Controls, Start-Up, Operation, Service And Troubleshooting - Carrier

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LEGENDI 2 t — Current Squared TimeTable 21 — Low Ambient Temperature Controller Fault MessagesFAULT POSSIBLE CAUSES TROUBLESHOOTINGF0001OvercurrentF0002OvervoltageF0003UndervoltageF0004DriveOvertemperatureF0005Drive I 2 tF0011MotorOvertemperature I 2 tF0041Stator ResistanceMeasurement FailureF0051Parameter EEPROM FaultF0052Powerstack FaultF0060Asic TimeoutF0070CommunicationsBoard Setpoint ErrorF0071No Data for USS (RS232Link) DuringTelegram Off TimeF0072No Data from USS (RS485Link) DuringTelegram Off TimeF0080Analog Input -Lost Input SignalF0085External FaultF0101Stack OverflowF0221PI FeedbackBelow Minimum ValueF0222PI Feedback AboveMaximum ValueF0450(<strong>Service</strong> Mode Only)BIST Tests Failure• Motor power does not correspond to theinverter power• Motor lead short circuit• Ground faultCheck the following:1. Motor power (P0307) must correspond to inverter power (P0206)2. Motor cable and motor must have no short-circuits or ground faults3. Motor parameters must match the motor in use4. Motor must not be obstructed or overloadedAfter Steps 1-4 have been checked, increase the ramp time (P1120) and reduce theboost level (P1310, P1311, P1312).• DC-link voltage (r0026) exceeds trip level Check the following:(P2172)1. Supply voltage (P0210) must lie within limits indicated on rating plate• Overvoltage can be caused either by too high 2. DC-link voltage controller must be enabled (P1240) and have parameters setmain supply voltage or if motor is in regenerativemode3. Ramp-down time (P1121) must match inertia of loadcorrectly• Regenerative mode can be caused by fastramp downs or if the motor is driven from anactive load• Main supply failed• Shock load outside specified limits• Ambient temperature outside of limits• Fan failure• Drive overloaded• Duty cycle too demanding• Motor power (P0307) exceeds drive powercapability (P0206)• Motor overloaded• Motor data incorrect• Long time period operating at low speedsStator resistance measurement failureReading or writing of the non-volatile parameterstorage has failedReading of the powerstack information hasfailed or the data is invalidInternal communications failureNo setpoint received from communicationsboard during telegram off timeNo response during telegram off time via USS(BOP link)No response during telegram off time via USS(COM link)• Broken wire• Signal out of limitsExternal fault is triggered via terminal inputsSoftware error or processor failurePID Feedback below minimum value P2268PID Feedback above maximum value P2267Check the following:1. Supply voltage (P0210) must lie within limits indicated on rating plate2. Supply must not be susceptible to temporary failures or voltage reductionsCheck the following:1. Fan must turn when inverter is running2. Pulse frequency must be set to default value3. Air inlet and outlet points are not obstructed4. Ambient temperature could be higher than specified for the drive.Check the following:1. Load duty cycle must lie within specified limits2. Motor power (P0307) must match drive power (P0206)1. Check motor data2. Check loading on motor3. Boost settings too high (P1310,P1311, P1312)4. Check parameter for motor thermal time constant5. Check parameter for motor I 2 t warning level1. Check if the motor is connected to the drive2. Check that the motor data has been entered correctly1. Factory reset and new parameters set2. Replace driveReplace drive1. Acknowledge fault2. Replace drive if repeated1. Check connections to the communications board2. Check the master1. Check connections to the communications board2. Check the master1. Check connections to the communications board2. Check the masterCheck connection to analog inputDisable terminal input for fault trigger1. Run self test routines2. Replace drive1. Change value of P22682. Adjust feedback gain1. Change value of P22672. Adjust feedback gainFault value1. Inverter may run but certain actions will not function correctly1 Some of the power section tests have failed 2. Replace drive2 Some of the control board tests have failed4 Some of the functional tests have failed8 Some of the IO module tests have failed16 The Internal RAM has failed its check onpower-up30
LEGENDI 2 t — Current Squared TimeCooler Pump Control (Configuration→OPTN→PUMP) — The 30RB units can be configured for coolerpump control. Cooler Pumps Sequence is the variable thatmust be confirmed in the field. Proper configuration of thecooler pump control is required to provide reliable chiller operation.The factory default setting for Cooler Pumps Sequence isPUMP=0 (No Pump), for units without the factory-installedhydronic package. For units with the hydronic package, thefactory default setting for Cooler Pumps Sequence is PUMP=1(1 pump only) for single pump units, or PUMP=2 (2 pumpsauto) for dual pump units. For dual pump hydronic optionunits, three control options exist. If the Cooler Pumps Sequence(PUMP) is set to 2, the control will start the pumps andautomatically alternate the operation of the pumps to even thewear of the pumps. If a flow failure is detected, the other pumpwill attempt to start. Two manual control options also exist.When the Cooler Pumps Sequence is set to PUMP=3 CoolerPump 1 will always operate. When the Cooler Pumps Sequenceis set to PUMP=4 Cooler Pump 2 will always operate.It is recommended for all chillers that the cooler pump controlbe utilized unless the chilled water pump runs continuouslyor the chilled water system contains a suitable concentration ofantifreeze solution. When the Cooler Pumps Sequence is configured,the cooler pump output will be energized when the chillerenters an “ON” mode. The cooler pump output is also energizedwhen certain alarms are generated. The cooler pump outputshould be used as an override to the external pump control ifcooler pump control is not utilized. The cooler pump output isenergized if a P.01 Water Exchanger Freeze Protection alarm isgenerated, which provides additional freeze protection if the systemis not protected with a suitable antifreeze solution.For all Cooler Pumps Sequence (PUMP) settings (including0), closure of both the chilled water flow switch (CWFS) andthe chilled water pump interlock contact (connected acrossTB-5 terminals 1 and 2) are required. In addition, for CoolerPumps Sequence settings of PUMP = 1, 2, 3, 4, normally openauxiliary contacts for Pump 1 and Pump 2 (wired in parallel)must be connected to the violet and pink wires located in theharness from the MBB-J5C-CH18 connector. The wires in theTable 22 — Alarm MessagesFAULT POSSIBLE CAUSES TROUBLESHOOTINGA0501Current LimitA0502Overvoltage LimitA0503Undervoltage LimitA0504DriveOvertemperatureA0505Drive I 2 tA0506Drive Duty CycleA0511MotorOvertemperature I 2 tA0541Motor DataIdentification ActiveA0600RTOS Overrun Warning• Motor power does not correspond to thedrive power• Motor leads are too short• Ground fault• Mains supply too high• Load regenerative• Ramp-down time too short• Mains supply too low• Short mains interruptionWarning level of inverter heat-sink temperature(P0614) is exceeded, resulting in pulse frequencyreduction and/or output frequencyreduction (depending on parameters set(P0610)Warning level is exceeded; current will bereduced if parameters set (P0610 = 1)Heatsink temperature and thermal junctionmodel are outside of allowable rangeMotor overloadedMotor data identification (P1910) selected orrunningSoftware error —1. Check whether the motor power corresponds to the drive power2. Check that the cable length limits have not been exceeded3. Check motor cable and motor for short-circuits and ground faults4. Check whether the motor parameters correspond with the motor being used5. Check the stator resistance6. Increase the ramp-up-time7. Reduce the boost8. Check whether the motor is obstructed or overloaded1. Check that mains supply voltage is within allowable range2. Increase ramp down timesNOTE: If the vdc-max controller is active, ramp-down times will be automaticallyincreasedCheck main supply voltage (P0210)1. Check if ambient temperature is within specified limits2. Check load conditions and duty cycle3. Check if fan is turning when drive is runningCheck if duty cycle is within specified limitsCheck if duty cycle is within specified limitsCheck the following:1. P0611 (motor I 2 t time constant) should be set to appropriate value2. P0614 (Motor I 2 t overload warning level) should be set to suitable level3. Are long periods of operation at low speed occurring4. Check that boost settings are not too highWait until motor identification is finishedharness are marked “PMP1-13” and “PMP1-14”. See the fieldwiring diagram in the 30RB Installation Instructions.Regardless of the cooler pump control option selected, ifthe chilled water flow switch/interlock does not close withinthe MINUTES OFF TIME (Configuration→OPTN→DELY) period after the unit is enabled and in an ON mode,alarm P.14 will be generated. Other conditions which will triggerthis alarm include:• Cooler pump interlock is open for at least 30 secondsduring chiller operation.• Lag chiller in Master/Slave Control pump interlock doesnot close after 1 minute of the pump start command.• Cooler pump control is enabled and the chilled waterflow switch/interlock is closed for more than 2 minutesfollowing a command to shut down the pump.The last alarm criterion can be disabled. If Flow Checked ifPmp Off (Configuration→OPTN→P.LOC) is set to NO, thecontrol will ignore the pump interlock input if the cooler pumpoutput is OFF.The ComfortLink controls is the ability to periodicallystart the pumps to maintain the bearing lubrication and seal integrity.If Periodic Pump <strong>Start</strong> (Configuration→OPTN→PM.PS) is set to YES, and if the unit is off at 2:00PM, a pump will be started once each day for 2 seconds. If theunit has 2 pumps, Pump 1 will be started on even days (such asday 2, 4, or 6 of the month); Pump 2 will be started on odddays. The default for this option is PM.PS=NO.The pump will continue to run for 60 seconds after an offcommand is issued.Machine Control Methods — Three variables controlhow the machine operates. One variable controls the machineOn-Off function. The second controls the set point operation.The third variable controls the Heat-Cool operation which isalways set to cool. Table 23 illustrates how the control methodand cooling set point select variables direct the operation of thechiller and the set point to which it controls. Table 23 alsoprovides the On/Off state of the machine for the givencombinations.31
Page 2 and 3: CONTENTS (cont)Page• COOLER LEAVI
Page 4 and 5: Table 2 — Main Base Board Inputs
Page 6 and 7: Table 3 — Scroll Protection Modul
Page 8 and 9: Table 4 — EXV1 Board Inputs and O
Page 10 and 11: Table 6 — Fan Board 1 (AUX1, AUX2
Page 12 and 13: Table 8 — Fan Board 3 (AUX1) Inpu
Page 14 and 15: SIO LENSIO LEN+ G - + G -2212212212
Page 16 and 17: Table 10 — ComfortLink Display Me
Page 18 and 19: Table 12 — Configuring the Master
Page 20 and 21: Capacity Control — The control sy
Page 22 and 23: STAGETOTALCAP.LEGENDMLC — Minimum
Page 24 and 25: If any of these conditions are met,
Page 26 and 27: Table 19 — Head Pressure Control
Page 28 and 29: Table 20 — Low Ambient Temperatur
Page 32 and 33: Control Method(OPER)0(Switch Ctrl)1
Page 34 and 35: Temperature Reset — Temperature r
Page 36 and 37: 5654FLUID TEMPERATURE (deg F)525048
Page 38 and 39: To use 4-20 mA Temperature Reset in
Page 40 and 41: Table 28 — 4 to 20 mA Temperature
Page 42 and 43: Table 29 — 2-Step Demand Limit Co
Page 44 and 45: PRE-START-UPIMPORTANT: Complete the
Page 46 and 47: Operation below minimum flow rate c
Page 48 and 49: MODE 12 (MD12) — Auto Changeover
Page 50 and 51: 1. Cable2. Glass Seal3. Motor Housi
Page 52 and 53: DISASSEMBLYClosedOpenNOTE: Open val
Page 54 and 55: 1130 26 2218 137 16 9 20243 5 28343
Page 56 and 57: Charging with Unit Off and Evacuate
Page 58 and 59: Table 37 — TroubleshootingSYMPTOM
Page 60 and 61: PREFIXCODECoCtFCMCSUFFIXCODE.F1.F2.
Page 62 and 63: Table 38 — Alarm Codes (cont)PREF
Page 64 and 65: Possible Causes — If this conditi
Page 66 and 67: a control option that requires the
Page 68 and 69: interlock (PMPI) contacts. The pump
Page 70 and 71: Suction Transducer FailurePr.04 —
Page 72 and 73: NOTE: The energy management module
Page 74 and 75: Table 43B — 5K Thermistor Tempera
Page 76 and 77: ALM RALT RCL-HTCWFSDLSVDPTEXVEMMFIO
Page 78 and 79: COMPRESSOR AND FAN LOCATIONFig. 37
Page 80 and 81:
COMPRESSOR AND FAN LOCATIONFig. 39
Page 82 and 83:
APPENDIX A — LOCAL DISPLAY TABLES
Page 84 and 85:
Page 86 and 87:
Page 88 and 89:
Page 90 and 91:
Page 92 and 93:
NOTE: See operating modes starting
Page 94 and 95:
APPENDIX B — CCN TABLES (cont)STA
Page 96 and 97:
Page 98 and 99:
Page 100 and 101:
NOTES:1. Compressor capacity will b
Page 102 and 103:
APPENDIX B — CCN TABLES (cont)SET
Page 104 and 105:
APPENDIX B — CCN TABLES (cont)MAI
Page 106 and 107:
APPENDIX B — CCN TABLES (cont)SER
Page 108 and 109:
APPENDIX C — CCN ALARM DESCRIPTIO
Page 110 and 111:
APPENDIX C — CCN ALARM DESCRIPTIO
Page 112 and 113:
Actual start-up 44Alarms and alerts
Page 114 and 115:
Copyright 2007 Carrier CorporationM
Page 116 and 117:
7. Electrical circuit protection ha
Page 118 and 119:
Record Configuration InformationMOD
Page 120 and 121:
Component Test — Complete the fol
Page 122 and 123:
Operating Data:Record the following
Page 124:
Copyright 2007 Carrier CorporationM
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Controls, Start-Up, Operation, Service And Troubleshooting - Carrier

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