Carrier Air Conditioner 19XRV User Manual

19XRV

with PIC III Controls

Rockwell PowerFlex 755 VFD Option

Start-Up and Service Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and

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.

reliable service when operated within design specifica-

tions. When operating this equipment, use good judgment

and safety precautions to avoid damage to equipment and

property or injury to personnel.

Be sure you understand and follow the procedures and

safety precautions contained in the chiller instructions as

well as those listed in this guide.

DANGER

ONLY QUALIFIED Electrical Personnel familiar with the construction

and operation of this equipment and the hazards involved should install,

adjust, operate, or service this equipment.

READ AND UNDERSTAND this manual and other applicable manuals in

their entirety before proceeding. Failure to observe this precaution could

result in severe bodily injury or loss of life.

DO NOT install modification kits with power applied to the drive. Discon-

nect and lock out incoming power before attempting such installation or

removal. Failure to observe this precaution could result in severe bodily

injury or loss of life

UNUSED WIRES in conduit must be grounded at both ends to avoid a

possible shock hazard caused by induced voltages. Also, if a drive sharing

a conduit is being serviced or installed; all drives using this conduit should

be disabled to eliminate the possible shock hazard from cross-coupled

motor leads. Failure to observe these precautions could result in bodily

injury.

DO NOT VENT refrigerant relief valves within a building. Outlet from

rupture disc or relief valve must be vented outdoors in accordance with the

latest edition of ANSI/ASHRAE 15 (American National Standards Insti-

tute/American Society of Heating, Refrigerating, and Air Conditioning

Engineers). The accumulation of refrigerant in an enclosed space can dis-

place oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,

especially for enclosed and low overhead spaces. Inhalation of high con-

centrations of vapor is harmful and may cause heart irregularities, uncon-

sciousness, or death. Misuse can be fatal. Vapor is heavier than air and

reduces the amount of oxygen available for breathing. Product causes eye

and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any

purpose. Oxygen gas reacts violently with oil, grease, and other common

substances.

CAUTION

TO AVOID an electric shock hazard, verify that the voltage on the bus

capacitors has discharged completely before servicing. Check the DC bus

voltage at the Power Terminal Block by measuring between the +DC and -

DC terminals, between the +DC terminal and the chassis, and between the

-DC terminal and the chassis. The voltage must be zero for all three mea-

surements.

THE USER is responsible to conform with all applicable local, national,

and international codes. Failure to observe this precaution could result in

damage to, or destruction of, the equipment.

THIS DRIVE contains ESD (Electrostatic Discharge) sensitive parts and

assemblies. Static control precautions are required when installing, testing,

servicing or repairing this assembly. Component damage may result if

ESD control procedures are not followed. For static control procedures,

reference Rockwell publication Guarding Against Electrostatic Damage, or

any other applicable ESD protection handbook.

DO NOT alter the setting of any jumper. Failure to observe this precaution

could result in damage to, or destruction of, the equipment.

USE OF power correction capacitors on the output of the drive can result

in erratic operation of the motor, nuisance tripping, and/or permanent dam-

age to the drive. Remove power correction capacitors before proceeding.

Failure to observe this precaution could result in damage to, or destruction

of, the equipment.

MOST CODES require that upstream branch circuit protection be pro-

vided to protect input power wiring. If fuses are chosen as the protection

method, refer to the PowerFlex 750 user manual. Failure to observe this

precaution could result in damage to, or destruction of, the equipment.

DO NOT route signal and control wiring with power wiring in the same

conduit. This can cause interference with drive operation. Failure to

observe this precaution could result in damage to, or destruction of, the

equipment.

DISTRIBUTION SYSTEM short circuit capacity shall not exceed the rat-

ing of the drive. Failure to observe this precaution could result in damage

to, or destruction of, the equipment.

DO NOT STEP on refrigerant lines. Broken lines can whip about and

release refrigerant, causing personal injury.

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 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.

WARNING

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all

refrigerant (liquid and vapor) has been removed from chiller. Traces of

vapor should be displaced with dry air or nitrogen and the work area

should be well ventilated. Refrigerant in contact with an open flame pro-

duces toxic gases.

DO NOT work on high-voltage equipment unless you are a qualified elec-

trician.

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.

DO NOT WORK ON electrical components, including control panels,

switches, VFD, or oil heater until you are sure ALL POWER IS OFF and

no residual voltage can leak from capacitors or solid-state components.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53190012-01 Printed in U.S.A. Form 19XRV-3SS Pg 1 711 3-11 Replaces: New

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Opening the VFD Access Door

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.

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.

Fig. 2 — Opening Access Door

A19-1831

L1 L2 L3

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

LOCKOUT/TAGOUT

DC+ DC–

DC BUS TEST

TERMINALS

LOCATED INSIDE

ACCESS DOOR

MULTIMETER

Fig. 3 — Check DC Bus Terminals

A19-1814

A19-1842

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

21P PF755 VFD

Customer

C – Carrier

Voltage Rating

1– 460 to 480 v, 60 Hz

2– 380 to 415 v, 50 Hz

3– 380 to 400 v, 60 Hz

4– 401 to 439 v, 60 Hz

Meter Package

0 – No Meter Package

1 – Analog Meter Package

Input Reactor

PF755 Full Load Amp Rating

(Maximum Continuous Amps)*

0248 – 248

0 – No Input Reactor

1 – 3% Input Line Reactor

0361 – 361

0477 – 477

Disconnect/Breaker Options

3 – 65 KAIC Capacity Breaker

4 – 100 KAIC Capacity Breaker

Drive Assembly

3 – Unit Mount NEMA 1 Liquid Cooled

* For Carrier applications, maximum continuous amp

ratings are 230, 335, and 445.

Fig. 4 — Drive Assembly Catalog Number Nomenclature

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A19-

1832

LEGEND

NO.

NAME

Power Terminals

PE Grounding Studs

DESCRIPTION

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

Terminating point to chassis ground

for incoming motor shield

DC Bus and Brake

Terminals

+DC, -DC, BR1, BR2

PE-A and PE-B

DC+ and DC-

MOV and CMC Jumper Wires

Bus Voltage Test Points

A19-1833

LEGEND

Fig. 5 — Frame 6 Drive Components

NO.

NAME

Power Terminals

PE Grounding Studs

DESCRIPTION

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

Terminating point to chassis ground

for incoming motor shield

DC Bus and Brake

Terminals

+DC, -DC, BR1, BR2

PE-A and PE-B

DC+ and DC-

MOV and CMC Jumper Wires

Bus Voltage Test Points

Fig. 6 — Frame 7 Drive Components

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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.

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

STANDARD

LUG CABLE

RANGE

ALTERNATE

LUG CABLE

RANGE

CIRCUIT

BREAKER

STANDARD

ABB LUG

ALTERNATE

ABB LUG

65 KAIC

(Standard)

100 KAIC

(Optional)

(3) 2/0 - 400

MCM

(2) 250 - 500

MCM

K6TJ

K6TH

Verify Installation — Record the following job

information:

1. Job Name

2. Job Number

A19-1834

Fig. 7 — Enclosure Dimensions - Frames 6 and 7

3. City

4. State

5. Zip Code

Record the following nameplate information:

START-UP

DANGER

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

the VFD enclosure:

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..

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

Before connecting the drive to the incoming power, make

sure that the switchgear enclosure door is closed.

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

module:

WARNING

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

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.

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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.

a19-

1846

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.

A United Technologies Company

Table 2 — VFD Configurations

MODEL NUMBER

SERIAL NUMBER

PARAMETER

Motor Nameplate Voltage

Compressor 100% Speed

Line Freq=60 Hz? (No=50)

Rated Line Voltage*

DEFAULT VALUE

MACHINE NAMEPLATE SUPPLY DATA

460

VOLTS/PHASE/HERTZ

LOCKED ROTOR AMPS

OVERLOAD TRIP AMPS

Yes

460

200

100

200

100

3456

100

MAX FUSE/CIRCUIT BREAKER SIZE

MIN SUPPLY CIRCUIT AMPACITY

Rated Line Amps*

MACHINE ELECTRICAL DATA

MOTOR NAMEPLATE VOLTAGE

Rated Line Kilowatts *

Motor Rated Load kW*

Motor Rated Load Amps*

Motor Nameplate Amps

Motor Nameplate RPM

Motor Nameplate KW

Inverter PWM Frequency (0 = 4 kHz, 1 =

2 kHz)

Skip Frequency 1 (Hz)

Skip Frequency 2 (Hz)

Skip Frequency 3 (Hz)

Skip Frequency Band Line (Hz)

Voltage % Imbalance

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

102.0

0.0

Line Volt Imbalance Time (sec)

Line Current % Imbalance

Line Current Imbal Time (sec)

Motor Current % Imbalance

Motor Current Imbal Time

Increase Ramp Time (sec)

Decrease Ramp Time (sec)

Single Cycle Dropout (DSABLE/ENABLE)

SAFETY CODE CERTIFICATION

THE COMPRESSOR MOTOR CONTROLLER AND OVERLOAD PROTECTION MUST BE

IN ACCORDANCEWITH CARRIER SPECIFICATION Z-420.

19XV05008701 REV. 3

DSABLE

Fig. 8 — Machine Nameplate

* 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.

a19-

1924

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:

Fig. 9 — Drive Module Label

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

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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

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)

(VAB + VBC + VCA)

Vavg

(Vmax – Vmin) x 100

Vavg

Imbalance %

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.

• Recommended hex socket = 7 mm

• Recommended screwdriver = T20 star type

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

jumpers.

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

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

tings on the ICVC.

LEGEND

NO.

NAME

HIM Connector

Fan Connector

DESCRIPTION

DPI Port 1 (HIM Cradle) connection.

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).

DPI Port 2

Cable connection for handheld and

remote HIM options.

Embedded EtherNet/ Rotary switches for setting lowest octet

IP Address Selectors of EtherNet address (forces address to

192.168.1.xxx).

Embedded EtherNet/ Network cable connection.

IP Connector

Jumper 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.

TB1

I/O terminal block.

a19-1921

TB1 I/O Terminal Designations

NAME

FIXED I/O

TERMINAL

DESCRIPTION

Digital Input 120V AC

Digital Input Common

Digital Input 24V DC

+24 Volt Power

Connections for AC power supply.

Digital input common

Di 0ac

Di C

Di 0dc

+24V

Di 0ac

Di C

Connections for DC power supply.

Connections for drive supplied 24V power.

Di 0dc

+24V

24VC

24 Volt Common

24VC

IMPORTANT: Wiring to pluggable terminal block connectors

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

vent unintentional disconnection

Fig. 10 — PF755 Main Control Board

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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

ICVC ALARM

VFD ALARM

VFD FAULT

See Tables 3-6 and Fig. 12.

A19-1835

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.

Fig. 11A — Jumper Wire Locations — Frame 6

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.

Allen-Bradley

A19-1836

Fig. 11B — Jumper Wire Locations — Frame 7

SERVICE

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.

1815

Fig. 12 — Drive Status Indicator

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Table 3 — Drive Status Indicator Descriptions

NAME

COLOR

Green

STATE

Flashing

Steady

DESCRIPTION

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

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.

STS (Status)

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

None (Unlit)

Flashing Alternately

Off

Drive is flash updating.

Adapter and/or network is not powered, adapter is not properly connected to

the network, or adapter needs an IP address.

Red

Flashing

Steady

Flashing Alternately

Flashing

An EtherNet/IP connection has timed out.

Adapter failed the duplicate IP address detection test.

Adapter is performing a self-test.

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

the network.

ENET

Red/Green

Green

Steady

Off

Flashing

Steady

Adapter is properly connected and communicating on the network.

Adapter is not powered or is not transmitting on the network.

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

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

None (Unlit)

Green

LINK

NOTES:

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

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

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

are user 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.

SWING UP KEY PAD

MOUNT TO ACCESS

CONTROL BOARDS

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.

a19-1843

Fig. 13 — Drive Module with Cover Removed

A typical wiring schematic is shown in Appendix A.

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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

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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.

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] Check oil heater for proper operation.

exceeded limit of [LIMIT]*.

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

104

PRESTART

ALERT

HIGH

103Comp Discharge Temp [VALUE] Allow discharge sensor to cool.

DISCHARGE

TEMP

exceeded limit of [LIMIT]*.

Check sensor wiring and accuracy.

Check for excessive starts.

Check Comp Discharge Alert setting in

SETUP1 screen.

PRESTART

ALERT

LOW

REFRIGERANT

TEMP

104Evaporator Refrig Temp [VALUE] Check transducer wiring and accuracy.

exceeded limit of [LIMIT]*.

Check for low chilled fluid supply

temperatures.

Check refrigerant charge.

Check Refrig Override Delta T in SETUP1

screen.

105

106

PRESTART

ALERT

PRESTART

ALERT

LOW OIL

105Oil Sump Temp [VALUE]

Check oil heater contactor/relay and power.

Check oil level and oil pump operation.

TEMPERATURE

exceeded limit of [LIMIT]*.

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

108

109

PRESTART

ALERT

LOW LINE

VOLTAGE

107Percent Line Voltage [VALUE]

Check voltage supply.

exceeded limit of [LIMIT]*.

Check voltage transformers and switch gear.

Consult power utility if voltage is low.

PRESTART

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.

Press STOP button on ICVC and perform

Guide Vane Calibration in Controls Test

screen.

Check guide vane actuator feedback

potentiometer.

PRESTART

ALERT

GUIDE VANE

CALIBRATION

109Actual Guide Vane Pos

Calibration Required Before Startup.

110

111

PRESTART

ALERT

HIGH

110Rectifier Temperature [VALUE]

Check that VFD refrigerant isolation valves

are open.

RECTIFIER

TEMP

exceeded limit of [LIMIT]*.

Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation

and blockage.

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.

*[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.

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Table 4 — ICVC Alert Codes (cont)

NORMAL RUN WITH OVERRIDES

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE

PRIMARY CAUSE

ADDITIONAL CAUSE/REMEDY

120

121

122

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.

RUN CAPACITY

LIMITED

HIGH MOTOR

TEMPERATURE

121Comp Motor Winding Check for closed valves or restriction in motor

Temp [VALUE] exceeded

limit of [LIMIT]*.

cooling lines.

Check for closed refrigerant isolation valves.

Check Comp Motor Temp Override setting in

SETUP1.

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

125

126

RUN CAPACITY

LIMITED

MANUAL GUIDE VANE

TARGET

124Run Capacity Limited: Target Guide Vane Position has been forced in

Manual Guide Vane Target. the COMPRESS screen. Select and RELEASE

force to return to normal (automatic) operation.

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.

RUN CAPACITY

LIMITED

HIGH RECTIFIER TEMP 126Rectifier Temperature Check Rectifier Temp Override in SETUP1

[VALUE] exceeded limit of

[LIMIT]*.

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.

128

RUN CAPACITY

LIMITED

HIGH INVERTER TEMP 128Inverter Temperature

[VALUE] exceeded limit of

Check Inverter Temp Override in SETUP1

screen.

Check that VFD refrigerant isolation valves are

open.

[LIMIT]*.

Check VFD refrigerant cooling solenoid.

Check for proper VFD cooling fan operation and

blockage.

*[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.

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Table 4 — ICVC Alert Codes (cont)

CHILLER ALERTS

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE

PRIMARY CAUSE

ADDITIONAL CAUSE/REMEDY

140

141

142

SENSOR ALERT

LEAVING COND WATER

TEMP

ENTERING COND WATER 141Sensor Fault: Check

TEMP

140Sensor Fault: Check

Check sensor resistance or voltage drop.

Leaving Cond Water Sensor. Check for proper wiring.

SENSOR ALERT

Check sensor resistance or voltage drop.

Entering Cond Water Sensor. Check for proper wiring.

142Low Oil Pressure Alert. Check for partially or closed shut-off valves.

Check Oil Filter.

LOW OIL

PRESSURE ALERT

CHECK OIL FILTER

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

144

AUTORESTART

PENDING

LINE CURRENT

IMBALANCE

143Line Current Imbal-

ance: Check VFD Fault His-

tory for Values.

144Single Cycle Line

Voltage Dropout.

Power loss has been detected in any phase.

Chiller automatically restarting.

AUTORESTART

PENDING

LINE VOLTAGE

DROP OUT

A drop in line voltage has been detected within

2 voltage cycles.

Chiller automatically restarting if Auto Restart is

enabled in OPTIONS screen.

145

146

147

AUTORESTART

PENDING

AUTORESTART

PENDING

AUTORESTART

PENDING

HIGH LINE VOLTAGE

LOW LINE VOLTAGE

VFD MODULE RESET

145High Percent Line

Check phase to phase and phase to ground line

power.

Check phase to phase and phase to ground line

power.

Voltage [VALUE].

146Low Percent Line

Voltage [VALUE].

147->VFD Module Power-On VFD Module has detected a hardware fault due

Reset When Running.

to electrical noise, power loss or software and

has reset. Chiller automatically restarting.

Check for power loss and sources of electro-

magnetic interference.

148

AUTORESTART

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 Check sensor resistance or voltage drop.

[VALUE] Exceeded Limit of

[LIMIT]*.

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

151

152

SENSOR ALERT

CONDENSER

HIGH BEARING

TEMPERATURE

150Comp Thrust Brg Temp Check sensor resistance or voltage drop.

[VALUE] exceeded limit of

[LIMIT]*.

Check for proper wiring.

Check for partially closed service valves.

Check oil cooler TXV.

Check oil level and oil temperature.

PUMP RELAY

PRESSURE ALERT ENERGIZED

151High Condenser Pres- Check sensor wiring and accuracy.

sure [VALUE]: Pump Ener-

gized to Reduce Pressure.

Check condenser flow and water temperature.

Check for fouled tubes.

This alarm is not caused by the High Pressure

Switch.

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

154

no message:

ALERT

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

Config: Duplicate Chiller

Illegal chiller address configuration in Lead/Lag

screen. Both chillers require a different address.

only

Address.

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

156

157

158

OPTION SENSOR

FAULT

REMOTE RESET

SENSOR

155Sensor Fault/Option

Disabled: Remote Reset

Sensor.

156Sensor Fault/Option

Disabled: Auto Chilled Water Check for proper wiring to CCM connector J5.

Reset.

157Sensor Fault/Option

Disabled: Auto Demand Limit Check for proper wiring to CCM connector J5.

Input.

158Spare Temperature 1

[VALUE] exceeded limit of

[LIMIT]*.

Check sensor resistance or voltage drop.

Check for proper wiring to CCM connector J4.

OPTION SENSOR

FAULT

AUTO CHILLED WATER

RESET

Check sensor resistance or voltage drop.

OPTION SENSOR

FAULT

AUTO DEMAND LIMIT

INPUT

Check sensor resistance or voltage drop.

SENSOR ALERT

SPARE TEMPERATURE

Check sensor resistance or voltage drop.

Check for proper wiring to CCM connector J4.

Check Spare Temp #1 Limit in SETUP1 screen.

*[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.

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Table 4 — ICVC Alert Codes (cont)

CHILLER ALERTS (cont)

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

163

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.

CONDENSER APPROACH 163Condenser Approach

[VALUE] Exceeded Limit of

Check sensors resistance or voltage drop.

Check for proper wiring.

[LIMIT]*.

Check Cond Approach Alert setting in SETUP1

screen.

Check for noncondensable gas in the

condenser.

Check that the condenser tubes are not fouled.

164

165

166

167

VFD SPEED ALERT LOW VFD SPEED

164Actual VFD Speed

Actual VFD Speed on COMPRESS screen must

exceeded limit of Target VFD be at least 90% of Target VFD Speed.

Speed –10%.

AUTORESTART

PENDING

LOW DC BUS VOLTAGE

165Low DC Bus Voltage:

[VALUE] Exceeded Limit of

[LIMIT]*.

166High DC Bus Voltage:

[VALUE] Exceeded Limit of

[LIMIT]*.

Verify phase to phase and phase to ground line

voltage.

AUTORESTART

PENDING

HIGH DC BUS VOLTAGE

Verify phase to phase and phase to ground line

voltage. Monitor AC line for high transient volt-

age conditions.

SYSTEM ALERT

HIGH DISCHARGE TEMP 167Comp Discharge Temp Check sensor resistance or voltage drop.

[VALUE] exceeded limit of

[LIMIT]*.

Check for proper wiring.

Check for excessive starts.

Check Comp Discharge Alert setting in SETUP1

screen.

168

SENSOR ALERT

HUMIDITY SENSOR

INPUT

168Sensor Fault: Check

Check humidity sensor wiring on CCM connec-

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

“OFF” position.

Check Humidity Sensor Input in Controls Test.

*[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.

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Table 5 — ICVC Alarm Codes

CHILLER PROTECTIVE LIMIT FAULTS

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE

PRIMARY CAUSE

ADDITIONAL CAUSE/REMEDY

200

201

202

PROTECTIVE LIMIT RECTIFIER POWER

200Rectifier Power Fault:

Malfunction within VFD Power Module.

Call Carrier Service.

Malfunction within VFD Power Module.

Call Carrier Service.

Check main circuit breaker for trip. Increase

Current % Imbalance in VFD_CONF screen.

FAULT

Check VFD Status.

PROTECTIVE LIMIT INVERTER POWER FAULT 201Inverter Power Fault:

Check VFD Status.

PROTECTIVE LIMIT MOTOR AMPS NOT

202Motor Amps Not

Sensed — Average Load

Current [VALUE].

SENSED

203

FAILURE TO START MOTOR ACCELERATION 203Motor Acceleration Fault Check that inlet guide vanes are fully closed at

FAULT

— Average Load Current

[VALUE].

start-up.

Check Motor Rated Load Amps in VFD_CONF

screen. Reduce unit pressure if possible.

204

205

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

VFD Circuit Board malfunction.

Call Carrier Service.

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.

Check Inverter Power Unit.

PROTECTIVE LIMIT HIGH DC BUS VOLTAGE

205High DC Bus Voltage:

[VALUE] exceeded limit of

[LIMIT]*.

206

207

PROTECTIVE LIMIT VFD FAULT

206VFD Fault Code:

[VALUE]; Check VFD Fault

Code List.

See VFD Fault Code description and corrective

action.

PROTECTIVE LIMIT HIGH CONDENSER

207High Cond Pressure

Check Compressor Discharge High Pressure

PRESSURE

trip. [VALUE] exceeded Switch switch wiring and accuracy.

Trippoint.

Check for high condenser water temperatures,

low water flow, fouled tubes.

Check for division plate/gasket bypass.

Check for noncondensables in refrigerant.

208

PROTECTIVE LIMIT EXCESSIVE MOTOR

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.

AMPS

209

PROTECTIVE LIMIT LINE CURRENT

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.

IMBALANCE

210

211

212

213

PROTECTIVE LIMIT LINE VOLTAGE DROPOUT 210Single Cycle Line Volt- Temporary loss of voltage. Disable Single Cycle

age Dropout. Dropout in VFD_CONF screen.

PROTECTIVE LIMIT HIGH LINE VOLTAGE

PROTECTIVE LIMIT LOW LINE VOLTAGE

PROTECTIVE LIMIT VFD MODULE RESET

211High Percent Line Volt- Check phase to phase and phase to ground dis-

age [VALUE]. tribution bus voltage. Consult power company.

212Low Percent Line Volt- Check phase to phase and phase to ground dis-

age [VALUE]. tribution bus voltage. Consult power company.

213VFD Module Power-On Temporary loss of VFD control voltage. Check

Reset When Running.

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

216

217

PROTECTIVE LIMIT LOW DC BUS VOLTAGE

215Low DC Bus Voltage:

[VALUE] exceeded limit of

[LIMIT]*.

216Line Voltage Imbal-

ance. Check VFD Fault His-

tory for Values.

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

voltage. VFD Circuit Board malfunction.

Call Carrier Service.

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

distribution bus voltage. Increase Line Voltage

% Imbalance in VFD_CONF screen.

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.

PROTECTIVE LIMIT LINE VOLTAGE

IMBALANCE

PROTECTIVE LIMIT MOTOR OVERLOAD TRIP 217Motor Overload Trip;

Check VFD configurations.

218

PROTECTIVE LIMIT VFD RECTIFIER

218VFD Rectifier Temp

Check that VFD refrigerant isolation valves are

OVERTEMP

Exceeded: Check Cooling and open.

VFD Config.

Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation and

blockage.

219

PROTECTIVE LIMIT VFD INVERTER

219VFD Inverter Temp

Check that VFD refrigerant isolation valves are

OVERTEMP

Exceeded: Check Cooling and open.

VFD Config.

Check VFD refrigerant cooling solenoid and

refrigerant strainer.

Check for proper VFD cooling fan operation and

blockage.

*[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.

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Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

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

222

PROTECTIVE LIMIT UNUSED

PROTECTIVE LIMIT LINE FREQUENCY TRIP 222Line Frequency —

221UNUSED

If operating from a generator, check generator

size and speed.

[VALUE] exceeded limit of

[LIMIT]; Check Power Supply. Check utility power supply.

223

224

LOSS OF

WITH VFD GATEWAY

223Loss of SIO Comm with Check VFD communication wiring and

COMMUNICATION MODULE

VFD Gateway: Check VFG

Module and Power.

connectors on VFD Gateway and DPI board.

Check for compatibility between ICVC and

Gateway software.

PROTECTIVE LIMIT VFD COMMUNICATIONS 224Loss of DPI Comm with Check VFD communication wiring and

FAULT

VFD Gateway: Check VFG to connectors.

VFD Comm.

Check status lights on DPI Communications

Interface Board.

Call Carrier Service.

225

PROTECTIVE LIMIT MOTOR CURRENT

225Motor Current Imbal-

ance: Check VFD Fault

History for Values.

Check Motor Current % Imbalance in

VFD_CONF screen.

IMBALANCE

226

227

PROTECTIVE LIMIT LINE PHASE REVERSAL 226Line Phase Reversal:

Reverse connections of any two line conductors

to circuit breaker.

Check Line Phases.

PROTECTIVE LIMIT OIL PRESS SENSOR

227Oil Pressure Delta P

[VALUE] (Pump Off): Check

Pump/Transducers.

Check transducer wiring and accuracy.

Check power supply to pump.

Check pump operation.

FAULT

Check transducer calibration.

228

PROTECTIVE LIMIT LOW OIL PRESSURE

228Low Operating Oil

Check transducer wiring and accuracy.

Pressure [VALUE]: Check Oil Check power supply to pump.

Pump and Filter.

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

229Low Chilled Water Flow; Perform pump control test.

FLOW

Check Switch/Delta P Config Check optional transducer calibration and

& Calibration.

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

231

PROTECTIVE LIMIT LOW CONDENSER

230Low Condenser Water Perform pump control test.

WATER FLOW

Flow; Check Switch/Delta P

Config & Calibration.

Check optional transducer calibration and

wiring.

Check condenser water valves.

Check for COND PRESS OVERRIDE + 5 psig.

PROTECTIVE LIMIT HIGH DISCHARGE TEMP 231Comp Discharge Temp Check for closed compressor discharge isola-

[VALUE] Exceeded Limit of

[LIMIT]*.

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

232Evaporator Refrig Temp Check for proper refrigerant charge.

TEMP

[VALUE] exceeded limit of

[LIMIT]*.

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.

*[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.

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Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE

PRIMARY CAUSE

ADDITIONAL CAUSE/REMEDY

233

PROTECTIVE LIMIT HIGH MOTOR

233Comp Motor Winding Check motor sensors wiring and accuracy.

TEMPERATURE

Temp [VALUE] exceeded

limit of [LIMIT]*.

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

234Comp Thrust Brg Temp Check oil heater for proper operation.

TEMPERATURE

[VALUE] exceeded limit of

[LIMIT]*.

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

236

PROTECTIVE LIMIT HIGH CONDENSER

235Condenser Pressure

[VALUE] exceeded limit of

[LIMIT]*.

Check for high condenser water temperatures, low

water flow, fouled tubes.

PRESSURE

Check for division plate/gasket bypass.

Check for noncondensables.

Check transducer wiring and accuracy.

Check for high condenser water temperatures, low

PROTECTIVE LIMIT COMPRESS SURGE/

236Compressor Surge:

LOW SPEED

Check condenser water temp water flow, fouled tubes.

and flow.

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

237Spare Safety Device.

238Compressor Surge:

Spare safety input has tripped or factory installed

jumper is not present on Terminal Block 4 terminals

17 and 20 in the VFD enclosure.

DEVICE

238

PROTECTIVE LIMIT EXCESSIVE COMPR

Check for high condenser water temperatures, low

SURGE

Check condenser water temp water flow, fouled tubes.

and flow.

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

240

PROTECTIVE LIMIT TRANSDUCER

239Transducer Voltage Ref Check that CCM transducer voltage reference is

VOLTAGE FAULT

[VALUE] exceeded limit of

[LIMIT]*.

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.

PROTECTIVE LIMIT LOW DISCHARGE

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.

SUPERHEAT

Check calibration of compressor discharge temper-

ature sensor.

241

242

PROTECTIVE LIMIT RECTIFIER

241Rectifier Overcurrent

Check for high water temperatures or changes in

water flow rates.

Check wiring and control power to CCM.

Confirm that all CCM SW1 switches are in the

“OFF” position.

OVERCURRENT

Fault: Check VFD Status.

LOSS OF

WITH CCM MODULE

242Loss of Communica-

tion With CCM, Check

Comm. Connectors.

COMMUNICATION

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.

*[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.

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Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

ICVC FAULT

STATE

PRIMARY

MESSAGE

SECONDARY

MESSAGE

PRIMARY CAUSE

ADDITIONAL CAUSE/REMEDY

245

246

247

PROTECTIVE LIMIT HIGH VFD SPEED

245Actual VFD Speed

Actual VFD Speed on COMPRESS screen must

exceeded limit of Target VFD not exceed Target VFD Speed by more than

Speed + 10%.

10%.

PROTECTIVE LIMIT INVALID DIFFUSER

246Diffuser Control Invalid Check 25%, 50%, and 75% Guide Vane and Dif-

Configuration: Check SETUP2 fuser Load Point entries in SETUP2 screen.

Entries.

247Diffuser Position Fault: Confirm that Diffuser Option in SETUP 2 screen

Check Guide Vane/Diffuser

Actuator.

CONFIG.

PROTECTIVE LIMIT DIFFUSER POSITION

FAULT

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.

248

PROTECTIVE LIMIT SPARE TEMPERATURE

248Spare Temperature #1 Check Spare Temperature Enable and Spare

[VALUE] exceeded limit of

[LIMIT]*.

Temperature Limit in SETUP1 Screen.

249

PROTECTIVE LIMIT SPARE TEMPERATURE

249Spare Temperature #2 Check Spare Temperature Enable and Spare

[VALUE] exceeded limit of

[LIMIT]*.

Temperature Limit in SETUP1 Screen.

250

251

UNUSED

250Unused State.

PROTECTIVE LIMIT VFD CONFIG CONFLICT 251VFD Config Conflict

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 Uploaded): Verify to

Reset Alarm.

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

253

PROTECTIVE LIMIT VFD CONFIG CONFLICT 252VFD Config Conflict

The VFD_CONF table in the Gateway does not

(VFD Downloaded): Verify to match that which is in the ICVC.

Reset Alarm.

PROTECTIVE LIMIT GUIDE VANE

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.

CALIBRATION

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

255

PROTECTIVE LIMIT VFD CHECKSUM ERROR 254Checksum Error:

Actual VFD checksum does not match calcu-

lated value.

Press Reset to Restore

Configuration

PROTECTIVE LIMIT VFD DEW PREVENTION 255Dew Prevention - Cool- VFD COLDPLATE TEMP is too close to dew

ant Too Cold. Check Solenoid point based on VFD ENCLOSURE TEMP and

& Cond T.

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

257

PROTECTIVE LIMIT INDUCTOR OVERTEMP

PROTECTIVE LIMIT VFD START INHIBIT

256Inductor Overtemp Trip - Check for cooling fan air flow obstructions.

Check Temp Switch and Cool-

ing Fans.

257VFD Start Inhibit: Check The VFD Start Inhibit is derived from the Alarm

VFD Diagnostic Parameters

212/214.

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.

258

UNUSED STATE

UNUSED

258Unused.

*[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.

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Table 5 — ICVC Alarm Codes (cont)

CHILLER PROTECTIVE LIMIT FAULTS (cont)

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

LINE FREQUENCY in POWER screen must be

[VALUE] Exceeded Configura- maintained between 45-52 Hz if LINE

tion Range.

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%

COMPRESSOR 100% SPEED in VFD_CONF

Speed Config Ranges: 50=Hz screen must be set between 45-52 Hz if LINE

45-52; 60 Hz=55-62.

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).

284

285

286

VFD GATEWAY

COMPATIBILITY

CONFLICT

284VFD Gateway Compati- VFD Gateway and VFD software versions are

bility Conflict: Check VFG/

VFD Versions.

not compatible.

Call Carrier Service.

COMPATIBILITY

CONFLICT

285VFD Gateway Compati- VFD Gateway and ICVC software versions are

bility Conflict: Check VFG/

ICVC Versions.

not compatible.

Call Carrier Service.

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.

*[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

260

261

262

SENSOR FAULT LEAVING CHILLED WATER 260Sensor Fault: Check

Check sensor resistance or voltage drop.

Leaving Chilled Water Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

SENSOR FAULT ENTERING CHILLED

261Sensor Fault: Check

Entering Chilled Water

Sensor.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

WATER

SENSOR FAULT CONDENSER PRESSURE 262Sensor Fault: Check

Check sensor wiring.

Condenser Pressure Sensor.

Check for disconnected or shorted wiring.

Check for condensation in transducer

connector.

263

SENSOR FAULT EVAPORATOR

263Sensor Fault: Check

Evaporator Pressure Sensor.

Check sensor wiring.

PRESSURE

Check for disconnected or shorted wiring.

Check for condensation in transducer

connector.

264

265

266

267

268

269

SENSOR FAULT COMPRESSOR BEARING 264Sensor Fault: Check

Check sensor resistance or voltage drop.

TEMP

Comp Thrust Brg Temp Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

SENSOR FAULT COMPRESSOR MOTOR

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.

TEMP

SENSOR FAULT COMP DISCHARGE TEMP 266Sensor Fault: Check

Check sensor resistance or voltage drop.

Comp Discharge Temp Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

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.

Check sensor resistance or voltage drop.

Check for proper wiring.

Check for disconnected or shorted wiring.

SENSOR FAULT COMP OIL PRESS DIFF

SENSOR FAULT CHILLED WATER FLOW

268Sensor Fault: Check Oil

Pump Delta P Sensor.

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

271

SENSOR FAULT COND WATER FLOW

270Sensor Fault: Check

Check sensor wiring and accuracy.

Cond Water Delta P Sensor.

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.

SENSOR FAULT EVAP SATURATION TEMP 271Sensor Fault: Check

Check sensor resistance or voltage drop.

Evap Saturation Temp Sensor. Check for proper wiring.

Check for disconnected or shorted wiring.

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Table 6 — Powerflex 755 Fault Code Descriptions and Corrective Actions

VFD

FAULT

CODE

ICVC

FAULT

STATE

FAULT TYPE

DESCRIPTION

CORRECTIVE ACTION

ON VFD

HIST

SCREEN

NONE

206

Processor memory fault

Consult VFD manual to resolve generic fault.

No Entry

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.

207

Auxiliary Input

Input is open.

Temporary loss of voltage. Disable Single Cycle

Dropout in VFD_CONF sceen.

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

voltage. VFD Circuit Board malfunction.

Call Carrier Service.

210

215

Power Loss

Line voltage dropout

Low DC bus voltage

Undervoltage

Verify phase to phase and phase to ground line

voltage. Monitor AC line for high transient voltage

conditions.

166

217

Overvoltage

High DC bus voltage

Any phase current > 106% RLA. Can result from

significant load side current imbalance when

running at full load.

Motor Overload

An internal electronic overload trip has occurred. Check entering condenser water temperature

and water flow rate.

Check Motor Rated Load Amps in VFD_CONF

screen.

Check that VFD refrigerant isolation valves are

open.

Heat Sink Over-

temp

Heat sink temperature has exceeded the maxi-

mum operating temperature

Check VFD refrigerant cooling orifice and refrig-

erant strainer.

219

Check for proper VFD cooling fan operation and

air flow blockage.

Check that VFD refrigerant isolation valves are

open.

Transistor Over-

temp

The output transistors have exceeded the maxi-

mum operating temperature

Check VFD refrigerant cooling orifice and refrig-

erant strainer.

219

Check for proper VFD cooling fan operation and

air flow blockage.

Check for high entering water temperature or low

condenser water flow. Check current settings in

VFD_CONF screen.

The drive output current has exceeded the hard-

ware current limit.

286

HW Overcurrent

Check the motor, motor terminals, and external

wiring to the drive output terminals for a

grounded condition.

A current path to earth ground greater than 25%

220

206

Ground Fault

of drive rating has occurred.

The ground current has exceeded the level set in

P467

Ground Warning

—

To reset the processor, cycle power to chiller,

If this fault appears, there may be a problem with check ICVC VFD_CONF settings and save set-

206

Load Loss

software configuration.

Line Voltage imbalance

tings when exiting VFD_CONF screen.

Check VFD parameters with Drive Explorer.

The DC bus ripple

has exceeded a

preset level.

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

tribution bus voltage. Increase Line Voltage %

Imbalance in VFD_CONF screen.

216

206

225

TorqPrv Spd Band See VFD Fault Code 15

See VFD Fault Code 15

The current in one or more phases has been lost Check Motor Current % Imbalance in

Output PhaseLoss

or remains below a preset level.

VFD_CONF screen.

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.

The drive is not following a commanded decelera-

tion because it is attempting to limit the bus volt-

age.

204

Decel Inhibit

206

AuRsts Exhausted See VFD Fault Code 15

See VFD Fault Code 15

The drive output current has exceeded the 1 ms Check for excess load, improper DC boost set-

current rating. ting, DC brake volts set too high.

286

SW Overcurrent

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

VFD

FAULT

CODE

ICVC

FAULT

STATE

FAULT TYPE

DESCRIPTION

CORRECTIVE ACTION

ON VFD

HIST

SCREEN

Phase U to Gnd

Phase V to Gnd

Phase W to Gnd

Phase UV Short

Phase VW Short

Phase WU Short

Phase UNot

Check the wiring between the drive and the

motor.

220

246

GROUND FAULT

Check motor for grounded phase.

Check Motor terminals. d. Replace drive.

Check the wiring between the drive and the

motor.

Check Motor terminals.

Replace drive.

206

Check the wiring between the drive and the

motor.

Check Motor terminals.

Replace drive.

Phase VNot ToGnd

Phase WNot

GROUND FAULT (no LF2 equivalent)

The temperature sensor on the main control

board detected excessive heat.

Check that VFD refrigerant isolation valves are

open.Check VFD refrigerant strainer

NONE Inverter Overtemp

206

Shear Pin 1

Shear Pin 2

See VFD Fault Code 15

Check for high entering water temperature or low

condenser water flow. Check current settings in

VFD_CONF screen.

206

Drive Overload

Drive is overloaded

206

OW TrqLvlTimeout See VFD Fault Code 15

See VFD Fault Code 15

IR Volts Range

See VFD Fault Code 15

FluxAmpsRef

Rang

206

See VFD Fault Code 15

Check that guide vanes are closed completely.

Check for high entering water temperature or low

condenser flow.

Motor did not come up to speed in the allotted

time

206

Excessive Load

Repeat Autotune

206

AutoTune Aborted See VFD Fault Code 15

See VFD Fault Code 15

Ixo voltae calculated from motor nameplate data Re-enter motor nameplate data in VFD_CONF

IXo VoltageRange

Pri VelFdbk Loss

is too high.

screen.

206

See VFD Fault Code 15

HW Enable Check See VFD Fault Code 15

Alt VelFdbk Loss See VFD Fault Code 15

Aux VelFdbk Loss See VFD Fault Code 15

PositionFdbkLoss See VFD Fault Code 15

Auto Tach Switch

See VFD Fault Code 15

Press ICVC reset.

Check VFD_CONF parameters.

Cycle power to the drive.

The checksum read from the board does not

match the checksum calculated.

100

206

Parameter Chksum

Press ICVC reset.

The main control board was moved to a different

power structure. Data set to default values.

107

113

NONE Replaced MCB-PB

Check VFD_CONF parameters.

Cycle power to the drive.

Press ICVC reset.

Cycle power to the drive

206

Tracking DataErr

Internal data error.

124

141

142

143

144

145

206

App ID Changed

Autn Enc Angle

Autn Spd Rstrct

Autotune CurReg

Autotune Inertia

Autotune Travel

Application firmware changed.

P78 [Encdrlss AngComp] is out of range

See VFD Fault Code 15

Verify application version.

See VFD Fault Code 15

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

VFD

FAULT

CODE

ICVC

FAULT

STATE

FAULT TYPE

DESCRIPTION

CORRECTIVE ACTION

ON VFD

HIST

SCREEN

Heatsink temperature sensor is reporting a value

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

circuit is open.

HeatSinkUnder-

Tmp

Check heat sink temperature sensor. Check heat

sink temperature.

168

206

HW En Jumper

Out

210

See VFD Fault Code 15

211

213

291

292

293

294

295

296

315

316

206

Safety Brd Fault

Safety Jumper In

HSFan Lifwe

InFan Life

MtrBrg Life

MtrBrg Lube

See VFD Fault Code 15

MachBrg life

MachBrg Lube

Excess Psn Error

Node Fault Error

Table 7 — Diode Checks

METER LEAD

METER READING

(-)

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.

(+)

DC+

DC-

DC+

DC-

DC+

DC-

DC+

DC-

0.5 V

infinite (OL)

Infinite (OL)

0.5 V

infinite (OL)

Infinite (OL)

0.5 V

Infinite (OL)

0.5 V

8. Reconnect the motor to the drive.

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

WARNING

Confirm that the DC bus has discharged before performing

diode checks.

0.5 V

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.

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Servicing the Drive

L1 L2 L3

WARNING

LOCKOUT/TAGOUT

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.

DC+ DC–

DC BUS TEST

TERMINALS

MULTIMETER

LOCATED INSIDE

ACCESS DOOR

Do not allow personnel or their limbs directly underneath

the drive when it is being lifted and mounted.

Fig. 17 — Check DC Bus Terminals

A19-1814

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.

SLIDE

ENCLOSURE

FORWARD

LOOSEN

ENCLOSURE

FASTENERS

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.

90°

A19-1816

Fig. 18 — Removing Enclosure

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.

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:

Table 8 — Frames 6 and 7 Power Terminal Block

MAXIMUM LUG

WIDTH

RECOMMENDED

TORQUE

TERMINAL

BOLT SIZE

FRAME

34.6 mm (1.36 in.) 11.3 N·m (100 in.-lb)

43.5 mm (1.71 in.) 11.3 N·m (100 in.-lb)

M8 x 1.25

• Drive weight for Frame 6: 85 lb.

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

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.

Fig. 16 — Open Access Door

A19-1831

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DRIVE RIGGING ACCESS

DRIVE WIDTH + 4 IN.

<45°

2 A

Fig. 20A — Rigging the Enclosure, Frame 6

A19-1837

<45°

2 A

FRONT VIEW

Fig. 20B — Rigging the Enclosure, Frame 7

2 IN.

DRIVE RIGGING

2 IN.

A19-1838

ACCESS

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.

DRIVE POSITIONED FOR

VERTICAL LIFT

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.

DRIVE EXTENDS

BEHIND MAIN

ENCLOSURE

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

COMM card to the connector on the mounting plate. See

Fig. 21.

SUPPORT FROM

BELOW

7. Install the enclosure. See Fig. 18.

SIDE VIEW

Fig. 19 — Enclosure Access for Removing Drive

a19-1817

A19-1818

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 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.

GATEWAY

MOUNTING PLATE

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.

0.45-0.67 N-m

(4.0-6.0 lb.-in.)

3 PLACES

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.

RIBBON CABLE

CHILL PLATE

FAN POWER

CONNECTION

A19-1819

Fig. 21 — COMM Card

CHILL PLATE FAN

MOUNTING PLATE

GATEWAY

T20

2.6 N•m (23 lb•in.)

Fig. 23 — Chill Plate Fan, Frame 6

A19-1839

2.6 N•m

(23 lb•in.)

T20

INTERNAL FAN

Fig. 22 — Mount COMM Card Plate to Drive

A19-1820

T20

2.6 N•m

(23 lb•in.)

A19-1840

Fig. 24 — Internal Fan, Frame 6

711

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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.

5.20 N•m

(46 lb•in.)

T15

INTERNAL FANS

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.

T15

2.6 N•m (23 lb•in.)

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

X 2

for parts descriptions and locations.

T20

CHILL PLATE FANS

2.6 N•m (23 lb•in.)

Fig. 25 — Chill Plate and Internal Fans, Removal

and Replacement, Frame 7

A19-1841

CR1

EA1

CR2

CR3

CR4

CR5

CR6

CR1

CR2

CR3

CR4

CR5

CR6

LINE-

CB1

CR6

TB4

CABLE

ACCESS

CUTOUT

DIST.

SIDE

FU2

FU1 FU3

TB1 TB2

CB2

TB1,TB2,

FU1-FU3

KTK/FNQ-R

TB4

30A

PT1

SECONDARY

SIDE

TOWARD

DOOR

SECONDARY SIDE

LEFT SIDEWALL

VIEW FROM INSIDE

FRONT VIEW

DOOR REMOVED

LEGEND

— Power Module

— Input Circuit Breaker

— 15 Amp Control Circuit Breaker

— Control Transformer

— Control Fuses

— Control Relays (CR1 - CR5)

a19-1847

Fig. 26 — Assembly Parts

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LEGEND

— PF750 Series, Precharge Kit

— PF750 Series, Gate Interface

— PF750 Series, Power Interface

— PowerFlex 750 Series, Flange Gasket

— PF755 Main Control Board

— PF750 Series, Backplane Interface

— PF750 Series, Type 4X/12 Chill Plate

(Heatsink) Fan Kit

a19-1848

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

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

left in place.

— Chill Plate Fan

Fig. 27 — Frame 6 Parts

LEGEND

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

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.

a19-1849

Fig. 28 — Frame 7 Parts

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APPENDIX A — WIRING SCHEMATICS

CHILLER CONTROL SCHEMATIC

(SHIELD)

EXT

4-20mA

(1-5vdc)

(RED)

AUTO DEMAND LIMIT

(OPTIONAL)

(BLK)

EXT

4-20mA

(1-5vdc)

(CLR)

AUTO CHILLED WATER

RESET (OPTIONAL)

(CLR)

(BLK)

(SHIELD)

4-20mAkw

OUTPUT

(RED)

EVAP ENT

WATER TEMP

(BLK)

(RED)

SWITCH POSITION

SW "ON" = EXT 4-20mA

SW "OFF" = EXT 1-5Vdc

EVAP LVG

WATER TEMP

(BLK)

(WHT)

(BLK)

SW2

(RED)

1 "OFF"

2 "ON"

3 "ON"

(BLU)

(ORN)

COND ENT

WATER TEMP

(BLK)

(RED)

COND LVG

WATER TEMP

(BLK)

(YEL)

(CLR)

G.V. POSITION

FEEDBACK

(BLK)

DIFFUSER ACTUATOR

10K

(SHIELD)

(BLK)

(WHT)

(RED)

(BLK)

EVAP REFRIG

LIQUID TEMP

(SHIELD)

COMMON

(CLR)

(RED)

(BLK)

REMOTE TEMP

RESET

(OPTIONAL)

G.V. INCREASE

(WHT)

(BLK)

G.V. DECREASE

GUIDE VANE ACTUATOR

(RED)

(BLK)

(CLR)

(BLK)

(SPARE)

(RED)

(BLK)

COMP'R

DISCH TEMP

(RED)

(BLK)

(CLR)

(BLK)

(BRN)

COMP'R THRUST

BRG TEMP

(YEL)

CB2

(BLK)

(BRN)

(BLU)

(BLK)

(WHT)

(ORN)

(BLK)

VFD COOLANT

SOLENOID

COMP'R OIL

SUMP TEMP

(BLK)

(CLR)

(BRN)

HGBP (OPTIONAL)

(WHT)

(CLR)

(BLK)

COMP'R

MOTOR TEMP

(BRN)

(SPARE)

NOISE

SUPPRESSOR

COMP'R OIL PUMP

(WHT)

(RED)

(GRY)

(BRN)

COMP'R OIL HEATER

(WHT)

(BLK)

(WHT)

(BLK)

SPARE TEMP #1

(OPTIONAL)

(WHT)

SPARE TEMP #2

(OPTIONAL)

(BLK)

(CLR)

(RED)

(BLK)

(CLR)

CCM

OIL SUMP

PRESS

100»f

OIL PUMP

DISCH PRESS

NOTE: GND SHIELDS AT THIS END ONLY

100»f

(RED)

(BLK)

(SHIELD)

LOAD RESISTOR

(RED)

(CLR)

(BLK)

(RED)

(WHT)

(BLK)

4.3K

RELATIVE

HUMIDITY

RMS

(RED)

CCN

(WHT)

ALL SWITCHES SET

TO "OFF" POSITION

LOAD RESISTOR

(RED)

(GRY)

10K

LOAD RESISTOR

4.3K

JUMPER

ALARM

LOAD RESISTOR

JUMPER

(RED)

(GRY)

(RED)

(GRY)

(BLK)

(CLR)

(RED)

24VAC

ICVC

CB1

4.3K

(GRY)

STOP

SERVICE

(BLK)

(CLR)

(RED)

(BLK)

(CLR)

(RED)

EVAP PRESS

COND PRESS

a19-1946

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APPENDIX A — WIRING SCHEMATICS (cont)

CHILLER CONTROL SCHEMATIC (cont)

(GRN)

TO TB-G **

230V

COM

COMP'R OIL HEATER

OPEN

4 CLOSE

(BLK)

(WHT)

(BLK)

(WHT)

(BLK)

(WHT)

115V

HGBP

ACTUATOR

(RED)

COM

(WHT)

(BLK)

(WHT)

230V WIRING MODIFICATION

COMP'R OIL HEATER

(BLK)

(BLU)

HOT GAS BYPASS

(WHT)

(BLK)

(WHT)

(BLK)

(RED)

(FR #7 & 8 HT EXCH)

115V CONTROL ONLY

(BLK)

(YEL)

(RED)

(ORN)

(BRN)

(BLK)

(CLR)

(BLK)

(RED)

(WHT)

(RED)

(WHT)

(RED)

(WHT)

(RED)

(WHT)

24VAC

(BLK)

(GRN)

TO VFD

(BRN)

(BLU)

(RED)

COMP'R DISCH

HIGH PRESS

(BLU)

(RED)

HGBP

SOLENOID

(YEL)

(BLK)

(SHIELD)

(BLK)

(RED)

(GRY)

(BLK)

(RED)

(GRY)

(YEL)

(RED)

(BLK)

SHOWN WIRED FOR 115V

(CLR)

(BLK)

(BRN)

(GRN)

WHT

UPC

(WHT)

(BLU)

(RED)

COMP'R OIL PUMP MOTOR

(BLU)

(RED)

(YEL)

(BLK)

WINDING HIGH TEMPERATURE

HGBP

SOLENOID

(WHT)

(RED)

(GRY)

(BLK)

(YEL)

(BLK)

230V WIRING MODIFICATION

HOT GAS BYPASS

(FR #1 - 6 HT EXCH)

a19-1947

YEL

(YEL)

VOLTAGE

PER JOB

REQM'T

BLK

(1-1/2 HP)

COMP'R OIL

PUMP MOTOR

(BLK)

(RED)

RED

LEGEND

Circuit Breater

Denotes Control Panel Terminal

Denotes Oil Pump Terminal

Denotes Power Panel Terminal

CCM

HGBP

ICVC

RHS

UPC

VFD

Chiller Control Module

Hot Gas Bypass

International Chiller Visual Controller

Relative Humidity Sensor

Universal Protocol Controller

Variable Frequency Drive

Denotes Motor Starter Panel Conn

Denotes Component Terminal

Wire Splice

Denotes Conductor male/Female Connector

Option Wiring

* Standard on LF2 drive; optional on machines equipped with

other VFDs.

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APPENDIX A — WIRING SCHEMATICS (cont)

ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical)



a19-1966

CONTINUED ON

FACING PAGE

NOT

USED

611

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APPENDIX A — WIRING SCHEMATICS (cont)



ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)

DETAIL A

TB4

CARRIER

FACTORY

WIRING

SEE

DETAIL

a19-1967

SEE

DETAIL

DETAIL B

POWER

PANEL

TB4

POWER

PANEL

CARRIER

FACTORY

WIRING

LEGEND

CAP

—

Capacitor

Circuit Breaker

Common

COM

COMM

COND

Communication

Condenser

Control Relay

DPI/SI

Internal Communication Protocols Connections

Electrical Assembly

Electro-Magnetic Interference

Evaporator

EMI

EVAP

Fuse

GND

JMPR

Ground

Jumper

Motor

Normally Closed

Normally Open

Potential Earth (Ground)

I/O Card Mounting Slot Board

Remote

POD

REM

ROC

SHLD

Relay Output Common

Shield

Terminal Block

* Located outside of starter; connected by field wiring.

611

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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.

10's

1's

5 ⁴

a48-8578

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.

5 ⁴

Fig. B — Address Rotary Switches

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.

BT485

TERMINATOR

BACNET

CONNECTION

(BAS PORT)

POWER LED

Tx1 LED

Rx1 LED

Tx2 LED

Rx2 LED

BACNET

BAUD RATE

DIP SWITCHES

EIA-485

JUMPERS

ADDRESS

ROTARY

SWITCHES

RUN LED

ERROR LED

Fig. A — UPC Open Controller

a48-8579

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

ing and Air Conditioning Engineers).

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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.

a48-

8580

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.

Fig. C — DIP Switches

Table A — SW3 Protocol Switch Settings

for MS/TP

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.

DS8

DS7

DS6

DS5

DS4

DS3

Off

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.

To wire the UPC Open controller to the BAS network:

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

BAS Port.

Table B — Baud Selection Table

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.

BAUD RATE

9,600

DS2

Off

DS1

Off

19,200

38,400

76,800

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.

a48-8581

Fig. D — Network Wiring

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APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

a48-8582

Fig. E — BT485 Terminator Installation

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

SPECIFICATION

Cable

Conductor

Insulation

Color Code

Twist Lay

RECOMMMENDATION

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

22 or 24 AWG stranded copper (tin plated)

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

Black/White

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

Aluminum/Mylar shield with 24 AWG TC drain wire

Shielding

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.

Jacket

DC Resistance

Capacitance

Characteristic Impedance

Weight

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

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

100 Ohms nominal

12 lb/1000 feet (17.9 kg/km)

SmokeGard 167°F (75°C)

Halar -40 to 302°F (-40 to 150°C)

UL Temperature Rating

Voltage

Listing

300 Vac, power limited

UL: NEC CL2P, or better

LEGEND

AWG

CL2P

— American Wire Gage

— Class 2 Plenum Cable

— Direct Current

FEP

NEC

O.D.

— Fluorinated Ethylene Polymer

— National Electrical Code

— Outside Diameter

— Tinned Copper

— Underwriters Laboratories

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APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Table D — Open System Wiring Specifications and Recommended Vendors

WIRING SPECIFICATIONS

Description

RECOMMENDED VENDORS AND PART NUMBERS

Connect Air

International

Contractors

Wire and Cable

Wire Type

Belden RMCORP

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

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

specifications.

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

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

for specifications.

W221P-22227

W241P-2000F

—

25160PV

CLP0520LC

MS/TP

Network (RS-485)

82841 25120-OR

21450

—

Rnet

4 conductor, unshielded, CMP, 18 AWG, plenum rated.

W184C-2099BLB 6302UE

CLP0442

LEGEND

— American Wire Gage

— Class 2 Plenum Cable

— Communications Plenum Rated

— Fluorinated Ethylene Polymer

— Tinned Copper

AWG

CL2P

CMP

FEP

LOCAL ACCESS TO THE UPC OPEN CONTROL-

LER — The user can use a BACview⁶handheld 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 BACview⁶unit 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.

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 BACview⁶dis-

play.

See the BACview Installation and User Guide for instruc-

tions on connecting and using the BACview⁶device.

To order a BACview⁶Handheld (BV6H), consult Commer-

Navigation: BACview→CCN

Home: Element Comm Stat

Element: 1

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.

Bus: 0

TROUBLESHOOTING — If there are problems wiring or

addressing the UPC Open controller, contact Carrier Technical

Support.

Fig. F — BACview⁶Device Connection

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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.

IMPORTANT: Power must be ON to the UPC Open when

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

be lost.

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

LED

STATUS

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.

Power

Run

Error

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

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

Lights based on controller status. See Table F.

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

RUN LED

ERROR LED

STATUS

2 flashes per second

5 flashes per second

7 flashes per second

Off

Normal

2 flashes, alternating with Run LED

3 flashes, then off

1 flash per second

Off

Five minute auto-restart delay after system error

Controller has just been formatted

Controller is alone on the network

Exec halted after frequent system errors or control programs halted

Exec start-up aborted, Boot is running

Firmware transfer in progress, Boot is running

Ten second recovery period after brownout

7 flashes per second, alternating with Run LED

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

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APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)



Table G — Network Points List

CCN

READ/

DEFAULT

VALUE

BACNET

OBJECT ID

BACNET

OBJECT NAME

POINT DESCRIPTION

UNITS

RANGE

POINT NAME WRITE

1st Current Alarm State

Active Demand Limit

Actual Guide Vane Position

Actual VFD Speed

Calc Evap Sat Temp

Chilled Water Deadband

Chilled Water Delta P

Chilled Water Delta T

Chilled Water Pump

Chilled Water Temp

Chiller Start/Stop

ALARM_01

DEM_LIM

GV_POS

VFD_ACT

EAT

R/W

N/A

1.0

N/A

OFF

N/A

STOP

N/A

OFF

N/A

0-270

40 to 100

0 to 100

AV:4

AV:6

AV:7

AV:11

AV:13

AV:14

AV:15

AV:16

BV:4

AV:17

BV:5

AV:18

AV:19

AV:20

BV:6

alarm_01_1

dem_lim_1

gv_pos_1

vfd_act_1

ert_1

°F

N/A

°F

N/A

°F

0 to 110

-40 to 245

0.5 to 2.0

-6.7 to 420

-40 to 245

OFF/ON

-40 to 245

STOP/START

-40 to 245

NO/YES

CWDB

cwdb_1

chwpd_1

CHWPD

CHW_DT

CHLP

CHW_TMP

CHIL_S_S

CMPD

MTRW

MTRB

CDW_FLOW

CDP

CRP

CRT

CDWPD

LCW_STPT

CHWSTPT

N/A

chw_dt_1

chlp_1

chw_tmp_1

chil_s_s_1

cmpd_1

mtrw_1

mtrb_1

cdw_flow_1

cdp_1

Comp Discharge Temp

Comp Motor Winding Temp

Comp Thrust Brg Temp

Cond Water Flow

°F

N/A

PSI

°F

PSI

°F

Cond Water Pump

OFF/ON

BV:7

Condenser Pressure

Condenser Refrig Temp

Condenser Water Delta P

Control Point

Current CHW Setpoint

Demand Level 1

Demand Level 2

Demand Level 3

Element Comm Status

-6.7 to 420

-40 to 245

-6.7 to 420

10 to 120

0.00 to 99.9

0 to 100

AV:21

AV:22

AV:23

AV:24

AV:25

AV:1

AV:2

AV:3

BV:2999

crp_1

crt_1

cdwpd_1

R/W

lcw_stpt_1

chwstpt_1

dmv_lvl_1_perct_1

dmv_lvl_2_perct_1

dmv_lvl_3_perct_1

element_stat_1

N/A

0 to 100

No Comm/Normal

N/A

Element Communications

Alarm

N/A

Inactive/Active

BV:20

comm_lost_alm_1

emstop_1

ENABLE/

EMSTOP

Emergency Stop

EMSTOP

ENABLE

BV:8

Entering Chilled Water

Entering Condenser Water

ECW

ECDW

°F

N/A

-40 to 245

AV:26

AV:27

ecw_1

ecdw_1

Comm Normal

Comm Lost

Equipment Alarm

N/A

BV:1

element_alarm_1

Evaporator Pressure

Evaporator Refrigerant Temp

ERP

ERT

PSI

°F

N/A

-6.7 to 420

-40 to 245

AV:28

AV:13

erp_1

ert_1

Leaving Chilled Water -

Prime Variable

LCW

°F

N/A

-40 to 245

AV:31

lcw_1

Leaving Condenser Water

Line Active Current

Line Active Voltage

Line Frequency

Line Power Factor

Local Schedule

Occupied?

Oil Sump Temperature

Remote Start Contact

LCDW

AMPS_ACT

VOLT_ACT

LINEFREQ

LINE_PF

N/A

OCC

OILT

REM_CON

R/W

°F

N/A

OPEN

-40 to 245

0.0 to 99999.0

0 to 99

0.00 to 2.00

No Comm/Normal

NO/YES

AV:32

AV:8

AV:9

AV:30

AV:34

BV:2

BV:10

AV:33

BV:11

lcdw_1

amps_act_1

volt_act_1

linefreq_1

line_pf_1

schedule_1

occ_1

N/A

°F

-40 to 245

OPEN/CLOSE

oilt_1

rem_con_1

N/A

0=Timeout,

1=Ready,

2=Recyle,

3=Startup,

4=Running,

5=Demand,

6=Ramping,

7=Autorest,

8=Override,

9=Tripout,

Run Status

STATUS

N/A

AV:35

status_1

10=Control Test,

11=Lockout,

12=Pumpdown,

13=Prestart

Service Ontime

Surge Line Delta T

S_HRS

DELTA_TX

R/W

°F

N/A

0 to 32767

0 to 200

AV:36

AV:38

s_hrs_1

delta_tx_1

1=Normal,

2=Alert, 3=Alarm

System Alert/Alarm

SYS_ALM

N/A

AV:40

sys_alm_1

611

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APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)

Table G — Network Points List (cont)

CCN

READ/

DEFAULT

VALUE

BACNET

OBJECT ID

BACNET

OBJECT NAME

POINT DESCRIPTION

UNITS

RANGE

POINT NAME WRITE

System Cooling Demand

Level

N/A

AV:9006

cool_demand_level_1

System Demand Limiting

Target Guide Vane Position

Target VFD Speed

N/A

GV_TRG

VFD_OUT

TFR_HIGH

TFR_LOW

N/A

OFF

N/A

OFF/ON

0 to 100

OFF/ON

N/A

BV:3

AV:41

AV:42

BV:13

dem_lmt_act_1

gv_trg_1

vfd_out_1

tfr_high_1

tfr_low_1

user_analog_1_1

user_analog_2_1

user_analog_3_1

user_analog_4_1

user_analog_5_1

user_binary_1_1

user_binary_2_1

user_binary_3_1

user_binary_4_1

user_binary_5_1

Tower Fan Relay High

Tower Fan Relay Low

User Defined Analog 1

User Defined Analog 2

User Defined Analog 3

User Defined Analog 4

User Defined Analog 5

User Defined Binary 1

User Defined Binary 2

User Defined Binary 3

User Defined Binary 4

User Defined Binary 5

N/A

BV:14

AV:2901

AV:2902

AV:2903

AV:2904

AV:2905

BV:2911

BV:2912

BV:2913

BV:2914

BV:2915

N/A

LEGEND

CHW

VFD

— Chilled Water

— Read

— Variable Frequency Drive

— Write

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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 40

711

3-11

Replaces: New

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