Carrier 19XRV manual

Manufacturer reserves the right to disco ntinue, or change at any time, specifications or de signs without notice and without inc urring obligations. Catalog No . 04-53 190012-01 Printed in U .S .A. Form 19XR V -3SS Pg 1 711 3-11 Replaces: Ne w Star t-Up and Ser vice Instr uctions SAFETY CONSIDERA TIONS Centrifugal liqui d chiller s are desig ned t[...]

2 CONTENTS Page SAFETY CONSIDERA TIONS . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ABBREVIA TIONS AND EXPLANA TIONS . . . . . . . . . . 2 Required Pub lications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Getting Assistan ce from Roc kwell Automati on[...]

3 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 Assembl y Catalog N umber — See Fig. 4 for an example Catalog Number . C[...]

4 LEGEND Fig. 5 — Frame 6 Drive Components NO . NAME DESCRIPTION 1 P ower T ermin als R/L1, S/L2, T/L3, U/T1, V /T2, W/T3 2 PE Grounding Studs T erminating point to chassis gr ound fo r incoming motor shield 3 DC Bus and Brak e T er minals +DC, -DC , BR1, BR2 4 PE-A and PE-B MO V and CMC Jumper Wires 5 DC+ and DC- Bus V oltage T est P oints A19- [...]

5 ST ART -UP Alternate Wire Lugs — In the case where the incoming power wire size does not fit the st andard lug, alternate lugs may be used. See T able 1. Note that lugs rated for a higher current than the circuit breaker may be used. Table 1 — Wire Lugs V erify Installation — Record the following job information: 1. Job Name 2. Job Number 3[...]

6 Configure the VFD — All configurations required by the VFD are supplied by the ICVC through the VFD Gateway . Any configuration changes nece ssary and possible are made on the ICVC screens. A complete se t of configurations is transmit- ted to the VFD each time the controls are powered up. The following is from the 19XR V PIC III ICVC screen. P[...]

7 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. T ake 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[...]

8 SER VICE T roubleshooting the Drive — The drive can display two kinds of error codes on the ICVC called the Alert and Alarm codes. These codes signa l a problem detected during self tuning or drive operation. Alert and Alarm codes are locat- ed in the 19XR V Start-Up, Operation and Maintenance Instruc- tions. Note the following diff erences bet[...]

9 Table 3 — Drive Status Indicator Descriptio ns NO TES: 1. A T ype 1 alar m indicates that a con dition e xists. T ype 1 alar ms are user configurable. 2. A T ype 2 alar m indicates that a configuration error e xists and the drive cannot be started . T ype 2 alarms are not configurab le. VERIFYING THA T DC BUS CAP ACITORS ARE DIS- CH AR GE D —[...]

10 DPI PORT 02 (COMPUTER PORT) DIGIT AL INPUT TERMINAL BLOCKS (SLOTS 04 & 05) ETHERNET/IP ADDRESS SWITCHES DIGIT AL OUTPUT TERMINAL BLOCKS (SLOTS 04 & 05) EMBEDDED ETHERNET/IP PORT MCB I/O TERMINALS (AUX F AUL T / HIGH PRESSURE FAUL T / ENABLE INPUT) Fig. 14 — MCB (Main Control Boar d) Components a19-1844 *Located outside of star ter; con[...]

11 Table 4 — ICVC Alert Codes PRE-ST ART ALER TS: These aler ts only delay start-u p . When aler t is co rrected, the star t-up will continue. No reset is necessar y . *[LIMIT] is shown on the ICVC as temperature, pressure, v oltage , etc., predefined or selected b y the operator as an ov erride or an alert. [V ALUE] is the actual pressure, tempe[...]

12 Table 4 — ICVC Al ert Codes (cont) NORMAL RUN WITH O VERRIDES *[LIMIT] is shown on the ICVC as the temperature , pressure, vo ltage , etc., set point predefined or selected by the operator as an override, aler t, or alarm conditio n. [V ALUE] is the act ual pressure, temperature , voltage , etc., at which the control tripped. ICVC F AUL T ST A[...]

13 Table 4 — ICVC Alert Codes (cont) CHILLER ALERTS *[LIMIT] is shown on the ICVC as the temperature , pressure, voltage , etc., set point prede fined or selected b y the operator as an override, aler t, or alarm conditio n. [V ALUE] is the actual pressure, tem perature , voltage, etc., at which the control tr ipped. ICVC F A UL T ST A TE PRIMAR [...]

14 Table 4 — ICVC Al ert Codes (cont) CHILLER ALER TS (cont) *[LIMIT] is shown on the ICVC as the temperature , pressure, vo ltage , etc., set point predefined or selected by the operator as an override, aler t, or alarm conditio n. [V ALUE] is the act ual pressure, temperature , voltage , etc., at which the control tripped. ICVC F AU L T ST A TE[...]

15 Table 5 — ICVC Alarm Codes CHILLER PRO TECTIVE LI MIT F A UL TS *[LIMIT] is shown on the ICVC as the temperature , pressure, voltage , etc., set point prede fined or selected b y the operator as an override, aler t, or alarm conditio n. [V ALUE] is the actual pressure, tem perature , voltage, etc., at which the control tr ipped. NO TE: ICVC Al[...]

16 Table 5 — ICVC Alarm Codes (cont) CHILLER PRO TECTIVE LI MIT F A UL TS (c ont) *[LIMIT] is shown on the ICVC as the temperature , pressure, vo ltage , etc., set point predefined or selected by the operator as an override, aler t, or alarm conditio n. [V ALUE] is the act ual pressure, temperature , voltage , etc., at which the control tripped. [...]

17 Table 5 — ICVC Alarm Codes (cont) CHILLER PRO TECTIVE LI MIT F A UL TS (cont) *[LIMIT] is shown on the ICVC as the temperature , pressure, voltage , etc., set point prede fined or selected b y the operator as an override, aler t, or alarm conditio n. [V ALUE] is the actual pressure, tem perature , voltage, etc., at which the control tr ipped. [...]

18 Table 5 — ICVC Alarm Codes (cont) CHILLER PRO TECTIVE LI MIT F A UL TS (c ont) *[LIMIT] is shown on the ICVC as the temperature , pressure, vo ltage , etc., set point predefined or selected by the operator as an override, aler t, or alarm conditio n. [V ALUE] is the act ual pressure, temperature , voltage , etc., at which the control tripped. [...]

19 Table 5 — ICVC Alarm Codes (cont) CHILLER PRO TECTIVE LI MIT F A UL TS (cont) *[LIMIT] is shown on the ICVC as the temperature , pressure, voltage , etc., set point prede fined or selected b y the operator as an override, aler t, or alarm conditio n. [V ALUE] is the actual pressure, tem perature , voltage, etc., at which the control tr ipped. [...]

20 Table 6 — Powerflex 755 Fault Code Description s and Corrective Actions VFD FAU LT CODE ON VFD HIST SCREEN ICVC FA U LT ST A TE F A UL T TYPE DESCRIPTION CORRECTIVE A CTION NONE 206 Processor memory fault Consult VFD manual to resolve generic f ault. 0 No Entr y 2 207 Auxiliary Input Input is open. Check Compressor Di scharge High Pressure swi[...]

21 Table 6 — Powerfle x 755 Fault Code Descriptions a nd Corrective Actions (cont) VFD FAU LT CODE ON VFD HIST SCREEN ICVC FA U LT ST A TE F A UL T TYPE DESCRIPTION CORRECTIVE A CTION 3 8 220 Phase U to Gnd GROUND F A UL T Check the wiring between the dr iv e and the motor . Check motor f or grounded phase. Check Motor terminals. d. Replace drive[...]

22 Table 6 — Powerfle x 755 Fault Code Descriptions a nd Corrective Actions (cont) Checkin g Po wer Modules and Motor Input with Input P ower Off — Use the following procedure to check the drive’ s power m odule circuitry with power of f: 1. T urn off and lock out input power . W ait five minutes. 2. V erify there is no voltage at the drive?[...]

23 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. RE MO VI NG TH E D RI VE — The dimensions and[...]

24 REPLACING THE GA TEW A Y (A-B20-750-20COMM OPTION CARD) — The f ollowing 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 term[...]

25 CHILL PLA TE F AN AND INTERNAL F AN REPLACE- ME NT — 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[...]

26 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 Sin[...]

27 LEGEND 1— PF750 Series, Precharge Kit 2— PF750 Serie s , Gate Inte rf ace 3— PF750 Serie s , Po wer Interface 4— P owerFlex 750 Series, Flange Gask et 5— PF755 Main Control Board 6— PF750 Series, Backplane Interf ace 7— PF750 Serie s , T ype 4X/12 Chill Plate (Heatsink) F an Kit 8 — Chill Plate F an NO TE: When replacing the Main[...]

28 APPENDIX A — WIRING SCHEMA TICS CHILLER CONTR OL SCHEMA TIC NOISE SUPPRESSOR VFD COOLANT SOLENOID ) R L C ( ) K L B ( ) N R B ( (BRN) RMS + S - RELATIVE HUMIDITY (BLK) (WHT) (RED) JUMPER JUMPER R STOP ICVC ALARM J7 J1 J8 5 4 24VAC 3 2G + - 1 (RED) (GRY) (RED) (BLK) (CLR) SERVICE 6 SW2 1 O N 3 2 SWITCH POSITION SW "ON" = EXT 4-20mA SW[...]

29 APPENDIX A — WIRING SCHEMA TICS (cont) CHILLER CONTR OL SCHEMA TIC (cont) (RED) (BLK) (BRN) (BRN) (WHT) T2 24VAC (GRN) (RED) (RED) (BLU) (BLU) (BLK) SOLENOID HGBP (YEL) (YEL) (BLK) (BLK) 21 23 3C 42 (WHT) (BLK) 3 6 5 4 2 1 HOT GAS BYPASS (FR #7 & 8 HT EXCH) 115V CONTROL ONLY (RED) ACTUATOR HGBP COM OPEN CLOSE (GRN) (BLK) (BLU) 3C 3C 42 65 [...]

30 APPENDIX A — WIRING SCHEMA TICS (cont) R OCKWELL PO WERFLEX 755 WIRING SCHEMA TIC (T ypical) NOT NO T U S ED U S ED a19-1966 CONTIN UED ON FA C I N G PAG E  61 1[...]

31 APPENDIX A — WIRING SCHEMA TICS (cont) ROCKW E LL PO WERFLEX 755 WIRING SCHEMA TIC (T ypical) (cont) 3 4 3 4 33 33 TB4 TB4 CARRIER F ACT ORY WIRING DET AIL A S EE DET AIL A 3 5 3 5 3 6 3 6 TB4 TB4 CARRIER F ACT ORY WIRING DET AIL B POWER P ANEL POWER P ANEL S EE DET AIL B 4 3 19 a19-1967 LEGEND CAP — Capacitor CB — Circuit Breaker COM — [...]

32 APPENDIX B — OPTIONAL BA CNET COMMUNICA TIONS WIR ING Optional B A Cnet * 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 [...]

33 APPENDIX B — OPTIONAL BA CNET COMMUNICA TIONS WI RING (cont) CONFIGURING THE BAS POR T 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 control[...]

34 APPENDIX B — OPTIONAL BA CNET COMMUNICA TIONS WIRING (cont) T o 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. T o order a BT485 terminator , consult Commercial Products i-V u Open Control System Master Prices. M[...]

35 APPENDIX B — OPTIONAL BA CNET COMMUNICA TIONS WI RING (cont) Table D — Open System Wiring Specification s and Recommended Vendors LEGEND LOCAL ACCESS TO THE UPC OPEN CONTROL- LE R — The user can use a BACview 6 handheld keypad dis- play unit or the V irtual BACview software as a local user inter - face to an Open controller . Th ese items [...]

36 APPENDIX B — OPTIONAL BA CNET COMMUNICA TIONS WIRING (cont) COMMUNICA TION LEDS — The LEDs indicate if the controller is communicating with the devices on the network. See T ables 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 locatio[...]

37 APPENDIX B — OPTIONAL BA CNET COMMUNICA TIONS WI RING (cont) Table G — Network Points List POINT DESCRIPTION CCN POINT NAME READ/ WRITE UNITS DEF AUL T VA L U E RANGE BA CNET OBJECT ID BA CNET OBJECT NAME 1st Current Alarm State ALARM_01 R N/A 0-270 A V:4 alar m_01_1 Active Demand Limit DEM_LIM R/W % N/A 40 to 100 A V:6 dem_lim_1 Actual Guid[...]

38 APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont) Table G — Network Points List (co nt) LEGEND POINT DESCRIPTION CCN POINT NAME READ/ WRITE UNITS DEF AUL T VA L U E RANGE BA CNET OBJECT ID BA CNET OBJECT NAME System Cooling Demand Level N/A R N/A N/A N/A A V:9006 cool_demand_le vel_1 System Demand Limiting N/A R N/A N/A OFF/ON BV:3 d[...]

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Manufacturer reserves the right to disco ntinue, or change at any time, specificatio ns or designs without notice and without inc urring obligations. Catalog No . 04-53190012-01 Pr i nted in U .S.A. Form 19XR V -3SS Pg 40 711 3-11 Replaces: Ne w Copy right 2011 Carrier Cor poration[...]