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Installation, Operation and Maintenance Manual

IOMM Starter

Group:

Chiller

Part Number: 331375501

Effective: Sept. 2005

Supercedes:

New

Starters for Centrifugal Chillers

Low Voltage, Solid State and Wye-Delta

Medium/High Voltage, Solid State and Across-the-Line

Содержание RVSS14

Страница 1: ... Maintenance Manual IOMM Starter Group Chiller Part Number 331375501 Effective Sept 2005 Supercedes New Starters for Centrifugal Chillers Low Voltage Solid State and Wye Delta Medium High Voltage Solid State and Across the Line ...

Страница 2: ...rs 200 600 Volts 27 Introduction 27 Viewing Data 27 Changing Parameters 32 Fault Code Troubleshooting Chart 40 General Troubleshooting Chart 48 Operation Medium High Voltage Starters 2300V 7 2KV 52 Introduction 52 Viewing Data 52 Changing Parameters 53 Quick Start 55 Troubleshooting 57 Fault Log Codes 59 LED Diagnostics 62 Maintenance 63 Index of Figures Tables 65 McQuay is a registered trademark ...

Страница 3: ...and figures are provided The low voltage 200 600 volts starters are characterized by their control software known as D3 Control Certain electrical operating data for these low voltage starters is transmitted to the chiller and can be viewed on the operator touch screen if the Full Metering Option has been ordered See page 27 for details Medium and high voltage 2300 7200 volts starters share common...

Страница 4: ...current The amount of current that a specific motor and starter combination will draw during start up Normal inrush current will be substantially less than LRA for all starter types except for across the line starters Full load amps FLA The maximum amps the motor is designed for Rated load amps RLA Actual amperage that the motor draws for a specific application Centrifugal compressor motors operat...

Страница 5: ...rol wiring factory installed or they can be free standing requiring field mounting remote from the unit and field wiring of power and control wiring Because of dimension restrictions for shipping some factory mounted starters for large chillers are shipped separate from the unit Mounting supports are on the unit and preassembled cable kits are provided Mounting and wiring on site are the customer ...

Страница 6: ...the National Electric Code NEC can require more clearance in and around electrical components and must be checked Mounting Make sure that the floor or structural support is adequate to support the full weight of the unit Standard NEMA 1 and NEMA 12 starters must be installed indoors in an area that is not exposed to direct water spray Do not install in areas where the ambient temperature falls bel...

Страница 7: ...he risk of electrical shock current carrying parts and other components of the starter should be inspected and replaced if damaged Equipment is at line voltage when AC power is connected Pressing the Stop push button on the chiller control panel does not remove AC mains potential All phases must be disconnected before it is safe to work on machinery or touch motor terminals and control equipment p...

Страница 8: ...power wiring connections Power wiring to compressors must be in proper phase sequence Motor rotation is set up for clockwise rotation facing the lead end with phase sequence of 1 2 3 Care must be taken that the proper phase sequence is carried through the starter to compressor With the phase sequence of 1 2 3 and L1 connected to T1 and T6 L2 connected to T2 and T4 and L3 connected to T3 and T5 rot...

Страница 9: ...OX to remove all dirt grime moisture and oil 3 Wrap the terminal with Scotchfil putty filling in all irregularities The final result should be smooth and cylindrical 4 Doing one terminal at a time brush the Scotchkote coating on the motor barrel to a distance of up to 1 2 in around the terminal and on the wrapped terminal the rubber insulation next to the terminal and the lug and cable for approxi...

Страница 10: ...the starter for any shipping damage 3 Ensure that all electrical connections are as per the system schematics supplied with the starter and or connection diagrams 4 Ensure that all connections are properly tightened 5 Test L to T resistance of each phase and ensure that it is greater than 50 kohms Reverse leads and test again 6 Check that the gate to cathode resistance of each SCR is between 8 and...

Страница 11: ...ct switch or circuit breaker the incoming connection size is determined by the device size as shown in the above table For standard power block the incoming connections are as shown in Table 2 Low Voltage Wye Delta Table 4 Wye Delta Connection Sizes Standard Power Block Starter Model No Note 1 Incoming Connection Size Power Block Outgoing Connection Size Note 2 D3WD11 2 C 6 300 0 31 D3WD12 2 C 6 3...

Страница 12: ...hen wiring to a starter either factory mounted or free standing with an optional disconnect switch or circuit breaker the incoming lug size is determined by the device size as shown in the above table For standard power block the incoming connections are as shown in Table 2 Medium Voltage Solid State Across the Line Incoming and outgoing connections are crimp type connectors standard bus tabs are ...

Страница 13: ... wiring as shown on Figure 4 if the optional full metering package is ordered with the unit The control circuit on the McQuay centrifugal packaged chiller is designed for 115 volts Control power can be supplied from three different sources If the unit is supplied with a factory mounted starter the control circuit power supply is factory wired from a transformer located in the starter A free standi...

Страница 14: ...ol power source and the unit control panel 2 Panel terminal connectors will accommodate up to number 10 AWG wire Larger conductors will require an intermediate junction box The Unit On Off switch located in the Unit Control Panel should be turned to the Off position any time compressor operation is not desired Low Voltage Starters Control wiring for low voltage starters is per the wiring diagram o...

Страница 15: ...the compressor controller under the operating buttons 3 The bias block is located on the rail just to the left of the compressor controller 4 Note that the connections are to to and SCOM to GND with a shield connection on the starter terminal board Medium high Voltage Starters Control wiring for medium and high voltage solid state and across the line starters is per the wiring diagram on page 16 ...

Страница 16: ...AGE STARTER COOLING TOWER SECONDH STAGE STARTER COOLING TOWER FIRST STAGE STARTER COOLING TOWER BYPASS VALVE COOLING TOWER VFD ALARM RELAY NOTE 4 MICROTECH COMPRESSOR CONTROL BOX TERMINALS CTB1 LOAD COMPRESSOR MOTOR STARTER NOTE 1 115 VAC STARTER LOAD SIDE TERMINBALS VFD STARTER LOAD SIDE TERMINBALS WYE DELTA STARTER LOAD SIDE TERMINBALS SOLID STATE STARTER LOAD SIDE TERMINBALS MEDIUM AND HIGH VOL...

Страница 17: ... lugs only All 24 Vac wiring must be run in separate conduit from 115 Vac wiring 3 Main power wiring between starter and motor terminal is factory installed when chillers are supplied with unit mounted starters 4 For wye delta and solid state starters connected to six 6 terminal motors low voltage the conductors between the starter and motor carry phase current and wire size selection is based on ...

Страница 18: ... Voltage Solid State LVSS LED Display Located on the starter control board View parameters messages and faults Shows software revision on power up Programming Press PARAM to enter the menu and then UP or DOWN to reach the desired parameter Press ENTER to show the present value of the parameter Press UP or DOWN to change the parameter value Press ENTER to store the new value or PARAM to abandon the...

Страница 19: ...age RMS 10 L3 L1 Voltage RMS 11 Overload 12 PF 13 KW 14 KVA 15 KWh 16 MWh 17 Phase Rotation 18 Line Frequency 19 Analog Input Analog Output Function P28 LVSS 0 OFF no output 1 Ave Current 0 200 RLA 2 Ave Current 0 800 RLA 3 Ave Voltage 0 750VAC 4 Thermal Overload 5 KW 0 10KW 6 KW 0 100KW 7 KW 0 1MW 8 KW 0 10MW 9 Analog Input 10 Output Voltage of FV 11 Calibrate full 100 output CT Burden Switch Set...

Страница 20: ...8 9 6 19 2 Kbps 19 2 P27 Modbus Timeout OFF 1 to 120 seconds 3 P28 Analog Output Function 0 to 11 1 P29 Analog Output Span 1 to 125 100 P30 Analog Output Offset 0 to 99 0 P31 Passcode 0 to 9999 P32 Fault Log xFyy Fault Alarm Codes LVSS Description Controlled Stop Auto Reset 00 No fault 01 UTS Time Limit Expired Y Y 02 Motor Thermal Overload Trip Y N 10 Phase Rotation Error not ABC N Y 12 Low Line ...

Страница 21: ...e is set to some value other than OFF then the fault will automatically be cleared after the time specified by P22 Low Voltage Wye Delta LVYD Operation LED Display View parameters messages and faults Shows software revision on power up Programming Press PARAM to enter the menu and then UP or DOWN to reach the desired parameter Press ENTER to show the present value of the parameter Press UP or DOWN...

Страница 22: ...Ave RMS Current 2 L1 RMS Current 3 L2 RMS Current 4 L3 RMS Current 5 Current Imbalance 6 Ground Fault Current 7 Ave L L Voltage RMS 8 L1 L2 Voltage RMS 9 L2 L3 Voltage RMS 10 L3 L1 Voltage RMS 11 Overload 12 PF 13 KW 14 KVA 15 KWh 16 MWh 17 Phase Rotation 18 Line Frequency 19 Analog Input Analog Output Function P20 LVYD 0 OFF no output 1 Ave Current 0 200 RLA 2 Ave Current 0 800 RLA 3 Ave Voltage ...

Страница 23: ...dbus Baud Rate 1 2 2 4 4 8 9 6 19 2 Kbps 19 2 P19 Modbus Timeout OFF 1 to 120 seconds 3 P20 Analog Output Function 0 to 11 1 P21 Analog Output Span 1 to 125 100 P22 Analog Output Offset 0 to 99 0 P23 Passcode 0 to 9999 P24 Fault Log xFyy Fault Alarm Codes LVYD Description Auto Reset 00 No fault 02 Motor Thermal Overload Trip N 10 Phase Rotation Error not ABC Y 12 Low Line Frequency Y 13 High Line ...

Страница 24: ...r every current based calculation If the motor FLA is not entered correctly the current ramp profile and many of the starter s advanced protection features will not function properly Parameter Values The motor FLA parameter is adjustable from 1 to 1200 amps in 1 amp increments Parameter Default The default value for the motor FLA is 1 amp Serv Fact Service Factor Description The service factor par...

Страница 25: ...start command the initial current should be increased If the motor takes off too quickly after a start command the initial current should be decreased The initial current must be set to a value that is lower than the maximum current parameter setting A typical setting for the initial current parameter is from 50 to 175 Values The initial current is adjustable from 50 to 400 in 1 intervals Default ...

Страница 26: ...conds Overload Default The default value for the overload parameter is 10 Phase Order Description The line phasing parameter sets the phase sensitivity of the starter This can be used to protect the motor from a possible change in the incoming phase sequence If the incoming phase sequence does not match the set phase rotation the starter will display phs err while stopped and will fault if a start...

Страница 27: ... wye delta starters with the exceptions noted at the end of the section beginning on page 36 Starter information is available on the starter mounted LED as explained beginning on page 30 If the optional Full Meter Display available only on low voltage starters is ordered with the unit power information will also be available on the chiller s operator interface touchscreen as explained below Figure...

Страница 28: ... Display is included with the unit If the Full Meter Display package is not ordered only the Percent Unit RLA amps will appear on the Home screen This Starter Power screen will remain visible until another display button such as STATE I O etc is selected The option will also provide a starter setpoint screen as in Figure 8 Without this option the setpoints are made on the starter keypad ...

Страница 29: ...r Current 4 600 100 to 800 of FLA SP1 T Sets the maximum current when the compressor starts Initial Starter Current 3 100 50 to 400 of FLA SP1 T Sets the initial current when the compressor starts Rated load Amps 2 1 A Factory set at design conditions T Value that gives the 100 RLA value and used for motor protection Full Load Amps 1 1 A Factory set to motor max current rating T Value used to comp...

Страница 30: ...the following special information under certain conditions Table 8 LED Special Characters Displayed PARAM DOWN UP ENTER RESET LED Display Operating Keys Reset Key No Line Ready Accelerating or Kicking Up to Speed Run Done with Accel ramp but not yet Up to Speed Decelerating Motor Overload Alarm The motor overload level is between 90 and 100 Overload Fault The motor overload level has reached 100 O...

Страница 31: ...ad content Press UP to display the incoming line phase order Press ENTER to display the status meter Log Press PARAM Select P24 and press ENTER The most recent fault will be displayed as xFyy where x will be 1 to indicate the most recent fault is being displayed and yy is the fault code Press DOWN to view older faults Up to 9 faults may be stored in the log tting a Fault First correct the cause of...

Страница 32: ...ilable parameters 3 The value of the parameter can be viewed by pressing the ENTER key 4 When viewing the parameter value the parameter can be changed by using the UP and DOWN keys 5 To store the new value press the ENTER key When the ENTER key is pressed the value will be saved and the display will go back to parameter P_ To exit parameter change mode without saving the new parameter value either...

Страница 33: ...999 Amps 10 P2 Motor RLA 1 to 9999 Amps 10 P3 Motor Service Factor 1 00 to 1 99 1 08 P4 Motor Overload Class OFF 1 to 40 10 P5 Initial Motor Current 50 to 400 FLA 100 P6 Maximum Motor Current 100 to 800 FLA 600 P7 Ramp Time 0 to 300 seconds 15 P8 UTS Time Up To Speed 1 to 900 seconds 30 P9 Stop Mode CoS Coast dcL Voltage Decel CoS P10 Decel Begin Level 100 to 0 Volts 40 P11 Decel End Level 50 to 0...

Страница 34: ...verload Alarm The motor overload level is between 90 and 100 Overload Fault The motor overload level has reached 100 Overload Lockout A start is not allowed until the motor overload level cools below 100 Control Power Lockout A start is not allowed because the control power is too low xxx xxx overload content Press DOWN to toggle xx xx Alarm code If the condition persists a fault will occur xx xx ...

Страница 35: ... The following meters can be selected using the Meter display parameter P13 Status Avg Voltage RMS KVA Avg RMS current L1 L2 Voltage RMS KWh Phase 1 RMS current L2 L3 Voltage RMS MWh Phase 2 RMS current L3 L1 Voltage RMS Phase Rotation Phase 3 RMS current Overload Line Frequency Current Imbalance Power Factor GF Current FLA KW Alarm Condition When an alarm condition exists the display alternates b...

Страница 36: ...s To restore ALL parameters to the factory default settings press and hold the PARAM and ENTER pushbutton switch on power up The display will blink dFLt Parameters unique to the motor starter applications will need to be set again to appropriate values before motor operation Resetting a Fault To reset from a fault condition press RESET Emergency Thermal Reset To perform an emergency thermal reset ...

Страница 37: ...e Delta starter mode to operate properly one output relay needs to be programmed to the RUN output function and another output relay needs to be programmed to the UTS output function Refer to parameters I 0 04 06 P42 44 for more information Wye Delta Operation When the D3 control Starter Type parameter FUN 07 P64 is set to Wye Delta the D3 control is configured to operate an electromechanical Wye ...

Страница 38: ...rting mode by energizing the relay programmed as RUN The transition to Wye Starting mode occurs as follows 1 Start command is given to the starter 2 The RUN relay is energized which energizes the 1S contactor 3 When the 1S contactor pulls in the 1M contactor is energized The D3 starter will remain in the Wye mode until either 1 The start command is removed 2 The Transition Time QST 09 P9 expires o...

Страница 39: ...lerating when in Wye mode and may stop accelerating at a low speed until the transition to Delta mode occurs If this occurs the start is unnecessarily prolonged and motor heating is increased A typical closed transition Wye Delta starting current profile is shown in Figure 11 Figure 11 Wye Delta Profile 100 200 300 400 500 600 0 100 speed Wye Delta Closed Transition Current Profile Full Load Motor...

Страница 40: ...rify that the motor FLA QST 01 P1 CT ratio FUN 03 P68 and burden switch settings are correct If motor OL trip occurs during starting review acceleration ramp profile settings Verify that there is not an input line power quality problem or excessive line distortion present Verify that PF caps if installed are ahead of CT s F02 F OL Motor Thermal Overload Trip Reset overload when content falls below...

Страница 41: ...er setting PFN 08 P31 was detected for longer than the Over Under Voltage Trip delay time PFN 09 P32 Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter FUN 05 P66 is set correctly Check input supply for open fuses or open connections F21 Low Line L1 L2 On medium voltage systems verify wiring of the voltage measurement circuit Low voltage below the Undervo...

Страница 42: ...L1 Verify that the Rated Voltage parameter FUN 05 P66 is set correctly Line power quality problems excessive line distortions The D3 control has detected the loss of one or more input or output phases when the starter was running Can also be caused by line power dropouts Check input supply for open fuses Check power supply wiring for open or intermittent connections Check motor wiring for open or ...

Страница 43: ...of under current condition A current imbalance larger than the Current Imbalance Trip Level parameter setting PFN 05 P28 was present for longer than ten 10 seconds Check motor wiring for cause of imbalance Verify dual voltage and 6 lead motors for correct wiring configuration Check for large input voltage imbalances that can result in large current imbalances F37 Current Imbalance Check motor for ...

Страница 44: ...pped F41 Current at Stop Verify that the motor FLA QST 01 P1 CT ratio FUN 03 P68 and burden switch settings are correct The D3 electronic power stack OL protection has detected an overload condition Check motor for jammed or overloaded condition Verify Starter Model Number parameter setting FUN 13 P70 is correct if available Verify that the CT ratio FUN 03 P68 and burden switch settings are correc...

Страница 45: ...rent Sensor Offset Error Consult factory if fault persists F52 Burden Switch Error The burden switch settings were changed when starter was running Only change burden switches when starter is not running DI 1 has been programmed as a fault type digital input and the input indicates a fault condition is present Verify that the appropriate Digital Input Configuration parameter has been programmed co...

Страница 46: ...display interface board when present is firmly attached to D3 control card F81 SPI Communication Fault Route keypad cables away from high power and or high noise areas to reduce possible electrical noise pickup Indicates that the starter has lost serial communications Fault occurs when the starter has not received a valid serial communications within the Communication Timeout parameter FUN 12 P59 ...

Страница 47: ... problem Consult factory F97 CPU Error SW Watchdog Fault The D3 control has detected an internal software problem Consult factory F98 CPU Error The D3 control has detected an internal CPU problem Consult factory The non volatile program memory has been corrupted F99 CPU Error Program EPROM Checksum Fault Consult factory Control software will need to be reloaded in to the D3 control card before nor...

Страница 48: ...ontrol board On medium voltage systems verify wiring of the voltage feedback measurement circuit NOL or No Line is displayed and a sratr command is given it will fault in F28 No line voltage has been detected by the D3 st is given rterarter See fault code troubleshooting table for more details During starting motor rotates but does not reach full speed Condition Cause Solution Fault Displayed Faul...

Страница 49: ...ation ramp settings Motor loading too high Reduce load on motor during starting Motor RLA P1 or CT ratio P15 parameter set incorrectly Verify that Motor FLA and CT ratio parameters are set correctly Abnormally low line voltage Fix cause of low line voltage Motor accelerates too slowly Ramp time to long Decrease ramp time Motor stops unexpectedly while running Condition Cause Solution Fault Display...

Страница 50: ...sues Motor Current or Voltage meters fluctuating with steady load Other equipment on same power feed causing power fluctuations and or distortion Fix cause of power fluctuations and or distortion Voltage Metering not reading correctly In medium voltage systems Rated Voltage parameter FUN 05 P66 set incorrectly Verify that Rated Voltage parameter is set correctly CT ratio parameter FUN 03 P68 set i...

Страница 51: ...ngs Motor Overheats Motor cooling obstructed damaged Remove cooling air obstructions Check motor cooling fan Fan power supply lost Verify fan power supply check fuses Fan wiring problem Check fan wiring Starter cooling fans do not operate When Present Fan failure Replace fan Voltage Current output jumper JP1 not set correctly Set jumper to give correct output Wiring problem Verify output wiring An...

Страница 52: ...2 to HVSS05 Solid State 5 1KV to 7 2KV Free standing MVAT12 to MVAT36 Across the Line 2300V Free standing MVAT16 to MVAT25 Across the Line 3300V Free standing MVAT13 to MVAT26 Across the Line 4160V Free standing HVAT27 Across the Line 6600V Free standing Figure 12 LED Display Keypad Viewing Data Follow these steps to access a specific parameter in the Micro II controller menu structure Press the M...

Страница 53: ...ss to enter a menu Press to enter a sub menu Press to change the parameter displayed Press to store the new value entered Select the menu to enter Select the sub menu to enter Scroll between parameters when in a specific menu or sub menu Increase a parameter value Press to view the meters when the main display is shown Select the menu to enter Select the sub menu to enter Scroll between parameters...

Страница 54: ...tup Run Rtd Setpnts 1 8 Comm Settings Factory Control RTD Setpnts 9 16 Options List Software Part Changing a Parameter To change a parameter follow these steps View the desired parameter by following the Viewing a Parameter instructions Press the Enter button to switch to the change parameter screen Press the Up or Down buttons to get the desired value on the screen Press the Enter button to store...

Страница 55: ...n and should not require further adjustment If the service factor of the motor is not known then the service factor should be set to 1 00 Values The service factor can be set from 1 00 to 1 99 in 0 01 increments NOTE The NEC National Electrical Code does not allow the service factor to be set above 1 40 Check with other local electrical codes for their requirements Default The default value for th...

Страница 56: ... current for the end of the ramp profile and sets the maximum current that is allowed to reach the motor while the motor is being started If the ramp time expires before the motor has reached full speed the starter will hold the current at the maximum current level until the stall time expires the motor reaches full speed or the overload trips Typically the maximum current is set to 600 unless the...

Страница 57: ... control voltage Replace FU1 Check ribbon cables Stopped Control Devices Display buttons disabled Check control devices Enable display buttons No line Missing at least one phase of main po Check power system Table 16 Motor rotates but does not reach full speed Display Cause Solution Fault displayed Shown on display See fault code table Accel or Running Mechanical problems Abnormally low line volta...

Страница 58: ... torque Contact McQuay Factory Service Accelerates too slowly Ramp time Initial current Maximum current setting Kick Start Improper FLA setting Initial torque Maximum torque Contact McQuay Factory Service Motor overheats Duty cycle High ambient Too long acceleration time Wrong overload setting Too long jog cycle Cool between starts Provide better ventilation Reduce motor load Select correct overlo...

Страница 59: ...ver voltage L1 The voltage on line 1 went above the high low voltage setting 18 NonC Over voltage L2 The voltage on line 2 went above the high low voltage setting 19 NonC Over voltage L3 The voltage on line 3 went above the high low voltage setting 20 NonC Low line voltage 1 The voltage on line 1 went below the high low voltage setting 21 NonC Low line voltage 2 The voltage on line 2 went below th...

Страница 60: ...ctly Set switches correctly 73 NonC Bypass Fault The bypass contactor failed to stay energized Check separate bypass for proper wiring Check integral bypass RSxB units control card fuses 74 NonC UTS Timer Limit The motor was not at full speed before the UTS time expired Check motor for jammed or overloaded condition 75 NonC External Trip Power was removed from the external trip input on the comput...

Страница 61: ... A start command was given 105 Stop Commanded A stop command was given 106 Stop Complete The stop sequence is complete and the starter has removed power fro 107 Log System UTS Log System UTS up to speed 147 Log BIST Entered Log BIST entered 148 Log BIST Passed Log BIST passed 154 Log Password CLR Log Password cleared 155 Log Events CLR Log Event log cleared 156 Log System Reset Log System Reset 15...

Страница 62: ...n card is receiving data LED1 Operation Flashes when card is operating Local I O Controller Card LED2 Communication On when valid data is received over the master link Indicates forward SCR condition Stop LEDs must be on or the SCR is shorted Start LEDs will become dimmer as motor accelerates Power LEDP1 LEDP2 LEDP3 SCR Status Run LEDs must be fully off or the SCR is open or misfiring L1 L6 Condit...

Страница 63: ...check for proper operation One Month After Commissioning Re torque all power connections including pre wired equipment If fans are installed check for proper operation After First Month of Operation Re torque all power connections including pre wired equipment annually Clean accumulated dust with clean compressed air Inspect cooling fans if present every three months Clean or replace air vent filt...

Страница 64: ...64 IOMM Starter ...

Страница 65: ...k 10 Table 3 Solid State Connection Sizes Disconnect Circuit Breaker 11 Table 4 Wye Delta Connection Sizes Standard Power Block 11 Table 5 Wye Delta Connection Size Disconnects Circuit Breakers 12 Table 6 Control Power Line Sizing 14 Table 7 Starter Setpoints 29 Table 8 LED Special Characters Displayed 30 Table 9 Setpoints Wye Delta Starter 32 Table 10 Setpoints Solid State Starter 33 Table 11 Sta...

Страница 66: ...nton Virginia 24402 2510 USA 800 432 1342 www mcquay com IOMM Starter 09 05 This document contains the most current product information as of this printing For the most up to date product information please go to www mcquay com ...

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