Carrier 19Xrv Users Manual 3ss Reprint 711

19XRV to the manual c058fb71-22d6-49ed-b558-7ff5cf3cacaa

2015-01-24

: Carrier Carrier-19Xrv-Users-Manual-310585 carrier-19xrv-users-manual-310585 carrier pdf

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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 1 711 3-11 Replaces: New

Start-Up and Service Instructions

SAFETY CONSIDERATIONS

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.

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.

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.

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.

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.

DANGER

WARNING

CAUTION

19XRV

with PIC III Controls

Rockwell PowerFlex 755 VFD Option

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 2

Required Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Getting Assistance from Rockwell Automation . . . 2

IDENTIFYING DRIVE COMPONENTS. . . . . . . . . . . . 2-5

Opening the VFD Access Door . . . . . . . . . . . . . . . . . . . 3

Drive Assembly Catalog Number . . . . . . . . . . . . . . . . . 3

Components and Physical Data . . . . . . . . . . . . . . . . . . 3

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Alternate Wire Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Verify Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Configure the VFD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Commissioning the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . 6

Check Internal Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

Troubleshooting the Drive . . . . . . . . . . . . . . . . . . . . . . . . 8

• ICVC ALERT CODES

• ICVC ALARM CODES

• TEST EQUIPMENT NEEDED TO TROUBLESHOOT

• VERIFYING THAT DC BUS CAPACITORS ARE

DISCHARGED

• HIGH TEMPERATURE ALARMS

• MAIN CONTROL BOARD (MCB) COMPONENTS

Checking Power Modules and Motor Input

with Input Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Servicing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

• REMOVING THE DRIVE

• RIGGING THE ENCLOSURE

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

OPTION CARD)

• CHILL PLATE FAN AND INTERNAL FAN

REPLACEMENT

Parts Identification and Location . . . . . . . . . . . . . . . . 26

APPENDIX A — WIRING SCHEMATICS . . . . . . . 28-31

APPENDIX B — OPTIONAL BACNET

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.

ABBREVIATIONS AND EXPLANATIONS

Frequently used abbreviations in this manual include:

Required Publications — The Carrier VFD option

Start-Up and Service Manual must be used with the following

manuals:

• The latest version of the PowerFlex 750-Series AC

Drives manuals

• The latest revision of the Start-Up, Operation, and Main-

tenance Instructions for the 19XRV with PIC III Controls

Getting Assistance from Rockwell Automa-

tion — Contact the local Rockwell Automation sales office

with any questions or problems relating to the products de-

scribed in this manual. For technical support on drives between

the hours of 7:00 am and 6:00 pm CST, M-F, call 1-262-512-

8176. For information about after-hours phone support and on-

site support call 1-800-800-0522.

Before calling, have the following information available

from the Allen-Bradley data nameplate located inside the en-

closure on the right wall. See Fig. 1.

• Allen-Bradley ID or CAT. NO.

• Carrier VFD Code

• Allen-Bradley serial number

IDENTIFYING DRIVE COMPONENTS

A chiller control schematic and a VFD schematic are in-

cluded in Appendix A.

CCM — Chiller Control Module

DC — Direct Current

DPI — Drive Peripheral Interface

ENET — Ethernet

ICVC — International Chiller Visual Controller

IGBT — Insulated Gate Bipolar Transistor

I/O — Inputs/Outputs

IP — Internet Protocol

IPWM — Inverter Pulse Width Modulation

MCB — Main Control Board

MOV — Metal Oxide Varistor

PE — Protective Earthing Conductor

SIO — Sensor Input/Output

STS — Status

WARNING

DC bus capacitors retain hazardous voltages after input

power has been disconnected. After disconnecting input

power, wait five (5) minutes for the DC bus capacitors to

discharge and then check the voltage with a voltmeter rated

for the DC bus voltage to ensure the DC bus capacitors are

discharged before touching any internal components. Fail-

ure to observe this precaution could result in severe bodily

injury or loss of life.

An isolated multimeter will be needed to measure DC bus

voltage and to make resistance checks. The drive’s DC bus

capacitors retain hazardous voltages after input power has

been disconnected.

Fig. 1 — Allen Bradley Data Nameplate

A19-1830



711

Opening the VFD Access Door

1. Using recommended screwdriver = 6.4 mm (0.25 in.) flat

or T20 star, open access door. See Fig. 2.

2. Check to be sure that the voltage between DC+ and DC-

and from each DC terminal to the chassis is zero before

proceeding. See Fig. 3.

Drive Assembly Catalog Number — See Fig. 4 for

an example Catalog Number.

Components and Physical Data — The Allen-

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.

19XVR0335... and 19XVR0445... respectively). See Fig. 6.

See Fig. 7 for the dimensions of Frames 6 and 7.

WARNING

Before removing the drive enclosure, open access door and

verify that the DC bus voltage has dropped to zero by

checking the terminals behind the access door. Failure to

observe this precaution could result in severe bodily injury

or loss of life.

Fig. 2 — Opening Access Door

A19-1831

L1 L2 L3

DC+ DC–

LOCKOUT/TAGOUT

MULTIMETER

DC BUS TEST

TERMINALS

LOCATED INSIDE

ACCESS DOOR

Fig. 3 — Check DC Bus Terminals

A19-1814

21P 1 0248 3-3-0-0 C-

21P PF755 VFD

Voltage Rating

Customer

C–Carrier

Meter Package

0– No Meter Package

1–Analog Meter Package

– 460 to 480 v, 60 Hz

–380 to 415 v, 50 Hz

–380 to 400 v, 60 Hz

PF755 Full Load Amp Rating

(Maximum Continuous Amps)*

0248 – 248

0361 –361

0477

477

Disconnect/Breaker Options

65 KAIC Capacity Breaker

Input Reactor

0– No Input Reactor

1–3% Input Line Reactor

– 401 to 439 v, 60 Hz

0477

–

477

–

KAIC

Capacity

Breaker

4– 100 KAIC Capacity Breaker

Drive Assembly

3– Unit Mount NEMA 1 Liquid Cooled

Fig. 4 — Drive Assembly Catalog Number Nomenclature

A19-1842

* For Carrier applications, maximum continuous amp

ratings are 230, 335, and 445.

LEGEND

Fig. 5 — Frame 6 Drive Components

NO. NAME DESCRIPTION

1Power Terminals R/L1, S/L2, T/L3, U/T1, V/T2, W/T3

2PE Grounding Studs Terminating point to chassis ground

for incoming motor shield

3DC Bus and Brake

Terminals

+DC, -DC, BR1, BR2

4PE-A and PE-B MOV and CMC Jumper Wires

5DC+ and DC- Bus Voltage Test Points

A19-

1832

LEGEND

Fig. 6 — Frame 7 Drive Components

NO. NAME DESCRIPTION

1Power Terminals R/L1, S/L2, T/L3, U/T1, V/T2, W/T3

2PE Grounding Studs Terminating point to chassis ground

for incoming motor shield

3DC Bus and Brake

Te r m i n a l s

+DC, -DC, BR1, BR2

4PE-A and PE-B MOV and CMC Jumper Wires

5DC+ and DC- Bus Voltage Test Points

A19-1833

START-UP

Alternate Wire Lugs — In the case where the incoming

power wire size does not fit the standard lug, alternate lugs may

be used. See Table 1. Note that lugs rated for a higher current

than the circuit breaker may be used.

Table 1 — Wire Lugs

Verify Installation — Record the following job

information:

1. Job Name

2. Job Number

3. City

4. State

5. Zip Code

Record the following nameplate information:

1. From the Allen-Bradley nameplate (Fig. 1) located inside

the VFD enclosure:

a. Allen-Bradley ID or CAT NO.

b. Allen-Bradley Serial Number

c. Carrier Part Number

2. From the machine nameplete (Fig. 8) located inside the

VFD enclosure:

a. Chiller Serial Number

b. Chiller Model

c. Motor rated load amps

d. Motor nameplate rpm

e. Motor nameplate kW

f. Motor nameplate voltage

g. IPWM (pulse width modulation) frequency

h. Voltage

3. From the drive module label (Fig. 9) located on the drive

module:

a. 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

DANGER

Internal components and circuit boards of the drive are live

when the drive is connected to incoming power. Coming

into contact with this voltage is extremely dangerous and

will result in severe personal injury or death.

The motor terminals U, V, W and the DC-link/brake resis-

tor terminals B+/R+, R- are live when the drive is con-

nected to incoming power, even if the motor is not running.

Do not make any connections when the drive is connected

to the incoming power.

After having disconnected the drive, wait until the indica-

tors on the keypad go out (if no keypad is attached see the

indicator through the keypad base). Wait 5 more minutes

before doing any work on drive connections. Do not even

open the cover before this time has expired..

Before connecting the drive to the incoming power, make

sure that the switchgear enclosure door is closed.

WARNING

The control I/O-terminals are isolated from the mains

potential. However, the relay outputs and other I/O termi-

nals may have a dangerous control voltage present even

when the drive is disconnected from incoming power.

Coming into contact with this voltage could result in severe

personal injury.

Fig. 7 — Enclosure Dimensions - Frames 6 and 7

A19-1834

CAUTION

If other than refrigerant cooling is used, before connecting

the drive to the incoming power, make sure that the coolant

is circulating and has no leaks.

CAUTION

When working with the Drive Explorer, never use the

Rotate function as the motor will immediately start and

severe compressor damage could result.

CIRCUIT

BREAKER

STANDARD

ABB LUG

STANDARD

LUG CABLE

RANGE

ALTERNATE

ABB LUG

ALTERNATE

LUG CABLE

RANGE

65 KAIC

(Standard) K6TJ (3) 2/0 - 400

MCM K6TH (2) 250 - 500

MCM

100 KAIC

(Optional)

Configure the VFD — All configurations required by

the VFD are supplied by the ICVC through the VFD Gateway.

Any configuration changes necessary and possible are made on

the 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. See Table 2.

Table 2 — VFD Configurations

* Parameters marked with an * are not downloadable to the VFD but are used

in other calculations and algorithms in the ICVC.

NOTES:

1. Parameters in italics are to be entered or confirmed at start-up.

2. Parameters in bold are to be changed only after consultation with ser-

vice engineering.

Commissioning the Unit — The commission proce-

dure is as follows:

1. If the chiller has been stored outdoors, allow at least 24

hours room temperature stabilization prior to commis-

sioning. Ensure any condensation that occurs as a result

of the ambient temperature is allowed to evaporate.

2. Enter parameters in the VFD_CONF screen.

3. Install surge suppression devices if required.

4. Review the power wiring and grounding to ensure that it

has been properly connected.

5. Visually examine the inside of the drive enclosure to:

a. Look for signs of corrosion or moisture residue.

b. Remove any dirt or debris.

c. Make sure all vents are clear.

6. Apply power to the drive and take thermal measurements

of the capacitor bank and power connections. Do this

again before start-up.

7. Measure and record the incoming line voltage. Line-to-

line voltages should be balanced within 3% as calculated

by Rockwell’s procedure below:

Measure voltages phase-to-phase and phase-to-ground.

MODEL NUMBER

SERIAL NUMBER

VOLTS/PHASE/HERTZ

LOCKED ROTOR AMPS

OVERLOAD TRIP AMPS

MAX FUSE/CIRCUIT BREAKER SIZE

MIN SUPPLY CIRCUIT AMPACITY

MOTOR NAMEPLATE VOLTAGE

COMPRESSOR 100% SPEED

RATED LINE VOLTAGE

RATED LINE AMPS

RATED LINE KILOWATTS

MOTOR RATED LOAD KW

MOTOR RATED LOAD AMPS

MOTOR NAMEPLATE AMPS

MOTOR NAMEPLATE RPM

MOTOR NAMEPLATE KW

INTERTER PWM FREQUENCY

MACHINE NAMEPLATE SUPPLY DATA

MACHINE ELECTRICAL DATA

SAFETY CODE CERTIFICATION

THE COMPRESSOR MOTOR CONTROLLER AND OVERLOAD PROTECTION MUST BE

IN ACCORDANCE WITH CARRIER SPECIFICATION Z-420.

19XV05008701 REV. 3

A United Technologies Company

Fig. 8 — Machine Nameplate

a19-

1846

Fig. 9 — Drive Module Label

a19-

1924

PARAMETER DEFAULT VALUE

Motor Nameplate Voltage 460

Compressor 100% Speed

Line Freq=60 Hz? (No=50) Yes

Rated Line Voltage* 460

Rated Line Amps* 200

Rated Line Kilowatts * 100

Motor Rated Load kW* 100

Motor Rated Load Amps* 200

Motor Nameplate Amps 100

Motor Nameplate RPM 3456

Motor Nameplate KW 100

Inverter PWM Frequency (0 = 4 kHz, 1 =

2kHz) 1

Skip Frequency 1 (Hz) 102.0

Skip Frequency 2 (Hz) 102.0

Skip Frequency 3 (Hz) 102.0

Skip Frequency Band Line (Hz) 0.0

Voltage % Imbalance 10

Line Volt Imbalance Time (sec) 10

Line Current % Imbalance 40

Line Current Imbal Time (sec) 10

Motor Current % Imbalance 40

Motor Current Imbal Time 10

Increase Ramp Time (sec) 30

Decrease Ramp Time (sec) 30

Single Cycle Dropout (DSABLE/ENABLE) DSABLE

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

8. Take a final thermal measurement of the capacitor bank

and power after finalizing the installation to ensure all

connections are good.

9. If a ground fault occurs, then do the following:

a. Check for a ground in the motor or motor wiring.

b. Check for damage to wiring insulation and that

wiring is dry.

c. Verify the motor wiring is separated from ground

and there is no connection between phases.

d. Check for failed IGBTs.

10. If an Overcurrent fault occurs, then do the following:

a. Check for excessive load and verify load limit set-

tings on the ICVC.

b. Check motor and wiring insulation.

c. Check parameter settings on VFD_CONF screen

in the ICVC.

Check Internal Jumpers — On the Main VFD Con-

trol board there are two jumpers labeled J1 HARDWARE EN-

ABLE and J2 SAFETY ENABLE. J1 should be removed and

J2 should be in place. See Fig. 10.

There are two jumper wires that connect a particular termi-

nal to chassis ground. The MOV and AC EMI jumper should

be connected to the PE-A terminal. The COMMON MODE

CAPACITORS to GROUND jumper should be connected to a

standoff rather than the PE-B terminal.

Use the recommended tools as follows when connecting

jumper wires in Frame 6 and in Frame 7:

• Recommended torque (screws and nuts) = 1.36 N·m

(120.0 lb·in)

• Recommended hex socket = 7 mm

• Recommended screwdriver = T20 star type

See Fig. 11A and Fig. 11B for the correct positions of the

jumpers.

Va v g = (VAB + VBC + VCA)

Imbalance % = (Vmax – Vmin) x 100

Vavg

LEGEND

NO. NAME DESCRIPTION

1HIM Connector DPI Port 1 (HIM Cradle) connection.

2Fan Connector Power supply for internal cooling fan

(Frames 2 & 3).

Battery

Receptacle

User installed CR1220 lithium coin cell

battery provides power to the Real Time

Clock (Optional, not supplied).

4DPI Port 2 Cable connection for handheld and

remote HIM options.

Embedded EtherNet/

IP Address Selectors

Rotary switches for setting lowest octet

of EtherNet address (forces address to

192.168.1.xxx).

6Embedded EtherNet/

IP Connector

Network cable connection.

7Jumper J2 SAFETY Safety enable jumper. Removed when

safety option is installed.

Jumper J1 ENABLE Hardware enable jumper. Removed

when a hardware enable configuration is

utilized.

9TB1 I/O terminal block.

Fig. 10 — PF755 Main Control Board

TB1 I/O Terminal Designations

FIXED I/O TERMINAL NAME DESCRIPTION

Di 0ac Digital Input 120V AC Connections for AC power supply.

Di C Digital Input Common Digital input common

Di 0dc Digital Input 24V DC Connections for DC power supply.

+24V +24 Volt Power Connections for drive supplied 24V power.

24VC 24 Volt Common

IMPORTANT: Wiring to pluggable terminal block connectors

should be supported by wire ties or other means to help pre-

vent unintentional disconnection

Di 0ac

Di C

Di 0dc

+24V

24VC

a19-1921

SERVICE

Troubleshooting the Drive — The drive can display

two kinds of error codes on the 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:

• A warning message on the ICVC is an ALERT.

• The same warning viewed with Rockwell Drive Explorer

is a VFD ALARM.

• A failure resulting in a shutdown is seen as an ALARM

on the ICVC and as a VFD FAULT when viewed with

Drive Explorer.

CONDITION CODES

ICVC ALERT = VFD ALARM

ICVC ALARM = VFD FAULT

See Tables 3-6 and Fig. 12.

ICVC ALERT CODES — An alert condition is indicated by

a message at the top of the ICVC default screen. In addition, an

exclamation point (!) will appear next to any affected point on

an ICVC display screen. The drive will continue to operate

during the alert condition. Investigate the cause of the alert to

ensure it does not lead to a fault condition. The alert code will

automatically be cleared from the ICVC when the condition

causing the alert no longer exists. See Table 4.

ICVC ALARM CODES — An alarm condition is also indi-

cated by a message at the top of the ICVC default screen. If an

alarm occurs, the drive coasts to stop. The STS (status) light on

the drive will turn from Green to Red or Yellow (see Table 3).

The detected fault message is maintained on the display until it

is cleared by pressing the RESET softkey. See Table 5.

TEST EQUIPMENT NEEDED TO TROUBLESHOOT —

An isolated multimeter adequately rated for the DC bus volt-

age will be needed to measure DC bus voltage and to make

resistance checks. Note that dedicated troubleshooting test

points are not provided.

WARNING

DC bus capacitors retain hazardous voltages after input

power has been disconnected. After disconnecting input

power, wait five (5) minutes for the DC bus capacitors to

discharge and then check the voltage with a voltmeter to

ensure the DC bus capacitors are discharged before touch-

ing any internal components. Failure to observe this pre-

caution could result in severe bodily injury or loss of life.

Fig. 11A — Jumper Wire Locations — Frame 6

A19-1835

Fig. 11B — Jumper Wire Locations — Frame 7

A19-1836

Allen-Bradley

Fig. 12 — Drive Status Indicator

1815

Table 3 — Drive Status Indicator Descriptions

NOTES:

1. A Type 1 alarm indicates that a condition exists. Type 1 alarms

are user configurable.

2. A Type 2 alarm indicates that a configuration error exists and

the drive cannot be started. Type 2 alarms are not configurable.

VERIFYING THAT DC BUS CAPACITORS ARE DIS-

CHARGED — The drive’s DC bus capacitors retain hazard-

ous voltages after input power has been disconnected. Perform

the following steps before touching any internal components:

1. Turn off and lock out input power. Wait five minutes.

2. Verify that there is no voltage at the drive’s input power

terminals.

3. Measure the DC bus potential with a voltmeter while

standing on a non-conductive surface and wearing insu-

lated gloves (1000 V). Measure the DC bus potential. See

Fig. 5 for the 248-amp drive and Fig. 6 for the 361 and

477-amp drives. The voltage between DC+ and DC-, and

from each DC terminal to the chassis must be zero before

proceeding.

4. Once the drive has been serviced, reapply input power.

HIGH TEMPERATURE ALARMS — Coolant flow

through the cold plate is controlled by an orifice in the refriger-

ant line leaving the cold plate. The orifice looks like one of the

O-ring face seal connectors and in fact is used as one of the

connections on the coolant tubing. The difference is that the

passage through the fitting is 0.375 in. (9.5 mm). If the orifice

is present and condenser liquid flow is present, the liquid will

flash to cooler temperature at the orifice. This temperature dif-

ference is great enough to be easily felt.

MAIN CONTROL BOARD (MCB) COMPONENTS —

Figure 13 shows the drive module with the cover removed. To

access the control boards, loosen the screw on the face of the

keypad mount and swing the keypad mount upward.

The components on the main control board (MCB) are

shown in Fig. 14. Note the location of the terminals labeled

MCB I/O. The high pressure switch is wired to these terminals

as shown in Fig. 15. In the event of a high condenser pressure

alarm, the connections at these terminals should be checked

and tightened if necessary.

A typical wiring schematic is shown in Appendix A.

NAME COLOR STATE DESCRIPTION

STS (Status)

Green Flashing Drive ready but not running, and no faults are present.

Steady Drive running, no faults are present.

Yellow Flashing Drive is not running. A type 2 (non-configurable) alarm condition exists and the

drive cannot be started.

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

Red Flashing A major fault has occurred. Drive cannot be started until fault condition is

cleared.

Steady A non-resettable fault has occurred.

Red/Yellow Flashing Alternately A minor fault has occurred. When running, the drive continues to run. System is

brought to a stop under system control. Fault must be cleared to continue. Use

parameter 950 [Minor Flt Config] to enable. If not enabled, acts like a major

fault.

Green/Red Flashing Alternately Drive is flash updating.

ENET

None (Unlit) Off Adapter and/or network is not powered, adapter is not properly connected to

the network, or adapter needs an IP address.

Red Flashing An EtherNet/IP connection has timed out.

Steady Adapter failed the duplicate IP address detection test.

Red/Green Flashing Alternately Adapter is performing a self-test.

Green Flashing Adapter is properly connected but is not communicating with any devices on

the network.

Steady Adapter is properly connected and communicating on the network.

LINK

None (Unlit) Off Adapter is not powered or is not transmitting on the network.

Green Flashing Adapter is properly connected and transmitting data packets on the network.

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

SWING UP KEY PAD

MOUNT TO ACCESS

CONTROL BOARDS

Fig. 13 — Drive Module with Cover Removed

a19-1843

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

a19-1844

*Located outside of starter; connected by field wiring.

Fig. 15 — High Pressure Switch Wiring

a19-1925

Table 4 — ICVC Alert Codes

PRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is

necessary.

*[LIMIT] is shown on the ICVC as temperature, pressure, voltage, etc., predefined or selected by the operator as an override or an alert. [VALUE] is

the actual pressure, temperature, voltage, etc., at which the control tripped.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

100 PRESTART

ALERT

STARTS LIMIT

EXCEEDED

100Excessive compressor starts

(8 in 12 hours).

Depress the RESET softkey if additional start

is required. Reassess start-up requirements.

101 PRESTART

ALERT

HIGH BEARING

TEMPERATURE

101Comp Thrust Brg Temp [VALUE]

exceeded limit of [LIMIT]*.

Check oil heater for proper operation.

Check for low oil level, partially closed oil sup-

ply valves, clogged oil filters.

Check the sensor wiring and accuracy.

Check Comp Thrust Brg Alert setting in

SETUP1 screen.

102 PRESTART

ALERT

HIGH MOTOR

TEMPERATURE

102Comp Motor Winding Temp

[VALUE] exceeded limit of [LIMIT]*.

Check motor sensors for wiring and accuracy.

Check motor cooling line for proper operation,

or restrictions.

Check for excessive starts within a short time

span.

Check Comp Motor Temperature Override

setting in SETUP1 screen.

103 PRESTART

ALERT

HIGH

DISCHARGE

TEMP

103Comp Discharge Temp [VALUE]

exceeded limit of [LIMIT]*.

Allow discharge sensor to cool.

Check sensor wiring and accuracy.

Check for excessive starts.

Check Comp Discharge Alert setting in

SETUP1 screen.

104 PRESTART

ALERT

LOW

REFRIGERANT

TEMP

104Evaporator Refrig Temp [VALUE]

exceeded limit of [LIMIT]*.

Check transducer wiring and accuracy.

Check for low chilled fluid supply

temperatures.

Check refrigerant charge.

Check Refrig Override Delta T in SETUP1

screen.

105 PRESTART

ALERT

LOW OIL

TEMPERATURE

105Oil Sump Temp [VALUE]

exceeded limit of [LIMIT]*.

Check oil heater contactor/relay and power.

Check oil level and oil pump operation.

106 PRESTART

ALERT

HIGH

CONDENSER

PRESSURE

106Condenser Pressure [VALUE]

exceeded limit of [LIMIT]*.

Check transducer wiring and accuracy.

Check for high condenser water

temperatures.

Check high condenser pressure switch wiring.

107 PRESTART

ALERT

LOW LINE

VOLTAGE

107Percent Line Voltage [VALUE]

exceeded limit of [LIMIT]*.

Check voltage supply.

Check voltage transformers and switch gear.

Consult power utility if voltage is low.

108PRESTART

ALERT

HIGH LINE

VOLTAGE

108Percent Line Voltage [VALUE]

exceeded limit of [LIMIT]*.

Check voltage supply.

Check power transformers.

Consult power utility if voltage is high.

109 PRESTART

ALERT

GUIDE VANE

CALIBRATION

109Actual Guide Vane Pos

Calibration Required Before Startup.

Press STOP button on ICVC and perform

Guide Vane Calibration in Controls Test

screen.

Check guide vane actuator feedback

potentiometer.

110 PRESTART

ALERT

HIGH

RECTIFIER

TEMP

110Rectifier Temperature [VALUE]

exceeded limit of [LIMIT]*.

Check that VFD refrigerant isolation valves

are open.

Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation

and blockage.

111 PRESTART

ALERT

HIGH

INVERTER

TEMP

111Inverter Temperature [VALUE]

exceeded limit of [LIMIT]*.

Check that VFD refrigerant isolation valves

are open.

Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation

and blockage.

Table 4 — ICVC Alert Codes (cont)

NORMAL RUN WITH OVERRIDES

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

120 RUN CAPACITY

LIMITED

HIGH CONDENSER

PRESSURE

120Condenser Pressure

[VALUE] exceeded limit of

[LIMIT]*.

Check condenser water pump operation.

Check for high condenser water temperatures or

low flow rate. Verify that isolation valves are

open.

Check Cond Press Override setting in SETUP1.

121 RUN CAPACITY

LIMITED

HIGH MOTOR

TEMPERATURE

121Comp Motor Winding

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check for closed valves or restriction in motor

cooling lines.

Check for closed refrigerant isolation valves.

Check Comp Motor Temp Override setting in

SETUP1.

122 RUN CAPACITY

LIMITED

LOW EVAP REFRIG

TEMP

122Evaporator Refrig

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check refrigerant charge.

Check that optional cooler liquid line isolation

valve is fully open.

Check for excessive condenser flow or low

chilled water flow.

Check for low entering cooler temperature.

Check that condenser inlet and outlet water

nozzles are piped correctly.

Check for waterbox division plate gasket bypass.

123 RUN CAPACITY

LIMITED

HIGH COMPRESSOR

LIFT

123Surge Prevention

Override: Lift Too High For

Compressor

Check for high condenser water temperature or

low suction temperature.

Check for high Evaporator or Condenser

approaches.

Check surge prevention parameters in

OPTIONS screen.

124 RUN CAPACITY

LIMITED

MANUAL GUIDE VANE

TA R G E T

124Run Capacity Limited:

Manual Guide Vane Target.

Target Guide Vane Position has been forced in

the COMPRESS screen. Select and RELEASE

force to return to normal (automatic) operation.

125 RUN CAPACITY

LIMITED

LOW DISCHARGE

SUPERHEAT

No Alert message. Check for oil loss or excess refrigerant charge.

Verify that the valves in the oil reclaim lines are

open.

126 RUN CAPACITY

LIMITED

HIGH RECTIFIER TEMP 126Rectifier Temperature

[VALUE] exceeded limit of

[LIMIT]*.

Check Rectifier Temp Override in SETUP1

screen.

Check that VFD refrigerant isolation valves are

open.

Check VFD refrigerant cooling solenoid.

Check for proper VFD cooling fan operation and

blockage.

127 RUN CAPACITY

LIMITED

MANUAL SPEED

CONTROL

No Alert message. Chiller is not in automatic temperature control.

128RUN CAPACITY

LIMITED

HIGH INVERTER TEMP 128Inverter Temperature

[VALUE] exceeded limit of

[LIMIT]*.

Check Inverter Temp Override in SETUP1

screen.

Check that VFD refrigerant isolation valves are

open.

Check VFD refrigerant cooling solenoid.

Check for proper VFD cooling fan operation and

blockage.

Table 4 — ICVC Alert Codes (cont)

CHILLER ALERTS

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

140 SENSOR ALERT LEAVING COND WATER

TEMP

140Sensor Fault: Check

Leaving Cond Water Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

141 SENSOR ALERT ENTERING COND WATER

TEMP

141Sensor Fault: Check

Entering Cond Water Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

142 LOW OIL

PRESSURE ALERT

CHECK OIL FILTER 142Low Oil Pressure Alert.

Check Oil Filter.

Check for partially or closed shut-off valves.

Check oil filter.

Check oil pump and power supply.

Check oil level.

Check for foaming oil at start-up.

Check transducer wiring and accuracy.

143 AUTORESTART

PENDING

LINE CURRENT

IMBALANCE

143Line Current Imbal-

ance: Check VFD Fault His-

tory for Values.

Power loss has been detected in any phase.

Chiller automatically restarting.

144 AUTORESTART

PENDING

LINE VOLTAGE

DROP OUT

144Single Cycle Line

Voltage Dropout.

A drop in line voltage has been detected within

2 voltage cycles.

Chiller automatically restarting if Auto Restart is

enabled in OPTIONS screen.

145 AUTORESTART

PENDING

HIGH LINE VOLTAGE 145High Percent Line

Voltage [VALUE].

Check phase to phase and phase to ground line

power.

146 AUTORESTART

PENDING

LOW LINE VOLTAGE 146Low Percent Line

Voltage [VALUE].

Check phase to phase and phase to ground line

power.

147 AUTORESTART

PENDING

VFD MODULE RESET 147->VFD Module Power-On

Reset When Running.

VFD Module has detected a hardware fault due

to electrical noise, power loss or software and

has reset. Chiller automatically restarting.

Check for power loss and sources of electro-

magnetic interference.

148AUTORESTART

PENDING

POWER LOSS 148Control Power-Loss

When Running.

Check 24 vac control power supply to ICVC.

149 SENSOR ALERT HIGH DISCHARGE TEMP 149Comp Discharge Temp

[VALUE] Exceeded Limit of

[LIMIT]*.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for proper inlet guide vane and optional

diffuser actuator operation.

Check for proper condenser flow and

temperature.

Check for high lift or low load.

Check for fouled tubes or noncondensables in

the chiller.

150 SENSOR ALERT HIGH BEARING

TEMPERATURE

150Comp Thrust Brg Temp

[VALUE] exceeded limit of

[LIMIT]*.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for partially closed service valves.

Check oil cooler TXV.

Check oil level and oil temperature.

151 CONDENSER

PRESSURE ALERT

PUMP RELAY

ENERGIZED

151High Condenser Pres-

sure [VALUE]: Pump Ener-

gized to Reduce Pressure.

Check sensor wiring and accuracy.

Check condenser flow and water temperature.

Check for fouled tubes.

This alarm is not caused by the High Pressure

Switch.

152 RECYCLE ALERT EXCESSIVE RECYCLE

STARTS

152Excessive recycle

starts.

Chiller load is too low to keep compressor on

line and there has been more than 5 starts in

4 hours.

Increase chiller load, adjust hot gas bypass,

increase RECYCLE RESTART DELTA T from

SETUP1 Screen.

153 no message:

ALERT

only

no message; ALERT only 153Lead/Lag Disabled-

Config: Duplicate Chiller

Address.

Illegal chiller address configuration in Lead/Lag

screen. Both chillers require a different address.

154 POTENTIAL

FREEZE-UP

COND PRESS/TEMP

TOO LOW

154Condenser freeze up

prevention.

The condenser pressure transducer is reading a

pressure that could freeze the condenser tubes.

Check for condenser refrigerant leaks.

Check fluid temperature.

Check sensor wiring and accuracy.

Place the chiller in PUMPDOWN mode if the

vessel is evacuated.

155 OPTION SENSOR

FAULT

REMOTE RESET

SENSOR

155Sensor Fault/Option

Disabled: Remote Reset

Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring to CCM connector J4.

156 OPTION SENSOR

FAULT

AUTO CHILLED WATER

RESET

156Sensor Fault/Option

Disabled: Auto Chilled Water

Reset.

Check sensor resistance or voltage drop.

Check for proper wiring to CCM connector J5.

157 OPTION SENSOR

FAULT

AUTO DEMAND LIMIT

INPUT

157Sensor Fault/Option

Disabled: Auto Demand Limit

Input.

Check sensor resistance or voltage drop.

Check for proper wiring to CCM connector J5.

158SENSOR ALERT SPARE TEMPERATURE

158Spare Temperature 1

[VALUE] exceeded limit of

[LIMIT]*.

Check sensor resistance or voltage drop.

Check for proper wiring to CCM connector J4.

Check Spare Temp #1 Limit in SETUP1 screen.

Table 4 — ICVC Alert Codes (cont)

CHILLER ALERTS (cont)

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

159 SENSOR ALERT SPARE TEMPERATURE

159Spare Temperature 2

[VALUE] exceeded limit of

[LIMIT]*.

Check sensor resistance or voltage drop.

Check for proper wiring to CCM connector J4.

Check Spare Temp #2 Limit in SETUP1 screen.

161 LOSS OF

COMMUNICATION

WITH WSM 161WSM Cool Source —

Loss of Communication.

Check settings in WSMDEFME screen.

Check CCN communications link with WSM

(Water System Manager) Module.

Check Supervisory Part of WSM.

162 SENSOR ALERT EVAPORATOR

APPROACH

162Evaporator Approach

[VALUE] Exceeded Limit of

[LIMIT]*.

Check that refrigerant charge level is adequate,

waterbox division plate gaskets are sealing,

evaporator tubes are not fouled and that oil

reclaim system is working.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check Evap Approach Alert setting in SETUP1

screen.

163 SENSOR ALERT CONDENSER APPROACH 163Condenser Approach

[VALUE] Exceeded Limit of

[LIMIT]*.

Check sensors resistance or voltage drop.

Check for proper wiring.

Check Cond Approach Alert setting in SETUP1

screen.

Check for noncondensable gas in the

condenser.

Check that the condenser tubes are not fouled.

164 VFD SPEED ALERT LOW VFD SPEED 164Actual VFD Speed

exceeded limit of Target VFD

Speed –10%.

Actual VFD Speed on COMPRESS screen must

be at least 90% of Target VFD Speed.

165 AUTORESTART

PENDING

LOW DC BUS VOLTAGE 165Low DC Bus Voltage:

[VALUE] Exceeded Limit of

[LIMIT]*.

Verify phase to phase and phase to ground line

voltage.

166 AUTORESTART

PENDING

HIGH DC BUS VOLTAGE 166High DC Bus Voltage:

[VALUE] Exceeded Limit of

[LIMIT]*.

Verify phase to phase and phase to ground line

voltage. Monitor AC line for high transient volt-

age conditions.

167 SYSTEM ALERT HIGH DISCHARGE TEMP 167Comp Discharge Temp

[VALUE] exceeded limit of

[LIMIT]*.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for excessive starts.

Check Comp Discharge Alert setting in SETUP1

screen.

168SENSOR ALERT HUMIDITY SENSOR

INPUT

168Sensor Fault: Check

Humidity Sensor Input Sensor.

Check humidity sensor wiring on CCM connec-

tors J3 and J5. CCM switch SW2-1 must be in

“OFF” position.

Check Humidity Sensor Input in Controls Test.

Table 5 — ICVC Alarm Codes

CHILLER PROTECTIVE LIMIT FAULTS

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

NOTE: ICVC Alarms 212-226 are declared as a result of VFD Faults.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

200 PROTECTIVE LIMIT RECTIFIER POWER

FAULT

200Rectifier Power Fault:

Check VFD Status.

Malfunction within VFD Power Module.

Call Carrier Service.

201 PROTECTIVE LIMIT INVERTER POWER FAULT 201Inverter Power Fault:

Check VFD Status.

Malfunction within VFD Power Module.

Call Carrier Service.

202 PROTECTIVE LIMIT MOTOR AMPS NOT

SENSED

202Motor Amps Not

Sensed — Average Load

Current [VALUE].

Check main circuit breaker for trip. Increase

Current % Imbalance in VFD_CONF screen.

203 FAILURE TO START MOTOR ACCELERATION

FAULT

203Motor Acceleration Fault

— Average Load Current

[VALUE].

Check that inlet guide vanes are fully closed at

start-up.

Check Motor Rated Load Amps in VFD_CONF

screen. Reduce unit pressure if possible.

204 FAILURE TO STOP VFD SHUTDOWN FAULT 204VFD Shutdown Fault:

Check Inverter Power Unit.

VFD Circuit Board malfunction.

Call Carrier Service.

205 PROTECTIVE LIMIT HIGH DC BUS VOLTAGE 205High DC Bus Voltage:

[VALUE] exceeded limit of

[LIMIT]*.

Verify phase to phase and phase to ground line

voltage. Monitor AC line for high transient volt-

age conditions. VFD Circuit Board malfunction.

Call Carrier Service.

206 PROTECTIVE LIMIT VFD FAULT 206VFD Fault Code:

[VALUE]; Check VFD Fault

Code List.

See VFD Fault Code description and corrective

action.

207 PROTECTIVE LIMIT HIGH CONDENSER

PRESSURE

207High Cond Pressure

trip. [VALUE] exceeded Switch

Trippoint.

Check Compressor Discharge High Pressure

switch wiring and accuracy.

Check for high condenser water temperatures,

low water flow, fouled tubes.

Check for division plate/gasket bypass.

Check for noncondensables in refrigerant.

208PROTECTIVE LIMIT EXCESSIVE MOTOR

AMPS

208Percent Load Current

[VALUE] exceeded limit of

[LIMIT]*.

Check Motor Rated Load Amps in VFD_CONF

screen. Percent Load Current > 110%.

Check Motor Rated Load Amps setting.

209 PROTECTIVE LIMIT LINE CURRENT

IMBALANCE

209Line Current Imbal-

ance: Check VFD Fault His-

tory for Values.

Check phase to phase and phase to ground

power distribution bus voltage.

Check Line Current % Imbalance in VFD_CONF

screen. Consult power company.

210 PROTECTIVE LIMIT LINE VOLTAGE DROPOUT 210Single Cycle Line Volt-

age Dropout.

Temporary loss of voltage. Disable Single Cycle

Dropout in VFD_CONF screen.

211 PROTECTIVE LIMIT HIGH LINE VOLTAGE 211High Percent Line Volt-

age [VALUE].

Check phase to phase and phase to ground dis-

tribution bus voltage. Consult power company.

212 PROTECTIVE LIMIT LOW LINE VOLTAGE 212Low Percent Line Volt-

age [VALUE].

Check phase to phase and phase to ground dis-

tribution bus voltage. Consult power company.

213 PROTECTIVE LIMIT VFD MODULE RESET 213VFD Module Power-On

Reset When Running.

Temporary loss of VFD control voltage. Check

VFD control power breaker, transformer and

fuses.

214 PROTECTIVE LIMIT POWER LOSS 214Control Power Loss

When Running.

Check phase to phase and phase to ground dis-

tribution bus voltage.

Check VFD fuses.

Check 24 vac power supply to ICVC.

Consult power company.

215 PROTECTIVE LIMIT LOW DC BUS VOLTAGE 215Low DC Bus Voltage:

[VALUE] exceeded limit of

[LIMIT]*.

Verify phase-to-phase and phase-to-ground line

voltage. VFD Circuit Board malfunction.

Call Carrier Service.

216 PROTECTIVE LIMIT LINE VOLTAGE

IMBALANCE

216Line Voltage Imbal-

ance. Check VFD Fault His-

tory for Values.

Check phase-to-phase and phase-to-ground

distribution bus voltage. Increase Line Voltage

% Imbalance in VFD_CONF screen.

217 PROTECTIVE LIMIT MOTOR OVERLOAD TRIP 217Motor Overload Trip;

Check VFD configurations.

Any phase current > 106% Rated Load Amps.

Can result from significant load side current

imbalance when running at full load.

Check entering condenser water temperature

and water flow rate.

Check Motor Rated Load Amps in VFD_CONF

screen.

218PROTECTIVE LIMIT VFD RECTIFIER

OVERTEMP

218VFD Rectifier Temp

Exceeded: Check Cooling and

VFD Config.

Check that VFD refrigerant isolation valves are

open.

Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation and

blockage.

219 PROTECTIVE LIMIT VFD INVERTER

OVERTEMP

219VFD Inverter Temp

Exceeded: Check Cooling and

VFD Config.

Check that VFD refrigerant isolation valves are

open.

Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation and

blockage.

Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

220 PROTECTIVE LIMIT GROUND FAULT 220Ground Fault Trip;

Check Motor and Current

Sensors.

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.

221 PROTECTIVE LIMIT UNUSED 221UNUSED

222 PROTECTIVE LIMIT LINE FREQUENCY TRIP 222Line Frequency —

[VALUE] exceeded limit of

[LIMIT]; Check Power Supply.

If operating from a generator, check generator

size and speed.

Check utility power supply.

223 LOSS OF

COMMUNICATION

WITH VFD GATEWAY

MODULE

223Loss of SIO Comm with

VFD Gateway: Check VFG

Module and Power.

Check VFD communication wiring and

connectors on VFD Gateway and DPI board.

Check for compatibility between ICVC and

Gateway software.

224 PROTECTIVE LIMIT VFD COMMUNICATIONS

FAULT

224Loss of DPI Comm with

VFD Gateway: Check VFG to

VFD Comm.

Check VFD communication wiring and

connectors.

Check status lights on DPI Communications

Interface Board.

Call Carrier Service.

225 PROTECTIVE LIMIT MOTOR CURRENT

IMBALANCE

225Motor Current Imbal-

ance: Check VFD Fault

History for Values.

Check Motor Current % Imbalance in

VFD_CONF screen.

226 PROTECTIVE LIMIT LINE PHASE REVERSAL 226Line Phase Reversal:

Check Line Phases.

Reverse connections of any two line conductors

to circuit breaker.

227 PROTECTIVE LIMIT OIL PRESS SENSOR

FAULT

227Oil Pressure Delta P

[VALUE] (Pump Off): Check

Pump/Transducers.

Check transducer wiring and accuracy.

Check power supply to pump.

Check pump operation.

Check transducer calibration.

228PROTECTIVE LIMIT LOW OIL PRESSURE 228Low Operating Oil

Pressure [VALUE]: Check Oil

Pump and Filter.

Check transducer wiring and accuracy.

Check power supply to pump.

Check pump operation.

Check oil level.

Check for partially closed service valves.

Check oil filters.

Check for foaming oil at start-up.

Check transducer calibration.

229 PROTECTIVE LIMIT LOW CHILLED WATER

FLOW

229Low Chilled Water Flow;

Check Switch/Delta P Config

& Calibration.

Perform pump control test.

Check optional transducer calibration and

wiring.

Check Evaporator Refrigerant Temperature

sensor.

Check chilled water valves.

Check for evaporator saturation temperature

< 34 F if not in Pumpdown Lockout mode. Place

unit in Pumpdown mode before removing

charge.

230 PROTECTIVE LIMIT LOW CONDENSER

WATER FLOW

230Low Condenser Water

Flow; Check Switch/Delta P

Config & Calibration.

Perform pump control test.

Check optional transducer calibration and

wiring.

Check condenser water valves.

Check for COND PRESS OVERRIDE + 5 psig.

231 PROTECTIVE LIMIT HIGH DISCHARGE TEMP 231Comp Discharge Temp

[VALUE] Exceeded Limit of

[LIMIT]*.

Check for closed compressor discharge isola-

tion valve.

Check if chiller was operating in surge.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for proper condenser flow and

temperature.

Check compressor discharge isolation valve.

Check for proper inlet guide vane and optional

diffuser actuator operation.

232 PROTECTIVE LIMIT LOW REFRIGERANT

TEMP

232Evaporator Refrig Temp

[VALUE] exceeded limit of

[LIMIT]*.

Check for proper refrigerant charge.

Check float valve operation.

Check for closed condenser liquid line isolation

valve. If problem occurs at high load, check for

low condenser pressure which causes inade-

quate flasc orifice differential pressure.

Check for proper water flow and temperature.

Confirm that condenser water enters bottom row

of condenser tubes first.

Check Evaporator Refrigerant Temperature

sensor.

Check for division plate gasket bypass.

Check for fouled tubes.

Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

233 PROTECTIVE LIMIT HIGH MOTOR

TEMPERATURE

233Comp Motor Winding

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check motor sensors wiring and accuracy.

Check motor cooling line and spray nozzle for

proper operation, or restrictions.

Check for excessive starts within a short time

span.

234 PROTECTIVE LIMIT HIGH BEARING

TEMPERATURE

234Comp Thrust Brg Temp

[VALUE] exceeded limit of

[LIMIT]*.

Check oil heater for proper operation.

Check for low oil level, partially closed oil supply

valves, or clogged oil filter.

Check oil cooler refrigerant thermal expansion

valves.

Confirm that TXV (thermostatic expansion valve)

bulb is secured in place and insulated.

Check for sensor wiring and accuracy.

This fault can result from extended operation at low

load with low water flow to the evaporator or

condenser.

235 PROTECTIVE LIMIT HIGH CONDENSER

PRESSURE

235Condenser Pressure

[VALUE] exceeded limit of

[LIMIT]*.

Check for high condenser water temperatures, low

water flow, fouled tubes.

Check for division plate/gasket bypass.

Check for noncondensables.

Check transducer wiring and accuracy.

236 PROTECTIVE LIMIT COMPRESS SURGE/

LOW SPEED

236Compressor Surge:

Check condenser water temp

and flow.

Check for high condenser water temperatures, low

water flow, fouled tubes.

Check for division plate/gasket bypass.

Check for noncondensables.

Check surge prevention parameters in OPTIONS

screen. Increase VFD Increase Step in SETUP2.

Check VFD Minimum Speed in SETUP2 screen.

237 PROTECTIVE LIMIT SPARE SAFETY

DEVICE

237Spare Safety Device. Spare safety input has tripped or factory installed

jumper is not present on Terminal Block 4 terminals

17 and 20 in the VFD enclosure.

238PROTECTIVE LIMIT EXCESSIVE COMPR

SURGE

238Compressor Surge:

Check condenser water temp

and flow.

Check for high condenser water temperatures, low

water flow, fouled tubes.

Check for division plate/gasket bypass.

Check for noncondensables.

Check surge prevention parameters in OPTIONS

screen.

Check cooling tower control settings and perfor-

mance to design/selection temperatures across the

entire operating range of the chiller.

Check cooler approach and water flow.

239 PROTECTIVE LIMIT TRANSDUCER

VOLTAGE FAULT

239Transducer Voltage Ref

[VALUE] exceeded limit of

[LIMIT]*.

Check that CCM transducer voltage reference is

between 4.5 v and 5.5 v.

Check that pressure transducers are not shorted to

ground. This fault is normally declared the first time

an ICVC is powered up if it was downloaded with

software when it was not connected to a CCM.

Call Carrier Service.

240 PROTECTIVE LIMIT LOW DISCHARGE

SUPERHEAT

240Check for Oil in Or

Overcharge of Refrigerant.

Check for oil loss or excessive refrigerant. If oil level

is low, refrigerant charge may be too low resulting in

ineffective oil reclaim. Excessive refrigerant charge

may cause liquid carryover into compressor.

Check calibration of evaporator pressure and con-

denser pressure sensors.

Check calibration of compressor discharge temper-

ature sensor.

241 PROTECTIVE LIMIT RECTIFIER

OVERCURRENT

241Rectifier Overcurrent

Fault: Check VFD Status.

Check for high water temperatures or changes in

water flow rates.

242 LOSS OF

COMMUNICATION

WITH CCM MODULE 242Loss of Communica-

tion With CCM, Check

Comm. Connectors.

Check wiring and control power to CCM.

Confirm that all CCM SW1 switches are in the

“OFF” position.

243 POTENTIAL

FREEZE-UP

EVAP PRESS/TEMP

TOO LOW

243Evaporator Refrig

Temp [VALUE] exceeded

limit of [LIMIT]*.

Check for proper refrigerant charge.

Check float valve operation.

Check for proper fluid flow and temperature.

Confirm that condenser water enters bottom row

of condenser tubes first.

Check Evaporator Refrigerant Temperature

sensor.

Check for division plate gasket bypass.

Check for fouled tubes.

244 POTENTIAL

FREEZE-UP

COND PRESS/TEMP

TOO LOW

244Condenser Refrig

Temp [VALUE] exceeded

limit of [LIMIT]*.

Condenser water too cold or chiller shut down with

brine below 32 F in cooler so equalization tempera-

ture in chiller approached 32 F.

Check condenser pressure transducer.

Check refrigerant charge.

Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

245 PROTECTIVE LIMIT HIGH VFD SPEED 245Actual VFD Speed

exceeded limit of Target VFD

Speed + 10%.

Actual VFD Speed on COMPRESS screen must

not exceed Target VFD Speed by more than

10%.

246 PROTECTIVE LIMIT INVALID DIFFUSER

CONFIG.

246Diffuser Control Invalid

Configuration: Check SETUP2

Entries.

Check 25%, 50%, and 75% Guide Vane and Dif-

fuser Load Point entries in SETUP2 screen.

247 PROTECTIVE LIMIT DIFFUSER POSITION

FAULT

247Diffuser Position Fault:

Check Guide Vane/Diffuser

Actuator.

Confirm that Diffuser Option in SETUP 2 screen

has not been Enabled if compressor does not

have a split ring diffuser. May indicate rotating

stall condition.

Check rotating stall transducer wiring accuracy

and sealing.

Check diffuser schedule and guide vane sched-

ule in SETUP2 screen.

Check for proper operation of diffuser and inlet

guide vane actuators including inlet guide vane

calibration.

Check diffuser actuator coupling for rotational

slip.

Check RC snubber on CCM J4-23 and J4-24.

Check 4.3k ohm resistor between CCM termi-

nals J3-7 and J3-8.

Check for electrical noise in CCM Diffuser Pres-

sure wiring. Do not continue to operate com-

pressor except for diagnostic purposes.

248PROTECTIVE LIMIT SPARE TEMPERATURE

248Spare Temperature #1

[VALUE] exceeded limit of

[LIMIT]*.

Check Spare Temperature Enable and Spare

Temperature Limit in SETUP1 Screen.

249 PROTECTIVE LIMIT SPARE TEMPERATURE

249Spare Temperature #2

[VALUE] exceeded limit of

[LIMIT]*.

Check Spare Temperature Enable and Spare

Temperature Limit in SETUP1 Screen.

250 UNUSED UNUSED 250Unused State.

251 PROTECTIVE LIMIT VFD CONFIG CONFLICT 251VFD Config Conflict

(VFD Uploaded): Verify to

Reset Alarm.

The VFD_CONF table in the Gateway does not

match that which is in the ICVC. This is a normal

fault if an ICVC has been uploaded with soft-

ware when it was not attached to the CCM.

Enter VFD_CONF screen and then exit

VFD_CONF screen by pressing EXIT then

CANCEL. Re-enter the VFD_CONF screen,

press EXIT then SAVE. Parameters stored in

the Gateway will be uploaded into the ICVC.

Confirm valid settings in VFD_CONF screen.

252 PROTECTIVE LIMIT VFD CONFIG CONFLICT 252VFD Config Conflict

(VFD Downloaded): Verify to

Reset Alarm.

The VFD_CONF table in the Gateway does not

match that which is in the ICVC.

253 PROTECTIVE LIMIT GUIDE VANE

CALIBRATION

253Guide Vane Fault

[VALUE]. Check Calibration.

Enter CONTROL TEST and execute Guide

Vane Calibration.

Check CCM guide vane feedback terminals J4-9

and J4-10.

Check guide vane feedback potentiometer.

Alarm before start indicates guide vane opening

is not less than 4%. Alarm running indicates

guide vane position is < -1% or > 103%, or feed-

back voltage is < .045 or > 3.15 VDC.

254 PROTECTIVE LIMIT VFD CHECKSUM ERROR 254Checksum Error:

Press Reset to Restore

Configuration

Actual VFD checksum does not match calcu-

lated value.

255 PROTECTIVE LIMIT VFD DEW PREVENTION 255Dew Prevention - Cool-

ant Too Cold. Check Solenoid

& Cond T.

VFD COLDPLATE TEMP is too close to dew

point based on VFD ENCLOSURE TEMP and

RELATIVE HUMIDITY in POWER screen.

Check for moisture in VFD enclosure.

Check Humidity Sensor in CONTROLS TEST.

Check for contamination on CCM J3-7 and J3-9

Humidity Sensor.

Check that VFD refrigerant cooling modulating

valve is closing.

256 PROTECTIVE LIMIT INDUCTOR OVERTEMP 256Inductor Overtemp Trip -

Check Temp Switch and Cool-

ing Fans.

Check for cooling fan air flow obstructions.

257 PROTECTIVE LIMIT VFD START INHIBIT 257VFD Start Inhibit: Check

VFD Diagnostic Parameters

212/214.

The VFD Start Inhibit is derived from the Alarm

bit being set in the VFD. The conditions causing

the alarm must be corrected in the VFD to

enable subsequent starts and operation. See

VFD parameters 212/214.

258UNUSED STATE UNUSED 258Unused.

Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or selected by the operator as an override, alert, or

alarm condition. [VALUE] is the actual pressure, temperature, voltage, etc., at which the control tripped.

OUT-OF-RANGE SENSOR

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

259 PROTECTIVE LIMIT CCN OVERRIDE STOP 259CCN Emergency/

Override Stop.

CCN has signaled the chiller to stop.This fault

must be manually reset from the default screen

of the ICVC.

282 PROTECTIVE LIMIT INVALID VFD CONFIG 282Line Frequency

[VALUE] Exceeded Configura-

tion Range.

LINE FREQUENCY in POWER screen must be

maintained between 45-52 Hz if LINE

FREQ=60Hz? is set to NO(50 Hz). LINE FRE-

QUENCY must be maintained between

55-62 Hz if LINE FREQ=60Hz? is set to YES

(60 Hz).

Check high pressure switch and connections to

TB4-24 and TB4-25.

283 PROTECTIVE LIMIT INVALID VFD CONFIG 283Compressor 100%

Speed Config Ranges: 50=Hz

45-52; 60 Hz=55-62.

COMPRESSOR 100% SPEED in VFD_CONF

screen must be set between 45-52 Hz if LINE

FREQ=60Hz? is set to NO(50 Hz). COMPRES-

SOR 100% SPEED must be set between

55-62 Hz if LINE FREQ=60Hz? is set to YES

(60 Hz).

284VFD GATEWAY COMPATIBILITY

CONFLICT

284VFD Gateway Compati-

bility Conflict: Check VFG/

VFD Versions.

VFD Gateway and VFD software versions are

not compatible.

Call Carrier Service.

285VFD GATEWAY COMPATIBILITY

CONFLICT

285VFD Gateway Compati-

bility Conflict: Check VFG/

ICVC Versions.

VFD Gateway and ICVC software versions are

not compatible.

Call Carrier Service.

286 PROTECTIVE LIMIT INVERTER

OVERCURRENT

286Inverter Overcurrent

Fault: Check VFD Status.

Check for high entering water temperature or

low condenser water flow.

Check current settings in VFD_CONF screen.

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE PRIMARY CAUSE ADDITIONAL CAUSE/REMEDY

260 SENSOR FAULT LEAVING CHILLED WATER 260Sensor Fault: Check

Leaving Chilled Water Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

261 SENSOR FAULT ENTERING CHILLED

WATER

261Sensor Fault: Check

Entering Chilled Water

Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

262 SENSOR FAULT CONDENSER PRESSURE 262Sensor Fault: Check

Condenser Pressure Sensor.

Check sensor wiring.

Check for disconnected or shorted wiring.

Check for condensation in transducer

connector.

263 SENSOR FAULT EVAPORATOR

PRESSURE

263Sensor Fault: Check

Evaporator Pressure Sensor.

Check sensor wiring.

Check for disconnected or shorted wiring.

Check for condensation in transducer

connector.

264 SENSOR FAULT COMPRESSOR BEARING

TEMP

264Sensor Fault: Check

Comp Thrust Brg Temp Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

265 SENSOR FAULT COMPRESSOR MOTOR

TEMP

265Sensor Fault: Check

Comp Motor Winding Temp

Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

266 SENSOR FAULT COMP DISCHARGE TEMP 266Sensor Fault: Check

Comp Discharge Temp Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

267 SENSOR FAULT OIL SUMP TEMP 267Sensor Fault: Check Oil

Sump Temp Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

268SENSOR FAULT COMP OIL PRESS DIFF 268Sensor Fault: Check Oil

Pump Delta P Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

269 SENSOR FAULT CHILLED WATER FLOW 269Sensor Fault: Check

Chilled Water Delta P Sensor.

Check sensor wiring and accuracy.

Check for disconnected or shorted wiring.

If pressure transducers are not installed,

check for presence of resistors and jumpers

on lower CCM terminal block J3.

270 SENSOR FAULT COND WATER FLOW 270Sensor Fault: Check

Cond Water Delta P Sensor.

Check sensor wiring and accuracy.

Check for disconnected or shorted wiring.

If pressure transducers are not installed,

check for presence of resistors and jumpers

on lower CCM terminal block J3.

271 SENSOR FAULT EVAP SATURATION TEMP 271Sensor Fault: Check

Evap Saturation Temp Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

Table 6 — Powerflex 755 Fault Code Descriptions and Corrective Actions

VFD

FAULT

CODE

ON VFD

HIST

SCREEN

ICVC

FAULT

STATE

FAULT TYPE DESCRIPTION CORRECTIVE ACTION

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

0No Entry

2207 Auxiliary Input Input is open.

Check Compressor Discharge High Pressure

switch wiring and accuracy.

Check for high condenser water temperatures,

low water flow, fouled tubes.

Check for division plate/gasket bypass. Check for

noncondensables in refrigerant.

3210 Power Loss Line voltage dropout Temporary loss of voltage. Disable Single Cycle

Dropout in VFD_CONF sceen.

4215 Undervoltage Low DC bus voltage

Verify phase-to-phase and phase-to-ground line

voltage. VFD Circuit Board malfunction.

Call Carrier Service.

5166 Overvoltage High DC bus voltage

Verify phase to phase and phase to ground line

voltage. Monitor AC line for high transient voltage

conditions.

7217 Motor Overload An internal electronic overload trip has occurred.

Any phase current > 106% RLA. Can result from

significant load side current imbalance when

running at full load.

Check entering condenser water temperature

and water flow rate.

Check Motor Rated Load Amps in VFD_CONF

screen.

8219 Heat Sink Over-

temp

Heat sink temperature has exceeded the maxi-

mum operating temperature

Check that VFD refrigerant isolation valves are

open.

Check VFD refrigerant cooling orifice and refrig-

erant strainer.

Check for proper VFD cooling fan operation and

air flow blockage.

9219 Transistor Over-

temp

The output transistors have exceeded the maxi-

mum operating temperature

Check that VFD refrigerant isolation valves are

open.

Check VFD refrigerant cooling orifice and refrig-

erant strainer.

Check for proper VFD cooling fan operation and

air flow blockage.

12 286 HW Overcurrent The drive output current has exceeded the hard-

ware current limit.

Check for high entering water temperature or low

condenser water flow. Check current settings in

VFD_CONF screen.

13 220 Ground Fault A current path to earth ground greater than 25%

of drive rating has occurred.

Check the motor, motor terminals, and external

wiring to the drive output terminals for a

grounded condition.

14 206 Ground Warning The ground current has exceeded the level set in

P467 —

15 206 Load Loss If this fault appears, there may be a problem with

software configuration.

To reset the processor, cycle power to chiller,

check ICVC VFD_CONF settings and save set-

tings when exiting VFD_CONF screen.

Check VFD parameters with Drive Explorer.

17 216

The DC bus ripple

has exceeded a

preset level.

Line Voltage imbalance

Check phase-to-phase and phase-to-ground dis-

tribution bus voltage. Increase Line Voltage %

Imbalance in VFD_CONF screen.

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

21 225 Output PhaseLoss The current in one or more phases has been lost

or remains below a preset level.

Check Motor Current % Imbalance in

VFD_CONF screen.

24 204 Decel Inhibit

The drive is not following a commanded decelera-

tion because it is attempting to limit the bus volt-

age.

Verify input voltage is within drive specified limits.

Verify system ground impedance follows proper

grounding techniques.

Disable bus regulation P186 and/or add dynamic

brake resistor and/or extend deceleration time

P537 and P538.

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

36 286 SW Overcurrent The drive output current has exceeded the 1 ms

current rating.

Check for excess load, improper DC boost set-

ting, DC brake volts set too high.

Table 6 — Powerflex 755 Fault Code Descriptions and Corrective Actions (cont)

VFD

FAULT

CODE

ON VFD

HIST

SCREEN

ICVC

FAULT

STATE

FAULT TYPE DESCRIPTION CORRECTIVE ACTION

220

Phase U to Gnd

GROUND FAULT

Check the wiring between the drive and the

motor.

Check motor for grounded phase.

Check Motor terminals. d. Replace drive.

39 Phase V to Gnd

40 Phase W to Gnd

246

Phase UV Short

GROUND FAULT

Check the wiring between the drive and the

motor.

Check Motor terminals.

Replace drive.

42 Phase VW Short

43 Phase WU Short

44 206 Phase UNot

GROUND FAULT (no LF2 equivalent)

Check the wiring between the drive and the

motor.

Check Motor terminals.

Replace drive.

45 206 Phase VNot ToGnd

46 206 Phase WNot

55 NONE Inverter Overtemp The temperature sensor on the main control

board detected excessive heat.

Check that VFD refrigerant isolation valves are

open.Check VFD refrigerant strainer

61 206 Shear Pin 1 See VFD Fault Code 15 See VFD Fault Code 15

62 206 Shear Pin 2 See VFD Fault Code 15 See VFD Fault Code 15

64 206 Drive Overload Drive is overloaded

Check for high entering water temperature or low

condenser water flow. Check current settings in

VFD_CONF screen.

65 206 OW TrqLvlTimeout See VFD Fault Code 15 See VFD Fault Code 15

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

78206 FluxAmpsRef

Rang See VFD Fault Code 15 See VFD Fault Code 15

79 206 Excessive Load Motor did not come up to speed in the allotted

time

Check that guide vanes are closed completely.

Check for high entering water temperature or low

condenser flow.

Repeat Autotune

80206 AutoTune Aborted See VFD Fault Code 15 See VFD Fault Code 15

87206 IXo VoltageRange Ixo voltae calculated from motor nameplate data

is too high.

Re-enter motor nameplate data in VFD_CONF

screen.

91 206 Pri VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15

93 206 HW Enable Check See VFD Fault Code 15 See VFD Fault Code 15

94 206 Alt VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15

95 206 Aux VelFdbk Loss See VFD Fault Code 15 See VFD Fault Code 15

96 206 PositionFdbkLoss See VFD Fault Code 15 See VFD Fault Code 15

97 206 Auto Tach Switch See VFD Fault Code 15 See VFD Fault Code 15

100 206 Parameter Chksum The checksum read from the board does not

match the checksum calculated.

Press ICVC reset.

Check VFD_CONF parameters.

Cycle power to the drive.

107 NONE Replaced MCB-PB The main control board was moved to a different

power structure. Data set to default values.

Press ICVC reset.

Check VFD_CONF parameters.

Cycle power to the drive.

113 206 Tracking DataErr Internal data error. Press ICVC reset.

Cycle power to the drive

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

141 206 Autn Enc Angle P78 [Encdrlss AngComp] is out of range See VFD Fault Code 15

142 206 Autn Spd Rstrct See VFD Fault Code 15 See VFD Fault Code 15

143 206 Autotune CurReg See VFD Fault Code 15 See VFD Fault Code 15

144 206 Autotune Inertia See VFD Fault Code 15 See VFD Fault Code 15

145 206 Autotune Travel See VFD Fault Code 15 See VFD Fault Code 15

Table 6 — Powerflex 755 Fault Code Descriptions and Corrective Actions (cont)

Checking Power Modules and Motor Input

with Input Power Off — Use the following procedure

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

1. Turn off and lock out input power. Wait five minutes.

2. Verify there is no voltage at the drive’s input power termi-

nals.

3. Using a voltmeter, check the DC bus potential as de-

scribed above to ensure the DC bus capacitors are dis-

charged.

4. Disconnect the motor from the drive.

5. Check all AC line and DC bus fuses.

6. Use a multimeter to check the input diodes and output

IGBTs if a fuse is open.

7. Check motor impedance.

8. Reconnect the motor to the drive.

9. Reapply input power. See Tables 7 and 8.

Table 7 — Diode Checks

NOTE: Digital meters require a special diode check function

because the current sourced by the meter during a normal resis-

tance (Ohms) test is too low to accurately test a diode. Make sure

the meter is set to the diode test function. Voltage readings may not

be exact as shown in above tables, but look for consistency during

each of the 4 tests. When performing a test that should return infinity

(OL) as shown in above tables, you may see a value slowly climbing

toward infinity. This is a result of the meter charging a capacitor and

is normal.

VFD

FAULT

CODE

ON VFD

HIST

SCREEN

ICVC

FAULT

STATE

FAULT TYPE DESCRIPTION CORRECTIVE ACTION

168206 HeatSinkUnder-

Tmp

Heatsink temperature sensor is reporting a value

below -18.7 C (-1.66 F) or the sensor feedback

circuit is open.

Check heat sink temperature sensor. Check heat

sink temperature.

210 206 HW En Jumper

Out See VFD Fault Code 15 See VFD Fault Code 15

211 206 Safety Brd Fault See VFD Fault Code 15 See VFD Fault Code 15

213 206 Safety Jumper In See VFD Fault Code 15 See VFD Fault Code 15

291 206 HSFan Lifwe See VFD Fault Code 15 See VFD Fault Code 15

292 206 InFan Life See VFD Fault Code 15 See VFD Fault Code 15

293 206 MtrBrg Life See VFD Fault Code 15 See VFD Fault Code 15

294 206 MtrBrg Lube See VFD Fault Code 15 See VFD Fault Code 15

295 206 MachBrg life See VFD Fault Code 15 See VFD Fault Code 15

296 206 MachBrg Lube See VFD Fault Code 15 See VFD Fault Code 15

315 206 Excess Psn Error See VFD Fault Code 15 See VFD Fault Code 15

316 206 Node Fault Error See VFD Fault Code 15 See VFD Fault Code 15

WARNING

Confirm that the DC bus has discharged before performing

diode checks.

METER LEAD METER READING

(+) (-)

R DC+ 0.5 V

S DC+ 0.5 V

T DC+ 0.5 V

R DC- infinite (OL)

S DC- Infinite (OL)

T DC- Infinite (OL)

U DC+ 0.5 V

V DC+ 0.5 V

W DC+ 0.5 V

U DC- infinite (OL)

V DC- Infinite (OL)

W DC- Infinite (OL)

DC+ R Infinite (OL)

DC+ S Infinite (OL)

DC+ T Infinite (OL)

DC- R 0.5 V

DC- S 0.5 V

DC- T 0.5 V

DC+ U Infinite (OL)

DC+ V Infinite (OL)

DC+ W Infinite (OL)

DC- U 0.5 V

DC- V 0.5 V

DC- W 0.5 V

Servicing the Drive

1. Using recommended screwdriver = 6.4 mm (0.25 in.) flat

or T20 star, open access door. 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. See Fig. 17.

3. Remove the enclosure. See Fig. 18.

REMOVING THE DRIVE — The dimensions and weights

specified must be taken into consideration when removing the

drive. All lifting equipment and lifting components (hooks,

bolts, lifts, slings, chains, etc.) must be properly sized and rated

to safely lift and hold the weight of the drive while removing it.

See Fig. 19. The drive weights are as follows:

• Drive weight for Frame 6: 85 lb.

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

When replacing the drive, reverse the procedures and tight-

en to the torques for the Frames 6 and 7 Power Terminal Block

referred to in Table 8.

Table 8 — Frames 6 and 7 Power Terminal Block

RIGGING THE ENCLOSURE — Where overhead room

and/or clearance in front of the drive enclosure is insufficient to

allow the drive to be safely removed from the enclosure, the

entire enclosure may have to be removed from the chiller.

The dimensions and weights specified must be taken into

consideration when removing the enclosure. The total weight

for Frames 6 and 7, including drive weight and enclosure, is

720 lb. All lifting equipment and lifting components (hooks,

bolts, lifts, slings, chains, etc.) must be properly sized and rated

to safely lift and hold the weight of the enclosure and drive

while removing. See Fig. 20A and Fig. 20B.

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.

3. Do not subject the drive to high rates of acceleration

or deceleration while transporting to the mounting lo-

cation or when lifting.

Do not allow personnel or their limbs directly underneath

the drive when it is being lifted and mounted.

WARNING

DC bus capacitors retain hazardous voltages after input

power has been disconnected. After disconnecting input

power, wait five (5) minutes for the DC bus capacitors to

discharge and then check the voltage with a voltmeter to

ensure the DC bus capacitors are discharged before touch-

ing any internal components. Failure to observe this pre-

caution could result in severe bodily injury or loss of life.

Fig. 16 — Open Access Door

A19-1831

FRAME MAXIMUM LUG

WIDTH

RECOMMENDED

TORQUE

TERMINAL

BOLT SIZE

634.6 mm (1.36 in.) 11.3 N·m (100 in.-lb) M8 x 1.25

743.5 mm (1.71 in.) 11.3 N·m (100 in.-lb) M8 x 1.25

L1 L2 L3

DC+ DC–

LOCKOUT/TAGOUT

MULTIMETER

DC BUS TEST

TERMINALS

LOCATED INSIDE

ACCESS DOOR

Fig. 17 — Check DC Bus Terminals

A19-1814

90°

SLIDE

ENCLOSURE

FORWARD

LOOSEN

ENCLOSURE

FASTENERS

Fig. 18 — Removing Enclosure

A19-1816

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

OPTION CARD) — The following are the steps for remov-

ing and replacing the existing gateway.

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. See Fig. 17.

3. Remove the enclosure. See Fig. 18.

4. Remove the 2 screws securing the mounting plate and re-

move the mounting plate and COMM card. See Fig. 21.

5. Mount the new COMM card and mounting plate and at-

tach with the 2 screws removed in Step 4. See Fig. 22.

6. Use the shorter ribbon cable to connect the plug on the

COMM card to the connector on the mounting plate. See

Fig. 21.

7. Install the enclosure. See Fig. 18.

DRIVE RIGGING ACCESS

DRIVE WIDTH + 4 IN.

FRONT VIEW

SIDE VIEW

DRIVE RIGGING

ACCESS

2 IN.

DRIVE POSITIONED FOR

VERTICAL LIFT

SUPPORT FROM

BELOW

DRIVE EXTENDS

BEHIND MAIN

ENCLOSURE

Fig. 19 — Enclosure Access for Removing Drive

A19-1818

a19-1817

>1/2 A

<45°

Fig. 20A — Rigging the Enclosure, Frame 6

A19-1837

>1/2 A

<45°

Fig. 20B — Rigging the Enclosure, Frame 7

A19-1838

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.

Frame 6:

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. See Fig. 17.

3. Remove the enclosure. See Fig. 18.

4. Remove and replace the chill plate fan. See Fig. 23.

5. Remove and replace the internal fan. See Fig. 24.

6. Install the enclosure. See Fig. 18.

0.45-0.67 N-m

(4.0-6.0 lb.-in.)

3 PLACES

MOUNTING PLATE

GATEWAY

RIBBON CABLE

Fig. 21 — COMM Card A19-1819

MOUNTING PLATE

GATEWAY

Fig. 22 — Mount COMM Card Plate to Drive

A19-1820

T20

2.6 N•m (23 lb•in.)

CHILL PLATE

FAN POWER

CONNECTION

CHILL PLATE FAN

Fig. 23 — Chill Plate Fan, Frame 6

A19-1839

T20

2.6 N•m

(23 lb•in.)

T20

2.6 N•m

(23 lb•in.)

INTERNAL FAN

Fig. 24 — Internal Fan, Frame 6

A19-1840



711

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. See Fig. 17.

3. Remove the enclosure. See Fig. 18.

4. Remove and replace the Heat Sink and Internal and fans.

See Fig. 25.

Install the enclosure. See Fig. 18.

Part Identification and Location — See Fig. 26-28

for parts descriptions and locations. X2

T20

5.20 N•m

(46 lb•in.)

T15

2.6 N•m (23 lb•in.)

T15

INTERNAL FANS

CHILL PLATE FANS

2.6 N•m (23 lb•in.)

Fig. 25 — Chill Plate and Internal Fans, Removal

and Replacement, Frame 7 A19-1841

KTK/FNQ-R

30A

111

222

1 2 34 5 6 7 8 9 10 11 12 1314 15 16 17 18 19 20 21 22 2324 25

TB4

26 27 28 29 30313233 343536373839 40 41 42 4344 45 46 47 48 49 50 51 52 5354 55 56 57 58 59 60 61 62 6364 65 66 67 68 69 70 71 72 7374 75 76 77 78 79 80

876 5

4321

12 11 10 13

CR1

876 5

4321

12 11 10 13

CR2

876 5

4321

12 11 10 13

CR3

876 5

4321

12 11 10 13

CR4

876 5

4321

12 11 10 13

CR5

876 5

4321

12 11 10 13

CR6

EA1

CB1

CABLE

ACCESS

CUTOUT

SECONDARY SIDE

PT1

123456 7 8 910 11 12 1314 15 16 17 18 19 20 21 22 2324 25

TB4

26 27 28 29 30313233 34353637383940 41 42 4344 45 46 47 48 49 50 51 52 5354 55 56 57 58 59 60 61 626364 65 66 67 68 69 70 7172 7374 75 76 77 78 79 80

8765

4321

12 11 10 13

CR1

8765

4321

12 11 10 13

CR2

8765

4321

12 11 10 13

CR3

8765

4321

12 11 10 13

CR4

8765

4321

12 11 10 13

CR5

8765

4321

12 11 10 13

CR6

PT1

SECONDARY

SIDE

TOWARD

DOOR

CB2

FRONT VIEW

DOOR REMOVED

LEFT SIDEWALL

VIEW FROM INSIDE

LINE-

TB1,TB2,

FU1-FU3

TB4

CR1

CR6

DIST.

SIDE

TB1 TB2

FU2

FU1 FU3

Fig. 26 — Assembly Parts

LEGEND

1—Power Module

2—Input Circuit Breaker

3—15 Amp Control Circuit Breaker

4—Control Transformer

5—Control Fuses

6—Control Relays (CR1 - CR5) a19-1847

LEGEND

1—PF750 Series, Precharge Kit

2—PF750 Series, Gate Interface

3—PF750 Series, Power Interface

4—PowerFlex 750 Series, Flange Gasket

5—PF755 Main Control Board

6—PF750 Series, Backplane Interface

7—PF750 Series, Type 4X/12 Chill Plate

(Heatsink) Fan Kit

8—Chill Plate Fan

NOTE: When replacing the Main Control Board (Item No. 1) the jumper marked

“J1 ENABLE” must be removed and the jumper marked “J1 SAFETY” must be

left in place.

a19-1848

Fig. 27 — Frame 6 Parts

Fig. 28 — Frame 7 Parts

LEGEND

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.

1—Slot for Gateway (Gateway Not Shown)

2—PF750 Series, Backplane Interface

3—PF750 Series, Type 4X/12 Heatsink Fan Kit

4—PF750 Series, Power Interface

5—PF750 Series, Bus Cap Assembly

6—PF750 Series, Power Interface Cable

7—PF750 Series, Current Transducer Kit

8—PF750 Series, Precharge Kit

9—Slot for 24V I/O Module (24V I/O Module Not Shown)

10 — PF755 Main Control Board

a19-1849

APPENDIX A — WIRING SCHEMATICS

CHILLER CONTROL SCHEMATIC

NOISE

SUPPRESSOR

VFD COOLANT

SOLENOID

)RLC

(

)

(

(BRN)

RMS

RELATIVE

HUMIDITY

(BLK)

(WHT)

(RED)

JUMPER

STOP

ICVC

ALARM

424VAC

(RED)

(GRY)

(RED)

(BLK)

(CLR)

SERVICE

SW2

SWITCH POSITION

SW "ON" = EXT 4-20mA

SW "OFF" = EXT 1-5Vdc

1 "OFF"

2 "ON"

3 "ON"

ALL SWITCHES SET

TO "OFF" POSITION

LOAD RESISTOR

4.3K

LOAD RESISTOR

4.3K

LOAD RESISTOR

4.3K

LOAD RESISTOR

10K

NOTE: GND SHIELDS AT THIS END ONLY

(RED)

(GRY)

(RED)

)

DLEIHS()

IHS(

(RED)

)

()K

NCC)

(

)RL

(

J9J10

(BLK)

(WHT)

)TH

(

OIL PUMP

DISCH PRESS

(RED)

(CLR)

(BLK)

100»f

OIL SUMP

PRESS

(RED)

(CLR)

(BLK)

100»f

CB2

CB1

(RED)

(GRY)

(GRY) (GRY)

(RED)

(GRY)

SW1

12345678

C2 C1

(WHT)

(BLK)

(BRN)

HGBP (OPTIONAL)

COMP'R OIL HEATER

COMP'R OIL PUMP

(BLK)

(BRN)

(WHT)

(BRN)

(ORN)

(WHT)

(BLK)

(BLU)

(BLK)

J12

(YEL)

(SHIELD)

4-20mA

EXT

(1-5vdc)

AUTO DEMAND LIMIT

(OPTIONAL)

AUTO CHILLED WATER

RESET (OPTIONAL)

+-+-+-

5432

COMMON

G.V. DECREASE

G.V. INCREASE

(SHIELD)

(RED)

(BLK)

GUIDE VANE ACTUATOR

(CLR) X

J11

(RED)

(CLR)

(BLK)

(CLR)

(RED)

234

-+-+

J3 (LOWER)

EVAP PRESS

(RED)

(CLR)

(BLK)

COND PRESS

(RED)

(CLR)

(BLK)

J3 (UPPER)

J4 (LOWER)

SPARE TEMP #1

(OPTIONAL)

(WHT)

(BLK)

SPARE TEMP #2

(OPTIONAL)

(WHT)

(BLK)

COMP'R

DISCH TEMP

(RED)

(BLK)

COMP'R THRUST

BRG TEMP

(CLR)

(BLK)

(SPARE)

COMP'R OIL

SUMP TEMP

(RED)

(BLK)

COMP'R

MOTOR TEMP

(CLR)

(BLK)

(SPARE)

G.V. POSITION

FEEDBACK

(CLR)

10K

(BLK)

(SHIELD)

REMOTE TEMP

RESET

(OPTIONAL)

(WHT)

(BLK)

EVAP ENT

WATER TEMP

(RED)

(BLK)

EVAP LVG

WATER TEMP

(RED)

(BLK)

COND ENT

WATER TEMP

(RED)

(BLK)

COND LVG

WATER TEMP

(RED)

(BLK)

EVAP REFRIG

LIQUID TEMP

(RED)

(BLK)

J4 (UPPER)

CCM

(BLK)

(WHT)

(BLU)

(ORN)

(CLR)

(BLK)

DIFFUSER ACTUATOR

4-20mAkw

OUTPUT

(SHIELD)

a19-1946

APPENDIX A — WIRING SCHEMATICS (cont)

CHILLER CONTROL SCHEMATIC (cont)

(RED)

(BLK)

(BRN) (BRN)

(WHT)

24VAC

(GRN)

(RED)

(BLU)

(BLK)

SOLENOID

HGBP

(YEL)

(BLK)

2123

(WHT)

(BLK)

HOT GAS BYPASS

(FR #7 & 8 HT EXCH)

115V CONTROL ONLY

(RED)

ACTUATOR

HGBP

COM

OPEN

(GRN)

(BLK)

(BLU)

(WHT)

230V WIRING MODIFICATION

COMP'R OIL HEATER

(BLK)

(WHT)

(BLK)

(FR #1 - 6 HT EXCH)

HOT GAS BYPASS

(BLU)

(BLK)

(GRN)

(RED)

(BLU)

(BLK)

SOLENOID

HGBP

(YEL)

(BLK)

SHOWN WIRED FOR 115V

230V WIRING MODIFICATION

(WHT)

(RED)

(BLK)(BLK)

(WHT)

WHT

)THW()TH

COMP'R OIL PUMP MOTOR

WINDING HIGH TEMPERATURE

WHT

(WHT)

(BLK)

COMP'R DISCH

HIGH PRESS

(CLR)

(RED)

(SHIELD)

(BLK)

(BRN)

(RED)

(ORN)

(BLK)

COMP'R OIL HEATER

(WHT)

(BLK)

(WHT)

(BLK)

115V

230V

COM

TO TB-G **

(RED)

(YEL)

(BLK)

RED

YEL

BLK

VOLTAGE

PER JOB

REQM'T

MCOMP'R OIL

PUMP MOTOR

(1-1/2 HP)

TO VFD

24VAC

(RED)

(BLK)

(BRN) (BRN)

(WHT)

(RED) (GRY)

(RED)

(GRY)

(WHT)

(BLK)

(BRN)

(YEL)

(RED)

(CLR)

(BLK)

(RED)

(BLK)

(BRN) (BRN)

(WHT)

24VAC

(RED) (GRY)

UPC

a19-1947

LEGEND

* Standard on LF2 drive; optional on machines equipped with

other VFDs.

CB Circuit Breater

CCM Chiller Control Module

HGBP Hot Gas Bypass

ICVC International Chiller Visual Controller

RHS Relative Humidity Sensor

UPC Universal Protocol Controller

VFD Var iable Frequency Drive

Denotes Control Panel Terminal

Denotes Oil Pump Terminal

Denotes Power Panel Terminal

** Denotes Motor Starter Panel Conn

Denotes Component Terminal

Wire Splice

Denotes Conductor male/Female Connector

Option Wiring

APPENDIX A — WIRING SCHEMATICS (cont)

ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical)

NOTNOT

USEDUSED

a19-1966

CONTINUED ON

FACIN G PAGE



611

APPENDIX A — WIRING SCHEMATICS (cont)

ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)

3434

3333

TB4

CARRIER

FACTORY

WIRING

DETAIL A

SEE

DETAIL

3535

3636

TB4

CARRIER

FACTORY

WIRING

DETAIL B

POWER

PANEL

POWER

PANEL

SEE

DETAIL

a19-1967

LEGEND

CAP — Capacitor

CB — Circuit Breaker

COM — Common

COMM — Communication

COND — Condenser

CR — Control Relay

DPI/SI — Internal Communication Protocols Connections

EA — Electrical Assembly

EMI — Electro-Magnetic Interference

EVAP — Evaporator

FU — Fuse

GND — Ground

JMPR — Jumper

M—Motor

NC — Normally Closed

NO — Normally Open

PE — Potential Earth (Ground)

POD — I/O Card Mounting Slot Board

REM — Remote

ROC — Relay Output Common

SHLD — Shield

TB — Terminal Block

* Located outside of starter; connected by field wiring.



611

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING

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 — The

user must give the UPC Open controller an address that is

unique on the BACnet network. Perform the following proce-

dure to assign an address:

1. If the UPC Open controller is powered, pull the screw ter-

minal connector from the controller's power terminals la-

beled Gnd and HOT. The controller reads the address

each time power is applied to it.

2. Using the rotary switches (see Fig. A and B), set the con-

troller's address. Set the Tens (10's) switch to the tens dig-

it of the address, and set the Ones (1's) switch to the ones

digit.

As an example in Fig. B, if the controller’s address is 25,

point the arrow on the Tens (10's) switch to 2 and the arrow on

the Ones (1's) switch to 5.

BACNET DEVICE INSTANCE ADDRESS — The UPC

Open controller also has a BACnet Device Instance address.

This Device Instance MUST be unique for the complete BAC-

net system in which the UPC Open controller is installed. The

Device Instance is auto generated by default and is derived by

adding the MAC address to the end of the Network Number.

The Network Number of a new UPC Open controller is 16101,

but it can be changed using i-Vu® Tools or BACView device.

By default, a MAC address of 20 will result in a Device In-

stance of 16101 + 20 which would be a Device Instance of

1610120.

10's

1's

Fig. B — Address Rotary Switches

a48-8578

Fig. A — UPC Open Controller

BACNET

BAUD RATE

DIP SWITCHES

ADDRESS

ROTARY

SWITCHES

POWER LED

RUN LED

ERROR LED

BACNET

CONNECTION

(BAS PORT)

BT485

TERMINATOR

Tx2 LED

Rx2 LED

Tx1 LED

Rx1 LED

EIA-485

JUMPERS

* Sponsored by ASHRAE (American Society of Heating, Refrigerat-

ing and Air Conditioning Engineers).

a48-8579

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

CONFIGURING THE BAS PORT FOR BACNET MS/

TP — Use the same baud rate and communication settings for

all controllers on the network segment. The UPC Open con-

troller is fixed at 8 data bits, No Parity, and 1 Stop bit for this

protocol's communications.

If the UPC Open controller has been wired for power, pull

the screw terminal connector from the controller's power termi-

nals labeled Gnd and HOT. The controller reads the DIP

Switches and jumpers each time power is applied to it.

Set the BAS Port DIP switch DS3 to “enable.” Set the BAS

Port DIP switch DS4 to “EIA-485.” Set the BMS Protocol DIP

switches DS8 through DS5 to “MSTP.” See Table A.

Table A — SW3 Protocol Switch Settings

for MS/TP

Verify that the EIA-485 jumpers below the CCN Port are set

to 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). See Fig. C and Table B.

Table B — Baud Selection Table

WIRING THE UPC OPEN CONTROLLER TO THE MS/

TP NETWORK — The UPC Open controller communicates

using BACnet on an MS/TP network segment communications

at 9600 bps, 19.2 kbps, 38.4 kbps, or 76.8 kbps.

Wire the controllers on an MS/TP network segment in a dai-

sy-chain configuration. Wire specifications for the cable are

22 AWG (American Wire Gage) or 24 AWG, low-capacitance,

twisted, stranded, shielded copper wire. The maximum length

is 2000 ft.

Install a BT485 terminator on the first and last controller on

a network segment to add bias and prevent signal distortions

due to echoing. See Fig. B, D, and E.

To wire the UPC Open controller to the BAS network:

1. Pull the screw terminal connector from the controller's

BAS Port.

2. Check the communications wiring for shorts and

grounds.

3. Connect the communications wiring to the BAS port’s

screw terminals labeled Net +, Net -, and Shield.

NOTE: Use the same polarity throughout the network

segment.

4. Insert the power screw terminal connector into the UPC

Open controller's power terminals if they are not current-

ly connected.

5. Verify communication with the network by viewing a

module status report. To perform a module status report

using the BACview keypad/display unit, press and hold

the “FN” key then press the “.” Key.

DS8DS7 DS6 DS5 DS4 DS3

OffOffOffOffOnOff

BAUD RATE DS2 DS1

9,600 Off Off

19,200 On Off

38,400 Off On

76,800 On On

Fig. C — DIP Switches

a48-

8580

Fig. D — Network Wiring

a48-8581

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

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

it.

To order a BT485 terminator, consult Commercial Products

i-Vu Open Control System Master Prices.

MS/TP WIRING RECOMMENDATIONS — Recommen-

dations are shown in Tables C and D. The wire jacket and UL

temperature rating specifications list two acceptable alterna-

tives. The Halar specification has a higher temperature rating

and a tougher outer jacket than the SmokeGard specification,

and it is appropriate for use in applications where the user is

concerned about abrasion. The Halar jacket is also less likely to

crack in extremely low temperatures.

NOTE: Use the specified type of wire and cable for maximum

signal integrity.

Table C — MS/TP Wiring Recommendations

LEGEND

Fig. E — BT485 Terminator Installation

a48-8582

SPECIFICATION RECOMMMENDATION

Cable Single twisted pair, low capacitance, CL2P, 22 AWG (7x30), TC foam FEP, plenum rated cable

Conductor 22 or 24 AWG stranded copper (tin plated)

Insulation Foamed FEP 0.015 in. (0.381 mm) wall 0.060 in. (1.524 mm) O.D.

Color Code Black/White

Twist Lay 2 in. (50.8 mm) lay on pair 6 twists/foot (20 twists/meter) nominal

Shielding Aluminum/Mylar shield with 24 AWG TC drain wire

Jacket SmokeGard Jacket (SmokeGard PVC) 0.021 in. (0.5334 mm) wall 0.175 in. (4.445 mm) O.D.

Halar Jacket (E-CTFE) 0.010 in. (0.254 mm) wall 0.144 in. (3.6576 mm) O.D.

DC Resistance 15.2 Ohms/1000 feet (50 Ohms/km) nominal

Capacitance 12.5 pF/ft (41 pF/meter) nominal conductor to conductor

Characteristic Impedance 100 Ohms nominal

Weight 12 lb/1000 feet (17.9 kg/km)

UL Temperature Rating SmokeGard 167°F (75°C)

Halar -40 to 302°F (-40 to 150°C)

Voltage 300 Vac, power limited

Listing UL: NEC CL2P, or better

AWG — American Wire Gage

CL2P — Class 2 Plenum Cable

DC — Direct Current

FEP — Fluorinated Ethylene Polymer

NEC — National Electrical Code

O.D. — Outside Diameter

TC — Tinned Copper

UL — Underwriters Laboratories

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Table D — Open System Wiring Specifications and Recommended Vendors

LEGEND

LOCAL ACCESS TO THE UPC OPEN CONTROL-

LER — The user can use a BACview6 handheld keypad dis-

play unit or the Virtual BACview software as a local user inter-

face to an Open controller. These items let the user access the

controller network information. These are accessory items and

do not come with the UPC Open controller.

The BACview6 unit connects to the local access port on the

UPC Open controller. See Fig. F. The BACview software must

be running on a laptop computer that is connected to the local

access port on the UPC Open controller. The laptop will re-

quire an additional USB link cable for connection.

See the BACview Installation and User Guide for instruc-

tions on connecting and using the BACview6 device.

To order a BACview6 Handheld (BV6H), consult Commer-

cial Products i-Vu® Open Control System Master Prices.

CONFIGURING THE UPC OPEN CONTROLLER'S

PROPERTIES — The UPC Open device and ComfortLink™

controls must be set to the same CCN Address (Element) num-

ber and CCN Bus number. The factory default settings for

CCN Element and CCN Bus number are 1 and 0 respectively.

If modifications to the default Element and Bus number are

required, both the ComfortLink and UPC Open configurations

must be changed.

The following configurations are used to set the CCN Ad-

dress and Bus number in the ComfortLink control. These con-

figurations can be changed using the scrolling marquee display

or accessory Navigator handheld device.

Configuration→CCN→CCN.A (CCN Address)

Configuration→CCN→CCN.B (CCN Bus Number)

The following configurations are used to set the CCN Ad-

dress and Bus Number in the UPC Open controller. These con-

figurations can be changed using the accessory BACview6 dis-

play.

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.

WIRING SPECIFICATIONS RECOMMENDED VENDORS AND PART NUMBERS

Wire Type Description Connect Air

International Belden RMCORP Contractors

Wire and Cable

MS/TP

Network (RS-485)

22 AWG, single twisted shielded pair, low capacitance, CL2P,

TC foam FEP, plenum rated. See MS/TP Installation Guide for

specifications.

W221P-22227 — 25160PV CLP0520LC

24 AWG, single twisted shielded pair, low capacitance, CL2P,

TC foam FEP, plenum rated. See MS/TP Installation Guide

for specifications.

W241P-2000F 82841 25120-OR —

Rnet 4 conductor, unshielded, CMP, 18 AWG, plenum rated. W184C-2099BLB 6302UE 21450 CLP0442

AWG — American Wire Gage

CL2P — Class 2 Plenum Cable

CMP — Communications Plenum Rated

FEP — Fluorinated Ethylene Polymer

TC — Tinned Copper

Fig. F — BACview6 Device Connection

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

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. See Fig. B for location of LEDs

on UPC Open module.

REPLACING THE UPC OPEN BATTERY — The UPC

Open controller's 10-year lithium CR2032 battery provides a

minimum of 10,000 hours of data retention during power

outages.

Remove the battery from the controller, making note of the

battery's polarity. Insert the new battery, matching the battery's

polarity with the polarity indicated on the UPC Open

controller.

NETWORK POINTS LIST — The points list for the control-

ler is shown in Table G.

Table E — LED Status Indicators

Table F — Run and Error LEDs Controller and Network Status Indication

IMPORTANT: Power must be ON to the UPC Open when

replacing the battery, or the date, time, and trend data will

be lost.

LED STATUS

Power

Lights when power is being supplied to the controller. The UPC Open controller is protected by internal solid-state polyswitches on

the incoming power and network connections. These polyswitches are not replaceable and will reset themselves if the condition

that caused the fault returns to normal.

Rx Lights when the controller receives data from the network segment; there is an Rx LED for Ports 1 and 2.

Tx Lights when the controller transmits data to the network segment; there is a Tx LED for Ports 1 and 2.

Run Lights based on controller status. See Table F.

Error Lights based on controller status. See Table F.

RUN LED ERROR LED STATUS

2 flashes per second Off Normal

2 flashes per second 2 flashes, alternating with Run LED Five minute auto-restart delay after system error

2 flashes per second 3 flashes, then off Controller has just been formatted

2 flashes per second 1 flash per second Controller is alone on the network

2 flashes per second On Exec halted after frequent system errors or control programs halted

5 flashes per second On Exec start-up aborted, Boot is running

5 flashes per second Off Firmware transfer in progress, Boot is running

7 flashes per second 7 flashes per second, alternating with Run LED Ten second recovery period after brownout

14 flashes per second 14 flashes per second, alternating with Run LED Brownout

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Table G — Network Points List

POINT DESCRIPTION CCN

POINT NAME

READ/

WRITE UNITS DEFAULT

VALUE RANGE BACNET

OBJECT ID

BACNET

OBJECT NAME

1st Current Alarm State ALARM_01 R N/A 0-270 AV:4 alarm_01_1

Active Demand Limit DEM_LIM R/W %N/A 40 to 100 AV:6 dem_lim_1

Actual Guide Vane Position GV_POS R %N/A 0 to 100 AV:7 gv_pos_1

Actual VFD Speed VFD_ACT R %N/A 0 to 110 AV:11 vfd_act_1

Calc Evap Sat Temp EAT R °F N/A -40 to 245 AV:13 ert_1

Chilled Water Deadband CWDB R ^F 1.0 0.5 to 2.0 AV:14 cwdb_1

Chilled Water Delta P CHWPD R ^F N/A -6.7 to 420 AV:15 chwpd_1

Chilled Water Delta T CHW_DT R ^F N/A -40 to 245 AV:16 chw_dt_1

Chilled Water Pump CHLP R N/A OFF OFF/ON BV:4 chlp_1

Chilled Water Temp CHW_TMP R °F N/A -40 to 245 AV:17 chw_tmp_1

Chiller Start/Stop CHIL_S_S R/W N/A STOP STOP/START BV:5 chil_s_s_1

Comp Discharge Temp CMPD R °F N/A -40 to 245 AV:18cmpd_1

Comp Motor Winding Temp MTRW R °F N/A -40 to 245 AV:19 mtrw_1

Comp Thrust Brg Temp MTRB R °F N/A -40 to 245 AV:20 mtrb_1

Cond Water Flow CDW_FLOW R N/A NO NO/YES BV:6 cdw_flow_1

Cond Water Pump CDP R N/A OFF OFF/ON BV:7 cdp_1

Condenser Pressure CRP R PSI N/A -6.7 to 420 AV:21 crp_1

Condenser Refrig Temp CRT R °F N/A -40 to 245 AV:22 crt_1

Condenser Water Delta P CDWPD R PSI N/A -6.7 to 420 AV:23 cdwpd_1

Control Point LCW_STPT R/W °F N/A 10 to 120 AV:24 lcw_stpt_1

Current CHW Setpoint CHWSTPT R °F N/A 0.00 to 99.9 AV:25 chwstpt_1

Demand Level 1 N/A R %N/A 0 to 100 AV:1 dmv_lvl_1_perct_1

Demand Level 2 N/A R %N/A 0 to 100 AV:2 dmv_lvl_2_perct_1

Demand Level 3 N/A R %N/A 0 to 100 AV:3 dmv_lvl_3_perct_1

Element Comm Status N/A R N/A N/A No Comm/Normal BV:2999 element_stat_1

Element Communications

Alarm N/A R N/A N/A Inactive/Active BV:20 comm_lost_alm_1

Emergency Stop EMSTOP R N/A ENABLE ENABLE/

EMSTOP BV:8emstop_1

Entering Chilled Water ECW R °F N/A -40 to 245 AV:26 ecw_1

Entering Condenser Water ECDW R °F N/A -40 to 245 AV:27 ecdw_1

Equipment Alarm N/A R N/A N/A Comm Normal

Comm Lost BV:1 element_alarm_1

Evaporator Pressure ERP R PSI N/A -6.7 to 420 AV:28erp_1

Evaporator Refrigerant Temp ERT R °F N/A -40 to 245 AV:13 ert_1

Leaving Chilled Water -

Prime Variable LCW R °F N/A -40 to 245 AV:31 lcw_1

Leaving Condenser Water LCDW R °F N/A -40 to 245 AV:32 lcdw_1

Line Active Current AMPS_ACT R A N/A 0.0 to 99999.0 AV:8amps_act_1

Line Active Voltage VOLT_ACT R V N/A 0.0 to 99999.0 AV:9 volt_act_1

Line Frequency LINEFREQ R Hz N/A 0 to 99 AV:30 linefreq_1

Line Power Factor LINE_PF R N/A 0.00 to 2.00 AV:34 line_pf_1

Local Schedule N/A R N/A N/A No Comm/Normal BV:2 schedule_1

Occupied? OCC R N/A NO NO/YES BV:10 occ_1

Oil Sump Temperature OILT R °F N/A -40 to 245 AV:33 oilt_1

Remote Start Contact REM_CON R/W N/A OPEN OPEN/CLOSE BV:11 rem_con_1

Run Status STATUS R N/A N/A

0=Timeout,

1=Ready,

2=Recyle,

3=Startup,

4=Running,

5=Demand,

6=Ramping,

7=Autorest,

8=Override,

9=Tripout,

10=Control Test,

11=Lockout,

12=Pumpdown,

13=Prestart

AV:35 status_1

Service Ontime S_HRS R/W hr N/A 0 to 32767 AV:36 s_hrs_1

Surge Line Delta T DELTA_TX R °F N/A 0 to 200 AV:38delta_tx_1

System Alert/Alarm SYS_ALM R N/A N/A 1=Normal,

2=Alert, 3=Alarm AV:40 sys_alm_1



611

APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Table G — Network Points List (cont)

LEGEND

POINT DESCRIPTION CCN

POINT NAME

READ/

WRITE UNITS DEFAULT

VALUE RANGE BACNET

OBJECT ID

BACNET

OBJECT NAME

System Cooling Demand

Level N/A R N/A N/A N/A AV:9006 cool_demand_level_1

System Demand Limiting N/A R N/A N/A OFF/ON BV:3 dem_lmt_act_1

Target Guide Vane Position GV_TRG R %N/A 0 to 100 AV:41 gv_trg_1

Target VFD Speed VFD_OUT R %N/A 0 to 100 AV:42 vfd_out_1

Tower Fan Relay High TFR_HIGH R N/A OFF OFF/ON BV:13 tfr_high_1

Tower Fan Relay Low TFR_LOW R N/A OFF OFF/ON BV:14 tfr_low_1

User Defined Analog 1 N/A R N/A N/A N/A AV:2901 user_analog_1_1

User Defined Analog 2 N/A R N/A N/A N/A AV:2902 user_analog_2_1

User Defined Analog 3 N/A R N/A N/A N/A AV:2903 user_analog_3_1

User Defined Analog 4 N/A R N/A N/A N/A AV:2904 user_analog_4_1

User Defined Analog 5 N/A R N/A N/A N/A AV:2905 user_analog_5_1

User Defined Binary 1 N/A R N/A N/A N/A BV:2911 user_binary_1_1

User Defined Binary 2 N/A R N/A N/A N/A BV:2912 user_binary_2_1

User Defined Binary 3 N/A R N/A N/A N/A BV:2913 user_binary_3_1

User Defined Binary 4 N/A R N/A N/A N/A BV:2914 user_binary_4_1

User Defined Binary 5 N/A R N/A N/A N/A BV:2915 user_binary_5_1

CHW — Chilled Water

R—Read

VFD — Variable Frequency Drive

W—Write

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 40 711 3-11 Replaces: New

Carrier 19Xrv Users Manual 3ss Reprint 711

19XRV to the manual c058fb71-22d6-49ed-b558-7ff5cf3cacaa

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