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

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

Start-Up and Service Instructions

SAFETY CONSIDERATIONS

Centrifugal liquid chillers are designed to provide safe and

reliable service when operated within design specifica-

tions. When operating this equipment, use good judgment

and safety precautions to avoid damage to equipment and

property or injury to personnel.

Be sure you understand and follow the procedures and

safety precautions contained in the chiller instructions as

well as those listed in this guide.

ONLY QUALIFIED Electrical Personnel familiar with the construction

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

adjust, operate, or service this equipment.

READ AND UNDERSTAND this manual and other applicable manuals in

their entirety before proceeding. Failure to observe this precaution could

result in severe bodily injury or loss of life.

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

nect and lock out incoming power before attempting such installation or

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

injury or loss of life

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

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

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

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

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

injury.

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

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

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

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

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

place oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance with ANSI/ASHRAE 15,

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

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

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

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

and skin irritation. Decomposition products are hazardous.

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

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

substances.

NEVER EXCEED specified test pressures, VERIFY the allowable test

pressure by checking the instruction literature and the design pressures on

the equipment nameplate.

DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF any safety device.

BE SURE that all pressure relief devices are properly installed and func-

tioning before operating any chiller.

THERE IS A RISK OF INJURY OR DEATH by electrocution. High volt-

age may be present on the motor leads even though the motor is not run-

ning. Open the power supply disconnect before touching motor leads or

terminals.

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

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

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

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

duces toxic gases.

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

trician.

DO NOT WORK ON electrical components, including control panels,

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

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

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS

INTERRUPTED, confirm that all circuits are deenergized before resuming

work.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes.

USE SAFETY GOGGLES. Wash any spills from the skin with soap and

water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES

with water and consult a physician.

DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while chiller is

under pressure or while chiller is running. Be sure pressure is at 0 psig (0

kPa) before breaking any refrigerant connection.

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

capacitors has discharged completely before servicing. Check the DC bus

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

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

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

surements.

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

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

damage to, or destruction of, the equipment.

THIS DRIVE contains ESD (Electrostatic Discharge) sensitive parts and

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

servicing or repairing this assembly. Component damage may result if

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

reference Rockwell publication Guarding Against Electrostatic Damage, or

any other applicable ESD protection handbook.

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

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

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

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

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

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

of, the equipment.

MOST CODES require that upstream branch circuit protection be pro-

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

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

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

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

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

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

equipment.

DISTRIBUTION SYSTEM short circuit capacity shall not exceed the rat-

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

to, or destruction of, the equipment.

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

release refrigerant, causing personal injury.

DO NOT climb over a chiller. Use platform, catwalk, or staging. Follow

safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move

inspection covers or other heavy components. Even if components are

light, use mechanical equipment when there is a risk of slipping or losing

your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE

THE VFD, TOWER FAN, OR PUMPS. Open the disconnect ahead of the

VFD, tower fans, or pumps.

USE only repair or replacement parts that meet the code requirements of

the original equipment.

PERIODICALLY INSPECT all valves, fittings, and piping for corrosion,

rust, leaks, or damage.

DANGER

WARNING

CAUTION

19XRV

with PIC III Controls

Rockwell PowerFlex 755 VFD Option

1 2 3 4 5 6 ... 39 40

Sommario

Pagina 1 - SAFETY CONSIDERATIONS

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

Pagina 2

10 DPI PORT 02 (COMPUTER PORT) DIGITAL INPUT TERMINAL BLOCKS (SLOTS 04 & 05)ETHERNET/IP ADDRESS SWITCHESDIGITAL OUTPUT TERMINAL BLOCKS (SLOTS 04

Pagina 3 - Opening the VFD Access Door

11Table 4 — ICVC Alert CodesPRE-START ALERTS: These alerts only delay start-up. When alert is corrected, the start-up will continue. No reset is neces

Pagina 4

12Table 4 — ICVC Alert Codes (cont)NORMAL RUN WITH OVERRIDES*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point prede

Pagina 5

13Table 4 — ICVC Alert Codes (cont)CHILLER ALERTS*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefined or se

Pagina 6 - — VFD Configurations

14Table 4 — ICVC Alert Codes (cont)CHILLER ALERTS (cont)*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predefine

Pagina 7

15Table 5 — ICVC Alarm CodesCHILLER PROTECTIVE LIMIT FAULTS*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., set point predef

Pagina 8 - Troubleshooting the Drive —

16Table 5 — ICVC Alarm Codes (cont)CHILLER PROTECTIVE LIMIT FAULTS (cont)*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., se

Pagina 9 - CONTROL BOARDS

17Table 5 — ICVC Alarm Codes (cont)CHILLER PROTECTIVE LIMIT FAULTS (cont)*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., se

Pagina 10

18Table 5 — ICVC Alarm Codes (cont)CHILLER PROTECTIVE LIMIT FAULTS (cont)*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., se

Pagina 11 - Table 4 — ICVC Alert Codes

19Table 5 — ICVC Alarm Codes (cont)CHILLER PROTECTIVE LIMIT FAULTS (cont)*[LIMIT] is shown on the ICVC as the temperature, pressure, voltage, etc., se

Pagina 12 - NORMAL RUN WITH OVERRIDES

2CONTENTSPageSAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pagina 13 - CHILLER ALERTS

20Table 6 — Powerflex 755 Fault Code Descriptions and Corrective ActionsVFD FAULT CODE ON VFD HIST SCREENICVC FAULT STATEFAULT TYPE DESCRIPTION CORREC

Pagina 14 - CHILLER ALERTS (cont)

21Table 6 — Powerflex 755 Fault Code Descriptions and Corrective Actions (cont)VFD FAULT CODE ON VFD HIST SCREENICVC FAULT STATEFAULT TYPE DESCRIPTION

Pagina 15 - Table 5 — ICVC Alarm Codes

22Table 6 — Powerflex 755 Fault Code Descriptions and Corrective Actions (cont)Checking Power Modules and Motor Inputwith Input Power Off — Use the fo

Pagina 16

23Servicing the Drive1. Using recommended screwdriver = 6.4 mm (0.25 in.) flator T20 star, open access door. See Fig. 16.2. Check to be sure that the

Pagina 17

24REPLACING THE GATEWAY (A-B20-750-20COMMOPTION CARD) — The following are the steps for remov-ing and replacing the existing gateway.1. Disconnect po

Pagina 18

25CHILL PLATE FAN AND INTERNAL FAN REPLACE-MENT — The following are the steps to replace the chill platefan and internal fan in Frames 6 and 7.Frame 6

Pagina 19 - OUT-OF-RANGE SENSOR

26Frame 7:1. Disconnect power to the drive. Before removing the en-closure, open the access door on the front of the drive. See Fig. 16.2. Check to be

Pagina 20 - Table 6

27LEGEND1—PF750 Series, Precharge Kit2—PF750 Series, Gate Interface3—PF750 Series, Power Interface4—PowerFlex 750 Series, Flange Gasket5—PF755 Main Co

Pagina 21

28APPENDIX A — WIRING SCHEMATICSCHILLER CONTROL SCHEMATICNOISESUPPRESSORVFD COOLANTSOLENOID)RLC()KLB()NRB((BRN)RMS+S-RELATIVEHUMIDITY(BLK)(WHT)(RED)JU

Pagina 22 - — Diode Checks

29APPENDIX A — WIRING SCHEMATICS (cont)CHILLER CONTROL SCHEMATIC (cont)(RED)(BLK)(BRN) (BRN)(WHT)T224VAC(GRN)(RED)(RED)(BLU)(BLU)(BLK)SOLENOIDHGBP(YEL

Pagina 23 - Where overhead room

3Opening the VFD Access Door1. Using recommended screwdriver = 6.4 mm (0.25 in.) flator T20 star, open access door. See Fig. 2.2. Check to be sure tha

Pagina 24 - <45°

30APPENDIX A — WIRING SCHEMATICS (cont)ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical)NOTNOTUSEDUSEDa19-1966CONTINUED ONFACIN G PAGE611

Pagina 25 - A19-1840

31APPENDIX A — WIRING SCHEMATICS (cont)ROCKWELL POWERFLEX 755 WIRING SCHEMATIC (Typical) (cont)34343333TB4TB4CARRIERFACTORYWIRINGDETAIL ASEEDETAILA353

Pagina 26 - VIEW FROM INSIDE

32APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRINGOptional BACnet* Communications Wiring —The following section is used to configure the UPC Open co

Pagina 27 - Fig. 28 — Frame 7 Parts

33APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)CONFIGURING THE BAS PORT FOR BACNET MS/TP — Use the same baud rate and communication settin

Pagina 28 - CHILLER CONTROL SCHEMATIC

34APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)To install a BT485 terminator, push the BT485 terminatoron to the BT485 connector located n

Pagina 29 - HOT GAS BYPASS

35APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)Table D — Open System Wiring Specifications and Recommended Vendors

Pagina 30 - FACIN G PAGE

36APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)COMMUNICATION LEDS — The LEDs indicate if thecontroller is communicating with the devices

Pagina 31

37APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)Table G — Network Points ListPOINT DESCRIPTIONCCNPOINT NAMEREAD/WRITEUNITSDEFAULTVALUERANGE

Pagina 32 - 1's

38APPENDIX B — OPTIONAL BACNET COMMUNICATIONS WIRING (cont)Table G — Network Points List (cont) LEGENDPOINT DESCRIPTIONCCNPOINT

Pagina 33

Pagina 34

4LEGENDFig. 5 — Frame 6 Drive Components NO. NAME DESCRIPTION1 Power Terminals R/L1, S/L2, T/L3, U/T1, V/T2, W/T32PE Grounding Studs Terminating point

Pagina 35

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

Pagina 36 - — The LEDs indicate if the

5START-UPAlternate Wire Lugs — In the case where the incomingpower wire size does not fit the standard lug, alternate lugs maybe used. See Table 1. No

Pagina 37 - Table G — Network Points List

6Configure the VFD — All configurations required bythe VFD are supplied by the ICVC through the VFD Gateway.Any configuration changes necessary and po

Pagina 38

7Vmax = Maximum measured phase-to-phase voltage (A to B, B to C, C to A)Vmin = Minimum measured phase-to-phase voltage Imbalance Calculation Formula8

Pagina 39

8SERVICETroubleshooting the Drive — The drive can displaytwo kinds of error codes on the ICVC called the Alert andAlarm codes. These codes signal a pr

Pagina 40

9Table 3 — Drive Status Indicator DescriptionsNOTES:1. A Type 1 alarm indicates that a condition exists. Type 1 alarmsare user configurable.2. A Type

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