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
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
I
1
See Fig. 7 for the dimensions of Frames 6 and 7.
LOCKOUT/TAGOUT
O
2
0V
DC+ DC–
DC BUS TEST
TERMINALS
LOCATED INSIDE
ACCESS DOOR
MULTIMETER
0V
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
3
A19-
1832
LEGEND
NO.
1
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
2
3
DC Bus and Brake
Terminals
+DC, -DC, BR1, BR2
4
5
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.
1
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
2
3
DC Bus and Brake
Terminals
+DC, -DC, BR1, BR2
4
5
PE-A and PE-B
DC+ and DC-
MOV and CMC Jumper Wires
Bus Voltage Test Points
Fig. 6 — Frame 7 Drive Components
4
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:
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.
5
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
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
1
102.0
102.0
102.0
0.0
10
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)
10
40
10
40
10
30
30
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.
6
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
=
=
3
(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.
1
NAME
HIM Connector
Fan Connector
DESCRIPTION
DPI Port 1 (HIM Cradle) connection.
Power supply for internal cooling fan
(Frames 2 & 3).
2
Battery
Receptacle
User installed CR1220 lithium coin cell
battery provides power to the Real Time
Clock (Optional, not supplied).
3
DPI Port 2
Cable connection for handheld and
remote HIM options.
4
5
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
6
7
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.
8
9
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
7
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
8
7
9
4
5
2
6
Fig. 11B — Jumper Wire Locations — Frame 7
1
3
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.
A1
9-
1815
Fig. 12 — Drive Status Indicator
8
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.
9
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
10
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
100Excessive 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
101Comp 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
102Comp 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
103Comp 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
104Evaporator 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
105Oil 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
106Condenser 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
107Percent 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
108Percent 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
109Actual Guide Vane Pos
Calibration Required Before Startup.
110
111
PRESTART
ALERT
HIGH
110Rectifier 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
111Inverter 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.
11
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
120Condenser 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
121Comp 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
122Evaporator 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
123Surge 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
124Run 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 126Rectifier 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 128Inverter 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.
12
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 141Sensor Fault: Check
TEMP
140Sensor 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.
142Low 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
143Line Current Imbal-
ance: Check VFD Fault His-
tory for Values.
144Single 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
145High Percent Line
Check phase to phase and phase to ground line
power.
Check phase to phase and phase to ground line
power.
Voltage [VALUE].
146Low 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
148Control Power-Loss
When Running.
Check 24 vac control power supply to ICVC.
149
SENSOR ALERT
HIGH DISCHARGE TEMP 149Comp 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
150Comp 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
151High 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
152Excessive 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 153Lead/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
154Condenser 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
155Sensor Fault/Option
Disabled: Remote Reset
Sensor.
156Sensor Fault/Option
Disabled: Auto Chilled Water Check for proper wiring to CCM connector J5.
Reset.
157Sensor Fault/Option
Disabled: Auto Demand Limit Check for proper wiring to CCM connector J5.
Input.
158Spare 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
#1
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.
13
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
#2
159Spare 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
161WSM 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
SENSOR ALERT
EVAPORATOR
APPROACH
162Evaporator 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 163Condenser 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
164Actual 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
165Low DC Bus Voltage:
[VALUE] Exceeded Limit of
[LIMIT]*.
166High 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 167Comp 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
168Sensor 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.
14
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
200Rectifier 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 201Inverter Power Fault:
Check VFD Status.
PROTECTIVE LIMIT MOTOR AMPS NOT
202Motor Amps Not
Sensed — Average Load
Current [VALUE].
SENSED
203
FAILURE TO START MOTOR ACCELERATION 203Motor 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 204VFD 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
205High DC Bus Voltage:
[VALUE] exceeded limit of
[LIMIT]*.
206
207
PROTECTIVE LIMIT VFD FAULT
206VFD Fault Code:
[VALUE]; Check VFD Fault
Code List.
See VFD Fault Code description and corrective
action.
PROTECTIVE LIMIT HIGH CONDENSER
207High 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
208Percent 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
209Line 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 210Single 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
211High Percent Line Volt- Check phase to phase and phase to ground dis-
age [VALUE]. tribution bus voltage. Consult power company.
212Low Percent Line Volt- Check phase to phase and phase to ground dis-
age [VALUE]. tribution bus voltage. Consult power company.
213VFD 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
214Control 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
215Low DC Bus Voltage:
[VALUE] exceeded limit of
[LIMIT]*.
216Line 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 217Motor Overload Trip;
Check VFD configurations.
218
PROTECTIVE LIMIT VFD RECTIFIER
218VFD 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
219VFD 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.
15
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
220Ground 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 222Line Frequency —
221UNUSED
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
223Loss 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 224Loss 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
225Motor 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 226Line Phase Reversal:
Reverse connections of any two line conductors
to circuit breaker.
Check Line Phases.
PROTECTIVE LIMIT OIL PRESS SENSOR
227Oil 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
228Low 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
229Low 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
230Low 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 231Comp 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
232Evaporator 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.
16
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
233Comp 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
234Comp 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
235Condenser 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/
236Compressor 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
237Spare Safety Device.
238Compressor 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
239Transducer 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
240Check 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
241Rectifier 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
242Loss of Communica-
tion With CCM, Check
Comm. Connectors.
COMMUNICATION
243
POTENTIAL
FREEZE-UP
EVAP PRESS/TEMP
TOO LOW
243Evaporator 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
244Condenser 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.
17
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
245Actual 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
246Diffuser Control Invalid Check 25%, 50%, and 75% Guide Vane and Dif-
Configuration: Check SETUP2 fuser Load Point entries in SETUP2 screen.
Entries.
247Diffuser 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
248Spare Temperature #1 Check Spare Temperature Enable and Spare
#1
[VALUE] exceeded limit of
[LIMIT]*.
Temperature Limit in SETUP1 Screen.
249
PROTECTIVE LIMIT SPARE TEMPERATURE
249Spare Temperature #2 Check Spare Temperature Enable and Spare
#2
[VALUE] exceeded limit of
[LIMIT]*.
Temperature Limit in SETUP1 Screen.
250
251
UNUSED
UNUSED
250Unused State.
PROTECTIVE LIMIT VFD CONFIG CONFLICT 251VFD 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 252VFD 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
253Guide 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 254Checksum Error:
Actual VFD checksum does not match calcu-
lated value.
Press Reset to Restore
Configuration
PROTECTIVE LIMIT VFD DEW PREVENTION 255Dew 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
256Inductor Overtemp Trip - Check for cooling fan air flow obstructions.
Check Temp Switch and Cool-
ing Fans.
257VFD 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
258Unused.
*[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.
18
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
259CCN 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
282Line 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
283Compressor 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
VFD GATEWAY
COMPATIBILITY
CONFLICT
284VFD Gateway Compati- VFD Gateway and VFD software versions are
bility Conflict: Check VFG/
VFD Versions.
not compatible.
Call Carrier Service.
COMPATIBILITY
CONFLICT
285VFD Gateway Compati- VFD Gateway and ICVC software versions are
bility Conflict: Check VFG/
ICVC Versions.
not compatible.
Call Carrier Service.
PROTECTIVE LIMIT INVERTER
OVERCURRENT
286Inverter 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 260Sensor 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
261Sensor 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 262Sensor Fault: Check
Check sensor wiring.
Condenser Pressure Sensor.
Check for disconnected or shorted wiring.
Check for condensation in transducer
connector.
263
SENSOR FAULT EVAPORATOR
263Sensor 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 264Sensor 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
265Sensor 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 266Sensor 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
267Sensor 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
268Sensor Fault: Check Oil
Pump Delta P Sensor.
269Sensor 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
270Sensor 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 271Sensor Fault: Check
Check sensor resistance or voltage drop.
Evap Saturation Temp Sensor. Check for proper wiring.
Check for disconnected or shorted wiring.
19
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
0
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.
2
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.
3
4
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.
5
7
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.
8
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.
9
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.
12
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%
13
14
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-
15
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.
17
216
20
21
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.
24
204
Decel Inhibit
33
36
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
20
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
38
39
40
41
42
43
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
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.
44
45
46
206
206
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
55
NONE Inverter Overtemp
61
62
206
206
Shear Pin 1
Shear Pin 2
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
Check for high entering water temperature or low
condenser water flow. Check current settings in
VFD_CONF screen.
64
206
Drive Overload
Drive is overloaded
65
77
206
206
OW TrqLvlTimeout See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
IR Volts Range
See VFD Fault Code 15
FluxAmpsRef
Rang
78
206
See VFD Fault Code 15
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
79
206
Excessive Load
Repeat Autotune
80
87
206
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.
91
93
94
95
96
97
206
206
206
206
206
206
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
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
206
206
206
206
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
See VFD Fault Code 15
See VFD Fault Code 15
Verify application version.
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
21
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
206
HW En Jumper
Out
210
See VFD Fault Code 15
See VFD Fault Code 15
211
213
291
292
293
294
295
296
315
316
206
206
206
206
206
206
206
206
206
206
Safety Brd Fault
Safety Jumper In
HSFan Lifwe
InFan Life
MtrBrg Life
MtrBrg Lube
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
See VFD Fault Code 15
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.
(+)
R
S
T
R
S
T
U
V
W
U
V
W
DC+
DC+
DC+
DC-
DC-
DC-
DC+
DC+
DC+
DC-
DC-
DC-
DC+
DC+
DC+
DC-
DC-
DC-
DC+
DC+
DC+
DC-
DC-
DC-
R
S
T
R
S
T
U
V
W
0.5 V
0.5 V
0.5 V
infinite (OL)
Infinite (OL)
Infinite (OL)
0.5 V
0.5 V
0.5 V
infinite (OL)
Infinite (OL)
Infinite (OL)
Infinite (OL)
Infinite (OL)
Infinite (OL)
0.5 V
0.5 V
0.5 V
Infinite (OL)
Infinite (OL)
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.
U
V
W
0.5 V
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.
22
Servicing the Drive
L1 L2 L3
I
1
2
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.
O
0V
DC+ DC–
DC BUS TEST
TERMINALS
MULTIMETER
0V
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
6
7
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
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
23
DRIVE RIGGING ACCESS
DRIVE WIDTH + 4 IN.
<45°
1
/
>
2 A
A
Fig. 20A — Rigging the Enclosure, Frame 6
A19-1837
<45°
1
/
>
2 A
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
24
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
25
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
6
CR2
CR3
CR4
CR5
CR6
CR1
CR1
CR2
CR3
CR4
CR5
CR6
LINE-
PE
CB1
CR6
1
TB4
1
TB4
2
CABLE
ACCESS
CUTOUT
DIST.
SIDE
FU2
FU1 FU3
TB1 TB2
CB2
1
1
1
TB1,TB2,
FU1-FU3
3P
KTK/FNQ-R
TB4
30A
2
2
2
PT1
PT1
SECONDARY
SIDE
TOWARD
DOOR
3
5
4
SECONDARY SIDE
LEFT SIDEWALL
VIEW FROM INSIDE
FRONT VIEW
DOOR REMOVED
80
LEGEND
1
2
3
4
5
6
— Power Module
— Input Circuit Breaker
— 15 Amp Control Circuit Breaker
— Control Transformer
— Control Fuses
— Control Relays (CR1 - CR5)
a19-1847
Fig. 26 — Assembly Parts
26
LEGEND
1
2
3
4
5
6
7
— 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.
8
— 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
27
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
6
OUTPUT
+
-
+
-
+
-
+
-
-
+
-
+
3
2
1
4
3
2
1
6
5
4
3
2
2
1
J5
J6
J7
J8
(RED)
1
EVAP ENT
WATER TEMP
(BLK)
(RED)
2
3
SWITCH POSITION
O
N
1
3
SW "ON" = EXT 4-20mA
SW "OFF" = EXT 1-5Vdc
EVAP LVG
WATER TEMP
(BLK)
(WHT)
(BLK)
4
SW2
(RED)
1 "OFF"
2 "ON"
3 "ON"
(BLU)
(ORN)
5
COND ENT
WATER TEMP
(BLK)
6
(RED)
7
COND LVG
WATER TEMP
(BLK)
(YEL)
8
L1
4
7
(CLR)
9
G.V. POSITION
FEEDBACK
L2
8
(BLK)
10
DIFFUSER ACTUATOR
10K
(SHIELD)
(BLK)
(WHT)
(RED)
(BLK)
11
12
EVAP REFRIG
LIQUID TEMP
(SHIELD)
COMMON
(CLR)
(RED)
(BLK)
X
3
REMOTE TEMP
RESET
(OPTIONAL)
G.V. INCREASE
3
(WHT)
(BLK)
13
14
2
1
G.V. DECREASE
2
L1
L2
15
16
17
18
19
20
GUIDE VANE ACTUATOR
(RED)
(BLK)
(CLR)
(BLK)
(SPARE)
(RED)
(BLK)
COMP'R
DISCH TEMP
(RED)
(BLK)
(CLR)
(BLK)
(BRN)
1
2
3
COMP'R THRUST
BRG TEMP
(YEL)
CB2
(BLK)
(BRN)
(BLU)
(BLK)
(WHT)
(ORN)
(BLK)
6
5
4
3
2
1
VFD COOLANT
SOLENOID
21
22
COMP'R OIL
SUMP TEMP
*
(BLK)
(CLR)
3
1
3C
(BRN)
HGBP (OPTIONAL)
(WHT)
1
2
3
(CLR)
(BLK)
23
24
COMP'R
MOTOR TEMP
(BRN)
C2
C1
(SPARE)
NOISE
SUPPRESSOR
2C
COMP'R OIL PUMP
(WHT)
(RED)
(GRY)
C2
C1
1C
(BRN)
(BRN)
COMP'R OIL HEATER
(WHT)
(BLK)
(WHT)
(BLK)
25
26
27
28
SPARE TEMP #1
(OPTIONAL)
(WHT)
SPARE TEMP #2
(OPTIONAL)
(BLK)
(CLR)
(RED)
(BLK)
(CLR)
CCM
1
2
3
4
5
6
7
8
9
-
OIL SUMP
PRESS
+
+
100»f
-
+
OIL PUMP
DISCH PRESS
+
NOTE: GND SHIELDS AT THIS END ONLY
100»f
(RED)
(BLK)
(SHIELD)
(SHIELD)
LOAD RESISTOR
(RED)
(CLR)
(BLK)
+
G
(RED)
(WHT)
(BLK)
-
4.3K
RELATIVE
HUMIDITY
S
RMS
(RED)
+
CCN
(WHT)
-
10
11
12
SP
1
ALL SWITCHES SET
TO "OFF" POSITION
LOAD RESISTOR
(RED)
(GRY)
10K
2
13
14
15
16
17
18
19
20
21
22
23
24
LOAD RESISTOR
4.3K
JUMPER
J7
J1
ALARM
R
6
LOAD RESISTOR
JUMPER
(RED)
(GRY)
(GRY)
(RED)
(GRY)
(BLK)
(CLR)
(RED)
5
4
3
2
1
2
1
24VAC
ICVC
CB1
4.3K
(GRY)
-
G
+
STOP
J8
SERVICE
(BLK)
(CLR)
(RED)
(BLK)
(CLR)
(RED)
1
2
3
4
5
6
-
+
EVAP PRESS
COND PRESS
-
+
a19-1946
28
APPENDIX A — WIRING SCHEMATICS (cont)
CHILLER CONTROL SCHEMATIC (cont)
(GRN)
1
2
3
TO TB-G **
230V
COM
COMP'R OIL HEATER
11
OPEN
21
22
23
11
12
13
4 CLOSE
5
(BLK)
(BLK)
1C
1C
1C
1C
1C
1C
(BLK)
(WHT)
(WHT)
(WHT)
6
12
13
(BLK)
(WHT)
(BLK)
(WHT)
115V
HGBP
ACTUATOR
(RED)
COM
(WHT)
(BLK)
3C
3C
6
5
(BLK)
2
(WHT)
230V WIRING MODIFICATION
COMP'R OIL HEATER
(BLK)
(BLU)
(BLU)
4
HOT GAS BYPASS
(WHT)
(BLK)
(WHT)
(BLK)
(RED)
(FR #7 & 8 HT EXCH)
115V CONTROL ONLY
(BLK)
(BLK)
(BLK)
(BLK)
(YEL)
(RED)
(ORN)
(BRN)
(BLK)
(CLR)
(BLK)
(RED)
(WHT)
(WHT)
(RED)
(WHT)
(RED)
(WHT)
(RED)
(WHT)
51
50
43
17
C
T3
24VAC
T1
24VAC
T2
24VAC
(BLK)
(BLK)
(GRN)
TO VFD
(BRN)
(BRN)
(BRN)
(BRN)
(BRN)
(BRN)
(BLU)
(RED)
COMP'R DISCH
HIGH PRESS
(BLU)
B
(RED)
HGBP
SOLENOID
(YEL)
(BLK)
A
(SHIELD)
(BLK)
(BLK)
(RED)
(GRY)
(BLK)
(RED)
(GRY)
(YEL)
4
2
(RED)
(BLK)
3C
SHOWN WIRED FOR 115V
(CLR)
(BLK)
(BRN)
23
21
2
1
(GRN)
WHT
WHT
UPC
(WHT)
(WHT)
(BLU)
(RED)
COMP'R OIL PUMP MOTOR
(BLU)
(RED)
(YEL)
(BLK)
WINDING HIGH TEMPERATURE
HGBP
SOLENOID
(WHT)
(RED)
(GRY)
(BLK)
(YEL)
(BLK)
4
2
3C
230V WIRING MODIFICATION
HOT GAS BYPASS
(FR #1 - 6 HT EXCH)
a19-1947
YEL
21
22
23
11
12
13
(YEL)
2C
2C
2C
VOLTAGE
PER JOB
REQM'T
BLK
(1-1/2 HP)
COMP'R OIL
PUMP MOTOR
(BLK)
(RED)
M
RED
LEGEND
CB
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.
29
APPENDIX A — WIRING SCHEMATICS (cont)
ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical)
a19-1966
CONTINUED ON
FACING PAGE
NOT
USED
611
30
APPENDIX A — WIRING SCHEMATICS (cont)
ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)
DETAIL A
34
TB4
TB4
33
CARRIER
FACTORY
WIRING
SEE
DETAIL
A
a19-1967
SEE
DETAIL
B
DETAIL B
POWER
PANEL
TB4
43
35
TB4
19
36
POWER
PANEL
CARRIER
FACTORY
WIRING
LEGEND
CAP
CB
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Capacitor
Circuit Breaker
Common
COM
COMM
COND
CR
Communication
Condenser
Control Relay
DPI/SI
EA
Internal Communication Protocols Connections
Electrical Assembly
Electro-Magnetic Interference
Evaporator
EMI
EVAP
FU
Fuse
GND
JMPR
M
Ground
Jumper
Motor
NC
Normally Closed
Normally Open
Potential Earth (Ground)
I/O Card Mounting Slot Board
Remote
NO
PE
POD
REM
ROC
SHLD
TB
Relay Output Common
Shield
Terminal Block
* Located outside of starter; connected by field wiring.
31
611
APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING
Optional BACnet* Communications Wiring —
0
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.
1
9
2
8
7
3
10's
1's
5 4
a48-8578
6
0
1
9
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.
2
8
7
3
5 4
6
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).
32
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
Off
Off
Off
On
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
On
Off
On
DS1
Off
Off
On
On
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
33
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
DC
— American Wire Gage
— Class 2 Plenum Cable
— Direct Current
FEP
NEC
O.D.
TC
— Fluorinated Ethylene Polymer
— National Electrical Code
— Outside Diameter
— Tinned Copper
— Underwriters Laboratories
UL
34
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
TC
LOCAL ACCESS TO THE UPC OPEN CONTROL-
LER — The user can use a BACview6 handheld keypad dis-
play unit or the Virtual BACview software as a local user inter-
face to an Open controller. These items let the user access the
controller network information. These are accessory items and
do not come with the UPC Open controller.
The BACview6 unit connects to the local access port on the
UPC Open controller. See Fig. F. The BACview software must
be running on a laptop computer that is connected to the local
access port on the UPC Open controller. The laptop will re-
quire an additional USB link cable for connection.
If modifications to the default Element and Bus number are
required, both the ComfortLink and UPC Open configurations
must be changed.
The following configurations are used to set the CCN Ad-
dress and Bus number in the ComfortLink control. These con-
figurations can be changed using the scrolling marquee display
or accessory Navigator handheld device.
Configuration→CCN→CCN.A (CCN Address)
Configuration→CCN→CCN.B (CCN Bus Number)
The following configurations are used to set the CCN Ad-
dress and Bus Number in the UPC Open controller. These con-
figurations can be changed using the accessory BACview6 dis-
play.
See the BACview Installation and User Guide for instruc-
tions on connecting and using the BACview6 device.
To order a BACview6 Handheld (BV6H), consult Commer-
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 — BACview6 Device Connection
35
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
Rx
Tx
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.
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
2 flashes per second
2 flashes per second
2 flashes per second
2 flashes per second
5 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
On
On
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
36
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
R/W
R
R
R
R
R
R
R
R
R/W
R
R
R
R
R
R
R
N/A
N/A
N/A
N/A
N/A
1.0
N/A
N/A
OFF
N/A
STOP
N/A
N/A
N/A
NO
OFF
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
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
^F
^F
^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
-40 to 245
-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
°F
N/A
N/A
PSI
°F
PSI
°F
°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
R/W
R
R
R
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
N/A
N/A
0 to 100
0 to 100
No Comm/Normal
R
R
N/A
Element Communications
Alarm
N/A
R
R
N/A
N/A
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
R
R
°F
°F
N/A
N/A
-40 to 245
-40 to 245
AV:26
AV:27
ecw_1
ecdw_1
Comm Normal
Comm Lost
Equipment Alarm
N/A
R
N/A
N/A
BV:1
element_alarm_1
Evaporator Pressure
Evaporator Refrigerant Temp
ERP
ERT
R
R
PSI
°F
N/A
N/A
-6.7 to 420
-40 to 245
AV:28
AV:13
erp_1
ert_1
Leaving Chilled Water -
Prime Variable
LCW
R
°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
R
R
R
R
R
R
R
R/W
°F
A
V
N/A
N/A
N/A
N/A
N/A
N/A
NO
N/A
OPEN
-40 to 245
0.0 to 99999.0
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
Hz
N/A
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
R
N/A
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
R
hr
°F
N/A
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
R
N/A
N/A
AV:40
sys_alm_1
611
37
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
R
N/A
N/A
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
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
N/A
%
%
N/A
N/A
N/A
OFF
OFF
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
OFF/ON
0 to 100
0 to 100
OFF/ON
OFF/ON
N/A
N/A
N/A
N/A
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
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
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
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
LEGEND
CHW
R
VFD
W
— Chilled Water
— Read
— Variable Frequency Drive
— Write
38
Copyright 2011 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190012-01
Printed in U.S.A.
Form 19XRV-3SS
Pg 40
711
3-11
Replaces: New
|