMINALS (115V) (24V) POWER * NOTE 7 NEUTRAL * NOTE 10 * COOLING TOWER FOURTH STAGE STARTER * NOTE 10 * COOLING TOWER THIRD STAGE STARTER * NOTE 10 * COOLING TOWER SECONDH STAGE... - Page 17 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.
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Page 18: Startup
In the rare instances where a starter is being replaced after the chiller has been in service, McQuay service is not automatically involved but can be contracted to supervise the starter installation. For general information, brief startup instructions are included on the following pages. - Page 19 Emergency Thermal Reset· • Press RESET and DOWN to perform an emergency thermal reset. Messages (LVSS) No Line Control Power Lockout – A start is Ready not allowed because the control Accelerating power is too low. Up to Speed xxx xxx = overload content. Press DOWN to toggle.
- Page 20 DESCRIPTION Values DEFAULT Decel End Level 50 to 0 %Volts Decel Time 1 to 180 seconds Default Meter Display 0 to 19 Overcurrent Trip Level OFF, 50 to 800 %RLA Overcurrent Trip Delay 0.1 to 90.0 seconds Time 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, Rated RMS Voltage 400, 415, 440, 460, 480,...
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Page 21: Low Voltage Wye-Delta
Controlled Auto Description Stop Reset Thermistor Trip (on DIN#1) Stack OT Switch Trip (on DIN#2) Analog Input Trip Modbus Timeout CPU Error – Software Fault CPU Error – Parameter Storage Fault CPU Error – Illegal Instruction Trap CPU Error – Software Watchdog Fault CPU Error –... - Page 22 Resetting a Fault • Press RESET to reset from a fault. Resetting Parameters • Press and hold PARAM and ENTER on power up to reset parameters to default values. Emergency Thermal Reset • Press RESET and DOWN to perform an emergency thermal reset. Messages (LVYD) No Line Control Power Lockout –...
- Page 23 DESCRIPTION Values DEFAULT Sequence Complete 0.1 to 5.0 seconds Delay Time Overcurrent Trip Level OFF, 50 to 800 %RLA Overcurrent Trip Delay 0.1 to 90.0 seconds Time 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, Rated RMS Voltage 400, 415, 440, 460, 480, 575, 600, 660, 1000 Volts Over Voltage Trip Level...
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Page 24: Medium/High Voltage, Solid State
Auto Description Reset Burden Switch Error Thermistor Trip (on DIN#1) Analog Input Trip Modbus Timeout CPU Error – Software Fault CPU Error – Parameter Storage Fault CPU Error – Illegal Instruction Trap CPU Error – Software Watchdog Fault CPU Error – Spurious Interrupt CPU Error –... - Page 25 Start Mode Description The Start Mode parameter allows for an optimal start of the motor based on the application. For a description of the possible Start Mode parameters, refer to page 31 in the Operations chapter. Values The Start Mode Parameter can be set to Curr, TT, or Tach. Default The default value for the Start Mode is Curr.
- Page 26 Default The default value for the maximum current is 600%. Ramp Time Description The ramp time sets the amount of time that it takes for the starter to linearly increase the current from the initial current level to the maximum current level. A typical ramp time setting is from 15 to 30 seconds.
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Page 27: Operation, Low Voltage Starters, 200 - 600 Volts
Introduction This section contains information on low voltage, Wye-Delta and solid-state starters as manufactured by Benshaw Inc. for McQuay centrifugal Chillers. They are known collectively as “D3” starters, which is their software designation. These low voltage starters have similar software (designated D3) and are grouped together in this manual. Model numbers are as... -
Page 28: Figure 7, Expanded Starter View Screen
Figure 7, Expanded Starter View Screen The screen shown to the right will be superimposed on the right side of the VIEW screen shown in Figure 6 when the optional “Full Meter Display” is included with the unit. If the “Full Meter Display” package is not ordered, only the Percent Unit RLA amps will appear on the Home screen. -
Page 29: Figure 8, Optional Starter Setpoint Screen
The setpoints shown above are for solid state starters. Other types of starters will have slightly different setpoints. Units without the starter display option will have their setpoints set in the starter itself. Do not change these setpoints after McQuay startup. Do not remove the D3 control wiring. If accidentally disconnected, contact McQuay service. IOMM Starter... -
Page 30: Figure 9, Starter-Mounted Led
Standard Starter Keypad and Display When the optional full metering display is not ordered, the LED display located in the starter provides information on starter operation and programming. The 4-digit, 7-segment display shows starter meter outputs and programming data. Special symbols provide further information about the starter operation (see the following section). - Page 31 Display Operation Display • • View parameters, messages and faults. Press PARAM, Select P24 and press ENTER. The most recent fault will be • Shows software revision on power up. displayed as “xFyy” where x will be 1 ramming to indicate the most recent fault is •...
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Page 32: Changing Parameters
2. Wait 60 seconds and the display will return to the default meter display. The starter setpoint parameters are factory set and subsequently reviewed during commissioning by the McQuay startup technician. They should not be changed unless authorized by McQuay. -
Page 33: Table 10, Setpoints, Solid State Starter
Description Default Values Overcurrent Trip Delay Time 0.1 to 90.0 seconds 208, 220, 230, 240, 380, 415, Rated RMS Voltage 440, 460, 480, 575 Volts Over Voltage Trip Level OFF, 1 to 40 % rated Volts Under Voltage Trip Level OFF, 1 to 40 % rated Volts Over/Under Voltage Delay Time 0.1 to 90.0 seconds... -
Page 34: Table 11, Status Messages, Wye-Delta Starter
Description Default Values Modbus Baud Rate 1.2, 2.4, 4.8, 9.6, 19.2 Kbps 19.2 Modbus Timeout OFF, 1 to 120 seconds Analog Output Function 0 to 11 Analog Output Span 1 to 125 % Analog Output Offset 0 to 99 % Passcode (See Note) 0 to 9999 Disabled... -
Page 35: Table 13, Default Meter Display
Table 13, Default Meter Display 0: Status Message 7: Ave L-L Voltage RMS 14: KVA 1: Ave RMS Current 8: L1-L2 Voltage RMS 15: KWh 2: L1 RMS Current 9: L2-L3 Voltage RMS 16: MWh 3: L2 RMS Current 10: L3-L1 Voltage RMS 17: Phase Rotation 4: L3 RMS Current 11: Overload %... -
Page 36: Figure 10, Wye Delta Motor Connection To The D3 Control
Faulted Condition When a fault condition exists, the display shows the fault code Fxx. The exceptions to this are as follows: • When the fault is thermal overload trip, “F OL” will be displayed. • When the fault is Instantaneous over current, ioc will be displayed. Quick Meters Although any meter may be viewed by changing the meter parameter, there are 3 “Quick Meters”... - Page 37 Figure 10, Wye Delta Motor Connection to the D3 Control T o T B 3, C1+ (W hite W ire) T o T B 3, C 1- (B lack W ire) T o T B3, C 2+ (W hite W ire ) C urrent F eedbacks to M X T o T B 3, C 2- (B lack W ire)
- Page 38 reducing motor heating. If a Wye to Delta transition has not already occurred, a transition will always occur when the complete UTS / Transition Time (QST 09, P9) expires. The D3 control can operate two configurations of Wye-Delta starters, open transition and closed transition.
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Page 39: Figure 11, Wye Delta Profile
The starter will remain in the Delta or running mode until the start command is removed or a fault occurs. Usually the D3 intelligent Wye to Delta transition algorithm provides an optimal transition point that minimizes the transient current and torque surges that can occur. However sometimes, based on the motor and loading, the Wye to Delta transition will occur only after the Transition Time has expired. -
Page 40: Fault Code Troubleshooting Chart
Fault Code Troubleshooting Chart The following is a list of possible fault messages that can be generated by the D3 starter control. Code Description Detailed Description of Fault / Possible Solutions Motor did not achieve full speed before the UTS timer (QST 09, P9) expired. Check motor for jammed or overloaded condition. - Page 41 Code Description Detailed Description of Fault / Possible Solutions Line frequency above 72 Hz was detected. Verify input line frequency. High Line Frequency If operating on a generator, check generator speed governor for malfunctions. Line power quality problem / excessive line distortion. Three-phase power has been detected when the starter is expecting single-phase power.
- Page 42 Code Description Detailed Description of Fault / Possible Solutions High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32). High Line L1-L2 Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (FUN 05, ) is set correctly.
- Page 43 Fault Description Detailed Description of Fault / Possible Solutions Code During operation, the D3 controller detected a very high level of current in one or more phases. I.O.C. Check motor wiring for short circuits or ground faults. (Instantaneous Check motor for short circuits or ground faults. Overcurrent Check if power factor or surge capacitors are installed on the motor side of the starter.
- Page 44 Fault Description Detailed Description of Fault / Possible Solutions Code Check if load is still connected to starter Check if motor may have been driven by the load (a regeneration condition) No Current at Run (Cont’d) Check Gate and Cathode connections to D3 for loose connections. Check for inline contactor or disconnect.
- Page 45 Fault Description Detailed Description of Fault / Possible Solutions Code Low control power (below 90V) has been detected while running, by the D3 controller. Verify that the control power input level is correct especially during starting when there may be significant line voltage drop. Control Power Low Check control power transformer tap setting (if available).
- Page 46 Fault Description Detailed Description of Fault / Possible Solutions Code Based on the Analog Input parameter settings, the analog input level has either exceeded or dropped below the Analog Input Trip Level setting (I/O 08, ) for longer than the Analog Input Trip Delay time (I/O 09, P47). Measure value of analog input to verify correct reading.
- Page 47 Fault Description Detailed Description of Fault / Possible Solutions Code If fault persists after performing a Factory Parameter reset, consult factory. CPU Error The D3 control has detected an internal CPU problem. Consult factory. CPU Error – SW Watchdog The D3 control has detected an internal software problem. Consult factory. Fault CPU Error The D3 control has detected an internal CPU problem.
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Page 48: General Troubleshooting Chart
General Troubleshooting Chart The following troubleshooting charts can be used to help solve many of the more common problems that may occur. Motor does not start, no output to motor Condition Cause Solution Check for proper control voltage input. Display Blank, CPU Heartbeat Control voltage absent. - Page 49 Acceleration not operating as desired Condition Cause Solution Ramp time ( P8) too short. Increase ramp time. Initial current ( P6) set too high. Decrease Initial current. Maximum current ( P7) set too high. Decrease Maximum current. Kick start current ( P13) too high. Decrease or turn off Kick current.
- Page 50 Metering incorrect Condition Cause Solution Verify correct CT wiring and verify that the CTs are installed with all the CTs installed or wired incorrectly. White dots towards the input line Power Metering not reading side. correctly. CT ratio parameter (FUN 03, P68) Verify that the CT ratio parameter is set incorrectly.
- Page 51 Other Situations Condition Cause Solution If input phasing correct, exchange any two output wires. Motor Rotates in Wrong Direction Phasing incorrect If input phasing incorrect, exchange any two input wires. Shut off all power and check all Erratic Operation Loose connections connections.
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Page 52: Operation, Medium/High Voltage Starters, 2300V - 7.2Kv
Introduction This section contains information on medium voltage, across-the-line and solid state starters as manufactured by Benshaw Inc. for McQuay centrifugal Chillers. Medium voltage starters have similar software (Micro II Control) and are grouped together in this manual. Model numbers are as follows:... -
Page 53: Changing Parameters
Changing Parameters The starter’s setpoint parameters are factory-set and subsequently reviewed during commissioning by the McQuay startup technician. They should not be changed unless authorized by McQuay. The programming procedure is explained below and the following table shows the range of values and defaults. -
Page 54: Table 14, Main Menu
Menu Structure The Micro II control has a 2 level menu structure. There are eight main menus that contain parameters related to the different functions of the starter and five of the main menus contain additional sub-menus that divide the parameters into functional groups. The following shows the structure of the menu structure. -
Page 55: Quick Start
• Press the Menu button repeatedly to return to the main display. Quick Start Motor FLA Parameter Description The motor FLA parameter must be set to the full load amps of the motor connected to the starter for the starter to function correctly. NOTE: The starter uses the entered motor FLA for every current based calculation. - Page 56 Int. Curr. (initial current) Description The initial current parameter is set as a percentage of the motor FLA parameter setting. The initial current parameter sets the current that will initially reach the motor when a start is commanded. If the motor does not rotate within a few seconds after a start command, the initial current should be increased.
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Page 57: Troubleshooting
Solution Fault Displayed. Shown on display. See fault code table. Watchdog LED on. CPU card problem. Consult McQuay Factory Service. Control voltage is absent. Check for proper control voltage. Display is blank. FU1 on power card. Replace FU1. Ribbon Cables. -
Page 58: Table 19, Other Situations
Loose connections. Shut off all power and check connections. Ramp time. Initial current. Maximum current setting. Accelerates too quickly. Kick Start. Contact McQuay Factory Service Improper FLA setting. Initial torque. Maximum torque. Ramp time. Initial current. Maximum current setting. Accelerates too slowly Kick Start. -
Page 59: Fault/Log Codes
Fault/Log Codes The following is a list of the possible fault and log codes that can be generated depending on the type of starter. The fault class lists the default setting for each fault; either critical or non-critical. NonC = Non-critical Crit = Critical Table 20, Fault/Log Codes Fault/... - Page 60 Fault/ Fault Fault/Event Description/Possible Solutions Log No. Class Recorder Text The door mounted keypad has failed. Crit Key Pad Failure The Stop or Start button was held down while a computer reset was while power was applied to the unit. During TruTorque ramping, the motor current exceeded the TruTorqu Crit TT Overcurrent Limit...
- Page 61 Fault/ Fault Fault/Event Description/Possible Solutions Log No Class Recorder Text The start/stop circuitry has failed. Crit Unauthorized RUN A fast start/stop sequence was performed. Check wire connected to terminal JC13-3. A shorted SCR on line 1 was detected Crit Shorted SCR •...
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Page 62: Led Diagnostics
LED Diagnostics There are several LEDs located on the Micro II circuit cards. These LEDs can be used to help troubleshoot problems with the starter. Refer to the circuit card layouts for LED locations. Table 21, LED Diagnostics CARD LED # NAME INDICATION Watch Dog/Power... -
Page 63: Maintenance
Maintenance Preventive Maintenance During Commissioning • Torque all power connections during commissioning, including pre- wired equipment. • Check all control wiring for loose connections. • If fans are installed, check for proper operation. One Month After Commissioning • Re-torque all power connections, including pre-wired equipment. •... - Page 64 IOMM Starter...
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Page 65: Index Of Figures & Tables
Index of Figures & Tables FIGURES Figure 1, Wye-Delta Starter .................. 3 Figure 2, Solid State Starter, Wall Mounted ............4 Figure 3, Starter Panel ..................14 Figure 4, Field Wiring for Optional D3 Communication........15 Figure 5, Control and Power Field Wiring............16 Figure 6, Optional Starter View Screen .............. - Page 66 This document contains the most current product information as of this printing. For the most up-to- date product information, please go to www.mcquay.com. Post Office Box 2510, Staunton, Virginia 24402-2510 USA • (800) 432-1342 • www.mcquay.com IOMM Starter (09/05)
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