Iomm Starter

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

Table of Contents General....................................................................................................................3 Variable Frequency Drives ............................................................................................................4 Basic Electrical Terms...................................................................................................................4

Installation..............................................................................................................5 Mounting Arrangements................................................................................................................5 Receiving and Setting....................................................................................................................6 Location and Mounting .................................................................................................................6

Power Wiring .........................................................................................................8 Connection Sizes.........................................................................................................................10

Control Wiring .....................................................................................................13 Low Voltage Starters...................................................................................................................14 Medium/high Voltage Starters .....................................................................................................15

Startup ..................................................................................................................18 Low Voltage Solid State (LVSS) .................................................................................................18 Low Voltage Wye-Delta (LVYD .................................................................................................21 Medium/High Voltage, Solid State..............................................................................................24

Operation, Low Voltage Starters, 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 of McQuay International © 2005 McQuay International "Illustrations and data cover McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice".

2

IOMM Starter

General These starters are completely automatic and require no operator intervention (other than clearing and resetting faults) to perform their function of providing a controlled connection of the compressor motor to the power supply. The Wye-Delta and solid-state starters have many similar software characteristics and are discussed together in their operating section. However, some parameters and data are different. Where this occurs, separate tables 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 software known as “Micro II Control”, not to be confused with the McQuay MicroTech II™ chiller control system. Figure 1, Wye-Delta Starter

Incoming Lugs Terminal Strip Surge Capacitor

LED Display D3 Controller

Control Transformer and Fuses Contactors Transition Resistors

IOMM Starter

3

Figure 2, Solid State Starter, Wall Mounted Terminal Strip

Disconnect Switch Primary Control Circuit Fuses D3 Controller LED Display SCRs (Behind) Bypass Contactor Control Transformer

Variable Frequency Drives While known and specified for their ability to control compressor motor speed for efficiency enhancement, VFDs also perform starting and motor protection functions. They are only available for 3/60/460-480 service. VFDs are available only from McQuay and when purchased as part of the original chiller purchase. Installation and operation are covered in McQuay manual IOMM VFD.

Basic Electrical Terms Locked rotor amps (LRA): The amount of current that a specific motor will draw at startup, when full voltage is applied across the line. The LRA may be 6 to 8 times FLA, or possibly higher in some cases. Inrush 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 operate at a RLA significantly below their maximum full load amps. RLA is used to determine electrical component sizing such as wire size and disconnect switches. Starting torque: Minimum torque required to begin the motor’s rotation. Bypass contactor: Contactors that bypass auto-transformers, reactors, or SCRs, and allow full power to reach the motor directly.

4

IOMM Starter

Interrupting capacity: The maximum fault current that a circuit breaker or fused disconnect can successfully interrupt. As the rating increases, the construction becomes heavier duty. For disconnect switches with fuses, the rating is based on 0 to 600 volts. For circuit breakers, the voltage and amperage relationship is considered with interrupting capacity decreasing as voltage increases. Withstand rating: There is a period of time that the short circuit current passes to the shorted circuit before the protection device can open. This time can be as long as 0.020 seconds (one cycle). The withstand rating of a starter is the maximum short circuit current that it can pass safely without emitting sparks or debris. Phase amps: The current draw inside the delta connection of a wye-delta motor winding. It is equal to 0.577 x RLA of the motor for a specific load. Open transition: A reduced voltage starter characteristic occurring when the motor is temporarily disconnected from power at the time the starter changes from the starting mode to the final running mode. A second smaller inrush spike will occur. McQuay does not recommend use of this type of starter. Closed transition: A reduced voltage starter characteristic when the motor is NOT temporarily disconnected from the line during the transition from starting mode to operating mode. The electrical load is transferred to resistors during the transition phase and the second inrush spike is suppressed.

Installation Mounting Arrangements Low voltage starters can be factory-mounted with power and control wiring factoryinstalled 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’s responsibility and can be subcontracted to McQuay Factory Service if desired. Medium voltage starters and some size low voltage starters on WSC 100 through 126 are only available for free-standing applications. Low voltage starters can be supplied in several different mounting arrangements depending on the chiller size and starter type. See Table 1 for available arrangements.

IOMM Starter

•

Factory-Mounted (optional): The starter is mounted on the chiller unit with the back of the starter against the motor terminal box and wired directly to the motor. This arrangement is only available on WSC/WDC 063, 079, or 087 units (cover photograph). On models WSC/WDC 048/050, the starter is factory-mounted on the front of the chiller unit and connected to the motor with conduit and cable.

•

Free-standing (standard): Floor-mounted, separate from the chiller unit, and field wired to the compressor motor. This is available on all units and is the only starter arrangement available for WDC/WCC 100 and 126 dual compressor units.

•

Brackets and cable (optional): Starters for WSC 100 and 126 single compressor units may be shipped separately from the chiller unit and furnished with mounting brackets and interconnecting cables for field mounting and connection by others. This option must be clearly specified when chillers are ordered since brackets are welded onto the evaporator during its construction.

5

Table 1, Starter/VFD Mounting Arrangements Size WSC/WDC 050 WSC/WDC 063 WSC/WDC 079 WSC/WDC 087 WSC 100 - 126 WDC 100 - 126 WCC 100 - 126

FactoryMounted X X X X

FreeStanding X X X X X X X

Brackets & Cables

X

Receiving and Setting Since factory-mounted starters are mounted and wired at the factory, this section will only apply to free-standing units. The unit should be inspected immediately after receipt for possible damage. All McQuay centrifugal starters are shipped FOB factory and all claims for handling and shipping damage are the responsibility of the consignee. Extreme care must be used when rigging the starter to prevent damage. See the certified dimension drawings included in the job submittal for the center of gravity of the unit. Consult the local McQuay sales office for assistance if the drawings are not available. The starter can be lifted by fastening the rigging hooks to the four lifting eyes located on the top of the unit.

Location and Mounting Clearance The starter must be mounted on a level concrete or steel base and must be located to provide adequate service. Local codes or 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 below 32°F (0°C) or exceeds 104°F (40°C) enclosed, or 122°F (50°C) open unless this was noted at the time of order placement and special precautions were taken to protect against these abnormal temperatures. Heatsink temperatures can run as high as 158°F (70°C) during normal operation. Do not mount the starter in contact with any material that cannot accept this heat. The starter must be mounted with the heat sink fins oriented vertically in an area that will not experience excessive shock or vibration.

Ventilation Requirements Provisions should be provided in the starter enclosure to ensure that the temperature inside the enclosure never rises above 122°F (50°C) or the starter could be damaged or the life of the starter could be reduced. As a general rule of thumb the following ventilation guidelines should be followed. These values are for starters with bypass. Bypassed starters generally do not require ventilation.

6

IOMM Starter

Safety Precautions Electrical codes require that all equipment (starter, motor, operator station, etc.) be properly grounded. An incoming disconnect must be locked open before wiring or servicing the starter, motor, or other related equipment. The equipment must only be serviced by qualified personnel fully familiar with the equipment. The opening of the branch circuit protective device may be an indication that a fault current has been interrupted. To reduce the 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 parts.

Power Factor Capacitors, Surge Capacitors and Lightning Arrestors These devices MUST NOT be used with solid state starters. The SCR’s in the starter will be damaged by the di/dt levels created. On wye-delta starters, they are connected between the starter and the motor.

IOMM Starter

7

Power Wiring Power wiring between the starter and the compressor motor terminals is field supplied and installed on units with remote-mounted, free-standing starters. See the field wiring diagram on page 16. Wiring, fuse and wire size must be in accordance with the National Electric Code (NEC). Standard NEMA motor starters require modification to meet McQuay specifications. Refer to McQuay Specification R35999901.

CAUTION Important: Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG-1, 1998 Standard. This is an important restriction that must be adhered to.

WARNING Qualified and licensed electricians must perform wiring. Shock hazard exists.

Refer to Figure 5 on page 16 for 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, rotation is proper. See diagram in terminal box cover. The McQuay start-up technician will check the phase sequence. Note: Do not make final connections to motor terminals until wiring has been checked and approved by a McQuay technician.

CAUTION Connections to terminals must be made with copper lugs and copper wire.

Under no circumstances should a compressor be brought up to speed unless proper sequence and rotation have been established. Serious damage can result if the compressor starts in the wrong direction. Such damage is not covered by product warranty.

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IOMM Starter

Motor Terminal Insulation It is the installing contractor's responsibility to insulate the compressor motor terminals when the unit voltage is 600 volts or greater, or in high humidity locations that could cause condensation on the motor terminals that are at about 50°F (10°C). The required material is shipped in as a kit (775123601) placed in the motor terminal box on all medium and high voltage units. It can be ordered for high humidity applications. This is to be done after the McQuay start-up technician has checked for proper phase sequence and motor rotation. Following this verification by the McQuay technician, the contractor should apply the following items. Materials required for 600+volts or high humidity:

1. Loctite® brand safety solvent (12 oz. package available as McQuay part number 350A263H72) 2. 3M™ Co. Scotchfil brand electrical insulation putty (available in a 60-inch roll as McQuay part number 350A263H81) 3. 3M Co. Scotchkote™ brand electrical coating (available in a 15 oz. can with brush as McQuay Part Number 350A263H16) 4. Vinyl plastic electrical tape The above items are also available at most electrical supply outlets. Application procedure:

1. Disconnect and lock out the power source to the compressor motor. 2. Using the safety solvent, clean the motor terminals, motor barrel adjacent to the terminals, lead lugs, and electrical cables within the terminal 4OX 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 approximately 10 in. Wrap additional Scotchfil insulation over the Scotchkote coating. 5. Tape the entire wrapped length with electrical tape to form a protective jacket. 6. Finally, brush on one more coat of Scotchkote coating to provide an extra moisture barrier.

General Wiring Practice Wire groups

Signal wiring refers to wires connected to the control terminals that are low voltage, below 15V. • Shielded wire is required to prevent electrical noise interference from causing improper operation or nuisance trips. • Signal wire should be rated for at least 300V. • Keep signal wire as far away as possible from control and power wiring. Control wiring is wiring connected to the control terminal strip that carry 24V to 220V. • Use only UL or CSA recognized wire. • Use copper wire rated for 60/75°C. • Power wiring to the motor must have the maximum possible separation from all other wiring. Do not run control wiring in the same conduit; this separation reduces the possibility of coupling electrical noise between circuits. Minimum spacing between metallic conduits containing different wiring groups should be three inches (76 mm). • Minimum spacing between different wiring groups should be six inches (152 mm). IOMM Starter

9

• Wire runs outside of an enclosure should be run in metallic conduit or have shielding/armor with equivalent attenuation. • Different wire groups should cross at 90 degrees whenever power and control wiring cross. • Different wire groups should be run in separate conduits. • Adhere to local electrical codes. • The National Electrical Code and Canadian Electrical Code requires that an approved circuit disconnecting device be installed in series with the incoming AC supply in a location readily accessible to personnel installing or servicing this equipment. If a disconnect switch is not supplied with the starter, one must be installed. • Supply and motor wiring will usually enter and leave the enclosure from the top. Wire connections can be determined to best suit specific installations. Wire runs should be properly braced to handle both starting and fault currents. Size power cable per local electrical codes. Long lengths of cable to the motor of over 150 feet must be de-rated.

BEFORE APPLYING MAIN POWER The starter has been fully tested before leaving the factory to help a rapid and problemfree start-up. Before applying power to the starter, consult the start-up checklist below. 1. Inspect starter and remove any foreign matter. 2. Inspect 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 50 ohms. 7. Check the resistance of all power and motor leads to ground to ensure that there is no foreign matter present or damage to the insulation which can short one or more of the phases to ground. 8. Apply 120 Vac control voltage to the starter.

Connection Sizes Low Voltage Solid State Table 2, Solid State Connection Sizes, Power Block Starter Model No. (Note 1) RVSS14 RVSS17 RVSS20 RVSS27 RVSS34 RVSS41 RVSS47 RVSS57 RVSS67 RVSS82 RVSS96 RVSS2K RVSS4K

10

Incoming Connection to Power Block 2/C #6-300 2/C #6-300 2/C #6-300 2/C #6-300 2/C #6-300 2/C #6-300 2/C #6-350 4/C 1/0 - 750 4/C 1/0 - 750 4/C 1/0 - 750 4/C 1/0 - 750 4/C 1/0 - 750 4/C 1/0 - 750

Outgoing Connection Size (Note 2) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

NOTES: 1. Data is the same for unit-mounted starters, RVST14, etc. 2. Outgoing are NEMA 1 hole pattern. 3. Outgoing connections are factoryconnected to the motor on factorymounted starters. 4. When connecting to a starter with the standard power block, the incoming connection size is determined by the starter size as listed in the above table.

IOMM Starter

Table 3, Solid State, Connection Sizes, Disconnect & Circuit Breaker 50/60 HZ Max RLA 74 93 148 163 185 296 444 593 889 1185 1481

Incoming Size Disc. Switch #6- 350 #6- 350 #6- 350 #6- 350 2/C 3/0 - 500 2/C 3/0 - 500 3/C 1/0 - 500 4/C 250 - 500 5/C 300 - 600 5/C 300 - 600 5/C 300 - 600

Incoming Size Circuit Breaker #6- 350 #6- 350 #6- 350 #6- 350 2/C 3/0 - 500 2/C 3/0 - 500 3/C 1/0 - 500 4/C 250 - 500 5/C 300 - 600 5/C 300 - 600 5/C 300 - 600

NOTES: 1. For field wiring free-standing starters, the outgoing connection size is determined by the starter size as listed under the “Outgoing Connection Size” column in Table 2. Outgoing connections are factory-connected to the motor on factory-mounted starters. 2. When wiring to a starter (either factory-mounted or free-standing) with an optional disconnect 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). D3WD11 D3WD12 D3WD14 D3WD15 D3WD25 D3WD31 D3WD34 D3WD43 D3WD62 D3WD65 D3WD86 D3WD1K D3WD2K

Incoming Connection Size, Power Block 2/C #6 - 300 2/C #6 - 300 2/C #6 - 300 2/C #6 - 300 2/C #6 - 300 2/C #6 - 300 2/C #6 - 300 2/C #6 - 300 2/C #6 - 350 2/C #6 - 350 4/C 1/0 - 750 4/C 1/0 - 750 4/C 1/0 - 750

Outgoing Connection Size (Note 2) 0.31 0.31 0.31 0.31 0.31 0.38 0.38 0.44 0.44 0.44 0.63 0.63 0.63

NOTES:

IOMM Starter

1.

Data is the same for unit-mounted starters, D3WT11, etc.

2.

Outgoing connection is NEMA 1 hole pattern, diameter in inches as shown.

3.

Outgoing connections are factory-connected to the motor on factory-mounted starters.

4.

When connecting to a power block, the connection size is determined by the starter size.

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Table 5, Wye-Delta Connection Size, Disconnects & Circuit Breakers 50/60 HZ Max RLA 74 93 148 163 185 296 444 593 889 1185 1481

Incoming Size Disc. Switch #6- 350 #6- 350 #6- 350 #6- 350 2/C 3/0 - 500 2/C 3/0 - 500 3/C 1/0 - 500 4/C 250 - 500 5/C 300 - 600 5/C 300 - 600 5/C 300 - 600

Incoming Size Circuit Breaker #6- 350 #6- 350 #6- 350 #6- 350 2/C 3/0 - 500 2/C 3/0 - 500 3/C 1/0 - 500 4/C 250 - 500 5/C 300 - 600 5/C 300 - 600 5/C 300 - 600

NOTES: 1. For field wiring free-standing starters, the outgoing connection size is determined by the starter size as listed under the “Outgoing Connection Size” column in Table 2. Outgoing lugs are factory-connected to the motor on factory-mounted starters.

2. When 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 NEMA 2.

Compressor Motor Connections Power wiring connections at the motor are “spark plug” type terminals with threaded copper bar, sized per the following table. Type/Size

12

Comp. Size

Terminal Size

Low Voltage to 275 A, to 575 V

CE 050

0.375-16 UNC-2A, 0.94 in. long

Low Voltage to 750 A, to 575V

CE 063-126

0.635-11 UNC-2A, 1.88 in. long

Med. Voltage to 275 A, to 4160 V

CE 063-126

0.375-16 UNC-2A, 0.97 in. long

Hi Voltage to 275 A, to 7200 V

CE 063-126

0.375-16 UNC-2A, 1.00 in. long

IOMM Starter

Control Wiring Control wiring is required between the starter and the unit for three purposes: 1. Transmit start and stop commands from the unit to the starter. 2. Transmit electrical information concerning motor operation from the starter to the unit control system. 3. Supply control power from the starter transformer to the unit control panels.

General Practice Signal wiring refers to wires connected to the control terminals that are low voltage, below 15V. •

Shielded wire is required to prevent electrical noise interference from causing improper operation or nuisance trips.

•

Signal wire should be rated for at least 300V.

•

Keep signal wire as far away as possible from control and power wiring.

Control wiring refers to wires connected to the control terminal strip that carry 24V to 220V. •

Use only UL or CSA recognized wire.

•

Use copper wire rated for 60/75°C.

Control Power Wiring Control power wiring for starters covered in this manual is shown on Figure 5 on page 16. Low voltage starters may have additional control 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-standing starter furnished by McQuay, or by the customer to McQuay specifications, will have a control transformer in it and requires field wiring to terminals in the compressor terminal box.

•

Power can be supplied from a separate circuit and fused at 20 amps inductive load. The control circuit disconnect switch must be tagged to prevent current interruption. Other than for service work, the switch is to remain on at all times in order to keep oil heaters operative and prevent refrigerant from diluting in oil.

DANGER If a separate control power source is used, the following must be done to avoid severe personal injury or death from electrical shock: Place a notice on the unit that multiple power sources are connected to the unit. Place a notice on the main and control power disconnects that another source of power to the unit exists.

IOMM Starter

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Separate Power Source Chiller control power usually comes from a control transformer located in the starter and factory or field wired to the chiller control panel. In the event a separate transformer supplies control voltage, it must be rated at 3 KVA, with an inrush rating of 12 KVA minimum at 80% power factor and 95% secondary voltage. For control wire sizing, refer to NEC. Articles 215 and 310. In the absence of complete information to permit calculations, the voltage drop should be physically measured. Table 6, Control Power Line Sizing Maximum Length, ft (m)

Wire Size (AWG)

Maximum Length, ft (m)

Wire Size (AWG)

0 (0) to 50 (15.2) 12 120 (36.6) to 200 (61.0) 50 (15.2) to 75 (22.9) 10 200 (61.0) to 275 (83.8) 75 (22.9) to 120 (36.6) 8 275 (83.8) to 350 (106.7) Notes: 1. Maximum length is the distance a conductor will traverse between the control 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.

6 4 3

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 on page 16. If the optional “Full Metering Display” has been ordered, the following section will apply. Wiring for Optional Remote D3 Display Figure 3, Starter Panel Remote mounted low voltage wye-delta and solid state starters require field wiring to activate the optional full metering display on the chiller’s operator interface panel. The wiring is from the D3 board in the starter to the compressor controller and to the bias block; both located in the compressor control panel. See Figure 4, Field Wiring for Optional D3 . The location of the connections in the starter are shown to the right.

Wiring Connection on Starter for Optional Display

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IOMM Starter

Figure 4, Field Wiring for Optional D3 Communication

NOTES. 1. See Figure 3 for Starter connection location. 2. The compressor controller serial card location is in the lower-center of 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.

IOMM Starter

15

Figure 5, Control and Power Field Wiring MICROTECH CONTROL BOX TERMINALS (115V)

GND

(24V)

PE

54

85 POWER

* NOTE 7

86

NEUTRAL

* NOTE 10 * COOLING TOWER FOURTH STAGE STARTER

55

O

C4

74

H

A

O

86

* NOTE 10 O

A

EP2

86

C

79

H

* COOLING TOWER THIRD STAGE STARTER

70

80

H

C3

73

H

A O

EP1

78

A

C

77

* NOTE 10 76

H

* COOLING TOWER SECONDH STAGE STARTER

O

C2

75

A

H O

* NOTE 10 O

A

CP2

H

* COOLING TOWER FIRST STAGE STARTER

C

T3-S

C1

A

EF CF

81

COMMON

82(NO)

A

83(NC)

ALARM RELAY (NOTE 4)

84

POWER

H

52 O

COOLING TOWER BYPASS VALVE

71

1-10 VDC

CP1

A

C

71 1-10 VDC

COOLING TOWER VFD

L1

L2

53

MICROTECH COMPRESSOR CONTROL BOX TERMINALS CTB1

L3

NOTE 2

(NOTE 1)

-LOAD-

U

V

W

115 VAC T1

GND

COMPRESSOR MOTOR STARTER

STARTER LOAD SIDE TERMINBALS VFD

PE

CP1

L1

CP2

L2

23(5A)

23

24(5)

24

25

25

T6

T2

T4

T3

T5

COMPRESSOR TERMINALS STARTER LOAD SIDE TERMINBALS WYE-DELTA T1

T2

T3

T2

T3

T4

T5

T6

T4

T5

T6

1

2

2

3

3

4

4

6

11

11

11

12

12

22

22

NOTE 2

LESS THAN 30V OR 24VAC

- FOR DETAILS OF CONTROL REFER TO UNIT CONTROL SCHEMATIC 330342101 - COMPRESSOR CONTROL SCHEMATIC 330342201 - LEGEND: 330343001

T1

COMPRESSOR TERMINALS 1

- FOR DC VOLTAGE AND 4-20 MA CONNECTIONS (SEE NOTE 3)

STARTER LOAD SIDE TERMINBALS SOLID STATE T1

T1

T2

T6

T2

* FIELD SUPPLIED ITEM NOTE 12

T3

T4

T3

T5

COMPRESSOR TERMINALS

STARTER LOAD SIDE TERMINBALS MEDIUM AND HIGH VOLTAGE T1

T2

T3

T1

T2

T3

COMPRESSOR TERMINALS

330387901-0A

See notes on the following page.

16

IOMM Starter

NOTES for Wiring Diagram 1.

Compressor motor starters are either factory-mounted and wired, or shipped separate for field-mounting and wiring. If provided by others, starters must comply with McQuay specification 359AB99. All line and load side power conductors must be copper.

2.

If starters are freestanding, then field control wiring between the starter and the control panel is required. Minimum wire size for 115 Vac is 12 GA for a maximum length of 50 feet. If greater than 50 feet, refer to McQuay for recommended wire size minimum. Wire size for 24 Vac is 18 GA. All wiring to be installed as NEC Class 1 wiring system and must be made with copper wire and copper 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 58 percent of the motor rated load amperes (RLA). Wiring of free-standing starters must be in accordance with the NEC and connection to the compressor motor terminals shall be made with copper wire and copper lugs only. Main power wiring between the starter and motor terminals is factory-installed when chillers are supplied with unit-mounted starters.

5.

The “Full Metering” option will require some field wiring when free-standing starters are used, as shown in Figure 4 on page 15.

IOMM Starter

17

Startup General The startup of McQuay centrifugal chillers, including the starters, is performed by McQuay authorized and trained technicians. They review the starter connections, phase sequence, and settings prior to starting the chiller. Setting a freestanding starter and power and control wiring from it to the chiller is the responsibility of the owner/contractor. See the installation and power and control wiring sections of this manual before commencing installation. In the rare instances where a starter is being replaced after the chiller has been in service, McQuay service is not automatically involved but can be contracted to supervise the starter installation. For general information, brief startup instructions are included on the following pages.

Low 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 change.

Quick Meters •

Press DOWN to display the motor thermal overload content.

•

Press UP to display the incoming line phase order.

•

Press ENTER to display the status meter.

Fault Log· •

Select P32 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.

Resetting a Fault·

18

•

Press RESET to reset from a fault.Resetting Parameters·

•

Press and hold PARAM and ENTER on power up to reset parameters to default values.

IOMM Starter

Emergency Thermal Reset· •

Press RESET and DOWN to perform an emergency thermal reset.

Messages (LVSS) No Line Ready Accelerating Up to Speed Run – Done with ramp but not yet Up to Speed. Decelerating Overload 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 60%.

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 = Fault code. Press RESET to clear. Instantaneous Overcurrent – Press RESET to clear. Default – Flashes when parameter defaults are loaded.

Default Meter Display (P13) (LVSS) 0: 1: 2: 3: 4: 5: 6:

Status Ave RMS Current L1 RMS Current L2 RMS Current L3 RMS Current Current Imbalance % Ground Fault Current

7: 8: 9: 10: 11: 12: 13:

14: KVA 15: KWh 16: MWh 17: Phase Rotation 18: Line Frequency 19: Analog Input

Ave L-L Voltage RMS L1-L2 Voltage RMS L2-L3 Voltage RMS L3-L1 Voltage RMS Overload % PF KW

Analog Output Function (P28) (LVSS) 0: 1: 2: 3: 4: 5:

OFF (no output) Ave Current (0 – 200% RLA) Ave Current (0 – 800% RLA) Ave Voltage (0 – 750VAC) Thermal Overload% KW (0 - 10KW)

6: 7: 8: 9: 10: 11:

KW (0 – 100KW) KW (0 – 1MW) KW (0 – 10MW) Analog Input Output Voltage (% of FV) Calibrate (full 100% output)

CT Burden Switch Settings (P1 and P23) (LVSS) 864:1 CTs 24 to 42 42 to 50 50 to 108 108 to 190

FLA in Amps 2640:1 CTs 5760:1 CTs 73 to128 160 to 280 128 to 151 280 to 330 151 to 330 330 to 720 330 to 590 720 to 1280

Setting SW1 SW2 Off Off Off On On Off On On

8000:1 CTs 223 to 390 390 to 465 465 to 1000 1000 to 1800

Parameters (LVSS) DESCRIPTION

Values

DEFAULT

P1 P2 P3 P4 P5 P6 P7 P8

Motor FLA Motor RLA Motor Service Factor Motor Overload Class Initial Motor Current Maximum Motor Current Ramp Time UTS Time

10 10 1.08 10 250 300 10 15

P9

Stop Mode

1 to 9999 Amps 1 to 9999 Amps 1.00 to 1.99 OFF, 1 to 40 50 to 400 %FLA 100 to 800 %FLA 0 to 300 seconds 1 to 900 seconds CoS: Coast dcL: Voltage Decel 100 to 0 %Volts

P10

Decel Begin Level

SET TO:

CoS 40

Continued on next page.

IOMM Starter

19

P11 P12 P13 P14 P15

DESCRIPTION

Values

DEFAULT

Decel End Level Decel Time Default Meter Display Overcurrent Trip Level Overcurrent Trip Delay Time

50 to 0 %Volts 1 to 180 seconds 0 to 19 OFF, 50 to 800 %RLA

20 15 1 OFF

0.1 to 90.0 seconds

2.0

P16

Rated RMS Voltage

P17 P18

P21 P22

Over Voltage Trip Level Under Voltage Trip Level Over/Under Voltage Delay Time Current Imbalance Trip Level Controlled Fault Stop Auto Fault Reset Time

P23

CT Ratio

P24

Control Source

P25 P26 P27 P28 P29 P30 P31 P32

Modbus Address Modbus Baud Rate Modbus Timeout Analog Output Function Analog Output Span Analog Output Offset Passcode Fault Log

P19 P20

100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 575, 600, 660, 1000 Volts OFF, 1 to 40 % rated Volts OFF, 1 to 40 % rated Volts

SET TO:

480 10 10

0.1 to 90.0 seconds

1.0

5 to 40 %

10

OFF, On OFF, 1 to 120 seconds 72, 96, 144, 288, 864, 2640, 2880, 5760, 8000 TEr: Terminal NEt: Network 1 to 247 1.2, 2.4, 4.8, 9.6, 19.2 Kbps OFF, 1 to 120 seconds 0 to 11 1 to 125 % 0 to 99 % 0 to 9999 xFyy

OFF 60 2640 tEr 1 19.2 3 1 100 0 – –

Fault/Alarm Codes (LVSS) Description 00 01 02 10 12 13 15 21 22 23 24 25 26 27 28 30 31 37 38 39 40 41 47 48 50 51 52

20

No fault UTS Time Limit Expired Motor Thermal Overload Trip Phase Rotation Error, not ABC Low Line Frequency High Line Frequency Input power not three phase Low Line L1-L2 Voltage Low Line L2-L3 Voltage Low Line L3-L1 Voltage High Line L1-L2 Voltage High Line L2-L3 Voltage High Line L3-L1 Voltage Phase Loss No Line Voltage I.O.C. (Instantaneous Overcurrent) Overcurrent Current Imbalance Ground Fault No Current at Run Shorted / Open SCR Current While Stopped Stack Protection Fault Bypass Contactor Fault (on STOP input) Control Power Low Current Sensor Offset Error Burden Switch Error

Controlled Stop Y Y N N N N Y Y Y Y Y Y N N N Y Y Y N N N N Y N N

Auto Reset Y N Y Y Y Y Y Y Y Y Y Y Y Y N N Y N Y N N Y N Y N N

IOMM Starter

Description 60 61 71 82 94 95 96 97 98 99

Thermistor Trip (on DIN#1) Stack OT Switch Trip (on DIN#2) Analog Input Trip Modbus Timeout CPU Error – Software Fault CPU Error – Parameter Storage Fault CPU Error – Illegal Instruction Trap CPU Error – Software Watchdog Fault CPU Error – Spurious Interrupt CPU Error – Program Storage Fault

Controlled Stop N N Y Y N N N N N N

Auto Reset N N Y Y N N N N N N

•

If a fault occurs that has a Y in the “Controlled Stop” column, and P21 (Controlled Fault Stop) is set to On, and P9 (Stop Mode) is set to dcL, then the starter will perform a voltage decel to stop. Otherwise it will coast to stop.

•

If a fault occurs that has a Y in the “Auto Reset” column, and P22 (Auto Fault Reset Time) 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 to change the parameter value.

•

Press ENTER to store the new value or PARAM to abandon the change.

Quick Meters· •

Press DOWN to display the motor thermal overload content.

•

Press UP to display the incoming line phase order.

•

Press ENTER to display the status meter.

Fault Log

IOMM Starter

•

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.

21

Resetting a Fault •

Press RESET to reset from a fault.

Resetting Parameters •

Press and hold PARAM and ENTER on power up to reset parameters to default values.

Emergency Thermal Reset •

Press RESET and DOWN to perform an emergency thermal reset.

Messages (LVYD) No Line Ready Running in wye mode. Running in delta mode. Overload 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 60%.

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 = Fault code. Press RESET to clear. Instantaneous Overcurrent – Press RESET to clear. Default – Flashes when parameter defaults are loaded.

Default Meter Display (P5) (LVYD) 0: 1: 2: 3: 4: 5: 6:

Status Ave RMS Current L1 RMS Current L2 RMS Current L3 RMS Current Current Imbalance % Ground Fault Current

7: 8: 9: 10: 11: 12: 13:

14: 15: 16: 17: 18: 19:

Ave L-L Voltage RMS L1-L2 Voltage RMS L2-L3 Voltage RMS L3-L1 Voltage RMS Overload % PF KW

KVA KWh MWh Phase Rotation Line Frequency Analog Input

Analog Output Function (P20) (LVYD) 0: 1: 2: 3: 4: 5:

OFF (no output) Ave Current (0 – 200% RLA) Ave Current (0 – 800% RLA) Ave Voltage (0 – 750VAC) Thermal Overload% KW (0 - 10KW)

6: 7: 8: 9: 10: 11:

KW (0 – 100KW) KW (0 – 1MW) KW (0 – 10MW) Analog Input Reserved Calibrate (full 100% output)

CT Burden Switch Settings (P1 and P15) (LVYD) 864:1 CTs 24 to 42 42 to 50 50 to 108 108 to 190

RLA in Amps 2640:1 CTs 5760:1 CTs 73 to 128 160 to 280 128 to 151 280 to 330 151 to 330 330 to 720 330 to 590 720 to 1280

8000:1 CTs 223 to 390 390 to 465 465 to 1000 1000 to 1800

Setting SW1 SW2 Off Off Off On On Off On On

Parameters (LVYD) P1 P2 P3 P4 P5

DESCRIPTION Motor RLA Motor Service Factor Motor Overload Class Transition Time Default Meter Display

Values 1 to 9999 Amps 1.00 to 1.99 OFF, 1 to 40 1 to 30 seconds 0 to 19

DEFAULT 1 1.08 10 10 0

Continued on next page.

22

IOMM Starter

P6 P7 P8

DESCRIPTION Sequence Complete Delay Time Overcurrent Trip Level Overcurrent Trip Delay Time

P9

Rated RMS Voltage

P10 P11

P14

Over Voltage Trip Level Under Voltage Trip Level Over/Under Voltage Delay Time Current Imbalance Trip Level Auto Fault Reset Time

P15

CT Ratio

P16

Control Source

P17 P18 P19 P20 P21 P22 P23 P24

Modbus Address Modbus Baud Rate Modbus Timeout Analog Output Function Analog Output Span Analog Output Offset Passcode Fault Log

P12 P13

Values

DEFAULT

0.1 to 5.0 seconds

2.0

OFF, 50 to 800 %RLA

OFF

0.1 to 90.0 seconds

2.0

100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 575, 600, 660, 1000 Volts OFF, 1 to 40 % rated Volts OFF, 1 to 40 % rated Volts

480 10 15

0.1 to 90.0 seconds

1.0

5 to 40 %

20

OFF, 1 to 120 seconds 72, 96, 144, 288, 864, 2640, 2880, 5760, 8000 TEr: Terminal NEt: Network 1 to 247 1.2, 2.4, 4.8, 9.6, 19.2 Kbps OFF, 1 to 120 seconds 0 to 11 1 to 125 % 0 to 99 % 0 to 9999 xFyy

60 2640 tEr 2 19.2 3 1 100 0 – –

Fault/Alarm Codes (LVYD) Description 00 02 10 12 13 15 21 22 23 24 25 26 27 28 30 31 37 38 39 40 41 48 50 51

IOMM Starter

No fault Motor Thermal Overload Trip Phase Rotation Error, not ABC Low Line Frequency High Line Frequency Input power not three phase Low Line L1-L2 Voltage Low Line L2-L3 Voltage Low Line L3-L1 Voltage High Line L1-L2 Voltage High Line L2-L3 Voltage High Line L3-L1 Voltage Phase Loss No Line Voltage I.O.C. (Instantaneous Overcurrent) Overcurrent Current Imbalance Ground Fault No Current at Run Open Line or Motor Lead Current While Stopped 2M Feedback Fault (on DIN#2) Control Power Low Current Sensor Offset Error

Auto Reset N Y Y Y Y Y Y Y Y Y Y Y Y N N Y N Y N N N Y N

23

Description 52 60 71 82 94 95 96 97 98 99

Burden Switch Error Thermistor Trip (on DIN#1) Analog Input Trip Modbus Timeout CPU Error – Software Fault CPU Error – Parameter Storage Fault CPU Error – Illegal Instruction Trap CPU Error – Software Watchdog Fault CPU Error – Spurious Interrupt CPU Error – Program Storage Fault

Auto Reset N N Y Y N N N N N N

If a fault occurs that has a Y in the “Auto Reset” column, and P14 (Auto Fault Reset Time) is set to some value other than OFF, then the fault will automatically be cleared after the time specified by P14.

Medium/High Voltage, Solid State Quick Start Motor FLA Parameter Description

The motor FLA parameter must be set to the full load amps of the motor connected to the starter for the starter to function correctly. NOTE: The starter uses the entered motor FLA for 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 parameter should be set to the service factor of the motor. The service factor is used for the overload calculations. The service factor is factory set, will be checked by the start-up technician and should not require further adjustment. If the service factor of the motor is not known, then the service factor should be set to 1.08. 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 the service factor is 1.08.

24

IOMM Starter

Start Mode Description

The Start Mode parameter allows for an optimal start of the motor based on the application. For a description of the possible Start Mode parameters, refer to page 31 in the Operations chapter. Values

The Start Mode Parameter can be set to Curr, TT, or Tach. Default

The default value for the Start Mode is Curr.

Stop Mode Description

The Stop Mode parameter allows for the most suitable stop of the motor based on the application. For a description of the possible Stop Mode parameters, refer to page 31 in the Operations chapter of the starter manual. Values

The Stop Mode can be set to Coas, VDCL, or TT. Default

The default value for the Stop Mode is Coas.

Int. Curr. (initial current) Description

The initial current parameter is set as a percentage of the motor FLA parameter setting. The initial current parameter sets the current that will initially reach the motor when a start is commanded. If the motor does not rotate within a few seconds after a 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

The default value for the initial current is 100%.

Max. Curr. (maximum current) Description

The maximum current parameter is set as a percentage of the motor FLA parameter setting. The maximum current parameter performs two functions. It sets the 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 power system or load dictates the setting of a lower maximum current. Values

The maximum current is adjustable from 100% to 600% in 1% intervals. IOMM Starter

25

Default

The default value for the maximum current is 600%.

Ramp Time Description

The ramp time sets the amount of time that it takes for the starter to linearly increase the current from the initial current level to the maximum current level. A typical ramp time setting is from 15 to 30 seconds. Settings

The ramp time is adjustable from 0 to 120 seconds in 1 second intervals. Default

The default value for the ramp time is 15 seconds.

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 is attempted. Values

The line phasing can be set to: • INS - will run with either phase sequence • ABC - will only run with ABC phase sequence • CBA - will only run with CBA phase sequence Default

The default value for the phase sensitivity parameter is ABC.

26

IOMM Starter

Operation, Low Voltage Starters, 200 – 600 Volts Introduction This section contains information on low voltage, Wye-Delta and solid-state starters as manufactured by Benshaw Inc. for McQuay centrifugal Chillers. They are known collectively as “D3” starters, which is their software designation. These low voltage starters have similar software (designated D3) and are grouped together in this manual. Model numbers are as follows: D3WD11 to D3WD2K Wye-Delta, Free-standing D3WT11 to D3WT65 Wye-Delta, Factory (Terminal) Mounted RVSS14 to RVSS4K Solid State, Free-standing RVST14 to RVST82 Solid State, Factory (Terminal) Mounted

Viewing Data The information in this section applies to low voltage, solid start and 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 6, Optional Starter View Screen

The ability to view the starter’s power characteristics and to set starter setpoints on the operator interface screen is an optional extra available at the time of purchase. If the optional “Full Meter Display” is supplied on the unit, the “POWER” button (or “STARTER” in some software versions) will be visible on the upper left side of the VIEW screen as shown above. Pressing this button will open the screen shown in Figure 7 in the blank area to the right of the screen shown above.

IOMM Starter

27

Figure 7, Expanded Starter View Screen The screen shown to the right will be superimposed on the right side of the VIEW screen shown in Figure 6 when the optional “Full Meter 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.

28

IOMM Starter

Figure 8, Optional Starter Setpoint Screen

Table 7, Starter Setpoints Description

No.

Default

Range

Password

Ground Fault Current Trip

8

1%

1 to 100% RLA

M

Ground Fault Enable

7

OFF

On or OFF

M

Maximum Current Unbalance

6

10%

5% to 40%

T

Comments Sets the value for ground current above which the compressor will be shut down Turns the ground fault option on or off Sets the value for current unbalance above which the compressor will be shut down Sets the time the starter ramps up the motor current Sets the maximum current when the compressor starts Sets the initial current when the compressor starts Value that gives the 100% RLA value and used for motor protection

0 to 30 T seconds Maximum Starter 100% to 800% 4 600% T Current of FLA (SP1) 50% to 400% Initial Starter Current 3 100% T of FLA (SP1) Factory set at Rated load Amps 2 1A design T conditions Factory set to Value used to compute SP3 Full Load Amps 1 1A motor max T and SP4 current rating 1. The setpoints shown above are for solid state starters. Other types of starters will have slightly different setpoints. Units without the starter display option will have their setpoints set in the starter itself. Starter Ramp Time

IOMM Starter

5

15 sec.

2.

Do not change these setpoints after McQuay startup.

3.

Do not remove the D3 control wiring. If accidentally disconnected, contact McQuay service.

29

Standard Starter Keypad and Display When the optional full metering display is not ordered, the LED display located in the starter provides information on starter operation and programming. The 4-digit, 7-segment display shows starter meter outputs and programming data. Special symbols provide further information about the starter operation (see the following section). Figure 9, Starter-mounted LED Reset Key RESET

LED Display

PARA M

DOW N

UP

ENTER

Operating Keys

The LED display and keypad is used to: 1. 2. 3. 4.

Perform operations View and set parameters (setpoints) View operating messages View faults and alarms

Special Messages Displayed The keypad’s display may show the following special information under certain conditions. Table 8, LED Special Characters Displayed No Line

Phase order meter showing ABC

Ready

Phase order meter showing CBA

Accelerating or Kicking

Phase order meter showing Single Phase

Up to Speed

xxx xx

xx = Parameter code.

Speed.

xx

xx = Alarm code. If the condition persists,

Decelerating Motor Overload Alarm – The motor overload level is

30

xxx = overload content.

Run – Done with Accel ramp but not yet Up to

a fault will occur. xx

xx = Fault code.

between 90% and 100%.

Instantaneous Overcurrent

Overload Fault – The motor overload level has

Default – Flashes when parameter defaults

reached 100%.

are loaded.

Overload Lockout – A start is not allowed until the

Energy Saver

motor overload level cools below 60%.

In reflash mode

IOMM Starter

Display Operation Display •

View parameters, messages and faults.

•

Shows software revision on power up.

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.

ramming •

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.

•

IOMM Starter

•

Press ENTER to store the new value or PARAM to abandon the change.

k Meters •

Press DOWN to display the motor thermal overload content.

•

Press UP to display the incoming line phase order.

•

tting a Fault

Press ENTER to display the status meter.

First correct the cause of the fault. Then press RESET to reset from a fault.

tting Parameters •

Press and hold PARAM and ENTER on power up to reset parameters to default values.

rgency Thermal Reset •

Press RESET and DOWN to perform an emergency thermal reset.

31

Changing Parameters Viewing Parameter Values Parameter view mode can be entered by: 1. At the default meter display, press the PARAM key to enter parameter mode. “P 1” will be displayed to indicate Parameter 1. 2. Use the UP and DOWN keys to scroll through the available parameters. 3. Pressing the UP key from “P 1” will advance to parameter “P 2”. 4. Pressing the DOWN key from “P 1” will wrap around to the highest parameter. 5. The value of the parameter can be viewed by pressing the ENTER key. 6. To view another parameter without changing/saving the parameter, press the PARAM key to return to the parameter number display. To return to the default meter display either: 1. Press the PARAM key while in the parameter number display mode. 2. Wait 60 seconds and the display will return to the default meter display.

Changing Parameter Values Parameter change mode can be entered by: 1. 2. 3. 4.

At the default meter display, press the PARAM key to enter parameter mode. Use the UP and DOWN keys to scroll through the available parameters. The value of the parameter can be viewed by pressing the ENTER key. 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:

1. Press the PARAM key to return to the parameter number display. 2. Wait 60 seconds and the display will return to the default meter display. The starter setpoint parameters are factory set and subsequently reviewed during commissioning by the McQuay startup technician. They should not be changed unless authorized by McQuay. The programming procedure is explained above and the following table shows the range of values and defaults. Table 9, Setpoints, Wye-Delta Starter P1 P2 P3 P4 P5 P6 P7

32

Description Motor RLA Motor Service Factor Motor Overload Class Transition Time Default Meter Display Sequence Complete Delay Time Overcurrent Trip Level Continued on next page.

Values 1 to 9999 Amps 1.00 to 1.99 OFF, 1 to 40 1 to 30 seconds 0 to 19 0.1 to 5.0 seconds OFF, 50 to 800 %RLA

Default 1 1.08 10 10 0 2.0 OFF

IOMM Starter

P8

Description Overcurrent Trip Delay Time

P9

Rated RMS Voltage

P10 P11 P12 P13 P14

Over Voltage Trip Level Under Voltage Trip Level Over/Under Voltage Delay Time Current Imbalance Trip Level Auto Fault Reset Time

P15

CT Ratio

P16

Control Source

P17 P18 P19 P20 P21 P22 P23 P24

Modbus Address Modbus Baud Rate Modbus Timeout Analog Output Function Analog Output Span Analog Output Offset Passcode (See Note) Fault Log

Values 0.1 to 90.0 seconds 208, 220, 230, 240, 380, 415, 440, 460, 480, 575 Volts OFF, 1 to 40 % rated Volts OFF, 1 to 40 % rated Volts 0.1 to 90.0 seconds 5 to 40 % OFF, 1 to 120 seconds 72, 96, 144, 288, 864, 2640, 2880, 5760, 8000 TEr: = Terminal, NEt: = Network 1 to 247 1.2, 2.4, 4.8, 9.6, 19.2 Kbps OFF, 1 to 120 seconds 0 to 11 1 to 125 % 0 to 99 % 0 to 9999 xFyy

Default 2.0 480 10 15 1.0 20 60 2640 TEr 2 19.2 3 1 100 0 Disabled –

Table 10, Setpoints, Solid State Starter P1 P2 P3 P4 P5 P6 P7 P8

Description Motor FLA Motor RLA Motor Service Factor Motor Overload Class Initial Motor Current Maximum Motor Current Ramp Time UTS Time (Up To Speed)

P9

Stop Mode

P10 P11 P12 P13 P14 P15

Decel Begin Level Decel End Level Decel Time Default Meter Display Overcurrent Trip Level Overcurrent Trip Delay Time

P16

Rated RMS Voltage

P17 P18 P19 P20 P21 P22

Over Voltage Trip Level Under Voltage Trip Level Over/Under Voltage Delay Time Current Imbalance Trip Level Controlled Fault Stop Auto Fault Reset Time

P23

CT Ratio

P24

Control Source

P25

IOMM Starter

Modbus Address Continued on next page.

Values 1 to 9999 Amps 1 to 9999 Amps 1.00 to 1.99 OFF, 1 to 40 50 to 400 %FLA 100 to 800 %FLA 0 to 300 seconds 1 to 900 seconds CoS: Coast dcL: Voltage Decel 100 to 0 %Volts 50 to 0 %Volts 1 to 180 seconds 0 to 19 OFF, 50 to 800 %RLA 0.1 to 90.0 seconds 208, 220, 230, 240, 380, 415, 440, 460, 480, 575 Volts OFF, 1 to 40 % rated Volts OFF, 1 to 40 % rated Volts 0.1 to 90.0 seconds 5 to 40 % OFF, On OFF, 1 to 120 seconds 72, 96, 144, 288, 864, 2640, 2880, 5760, 8000 Ter: Terminal, Net: Network 1 to 247

Default 10 10 1.08 10 100 600 15 30 CoS 40 20 15 0 OFF 2.0 480 10 15 1.0 35 OFF 60 2640 tEr 2

33

P26 P27 P28 P29 P30 P31 P32

Description Modbus Baud Rate Modbus Timeout Analog Output Function Analog Output Span Analog Output Offset Passcode (See Note) Fault Log

Values 1.2, 2.4, 4.8, 9.6, 19.2 Kbps OFF, 1 to 120 seconds 0 to 11 1 to 125 % 0 to 99 % 0 to 9999 xFyy

Default 19.2 3 1 100 0 Disabled –

NOTE: Passcode is a numerical password that can be entered in P31. The factory default is to disable the password requirement. It is recommended that a Passcode not be entered.

Messages Setpoint P5 for Wye-Delta or P13 for solid state can be set to establish what message is shown on the LED. Selecting meter display “0” (which is the default) will display the active status message as shown in Table 11 or Table 12, except if there is a fault (requiring a message) or some other information has been requested. Alternatively, parameter P5 or P13 can be set to select a message (1 to 19 as shown in Table 13). Table 11, Status Messages, Wye-Delta Starter No Line Ready Running in wye mode. Running in delta mode. Overload 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 = Fault code. Press RESET to clear. Instantaneous Overcurrent – Press RESET to clear. Default – Flashes when parameter defaults are loaded.

Table 12, Status Messages, Solid State Starter No Line Ready Accelerating Up to Speed Run – Done with ramp but not yet Up to Speed. Decelerating Overload 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%.

34

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 = Fault code. Press RESET to clear. Instantaneous Overcurrent – Press RESET to clear. Default – Flashes when parameter defaults are loaded.

IOMM Starter

Table 13, Default Meter Display 0: 1: 2: 3: 4: 5: 6:

Status Message Ave RMS Current L1 RMS Current L2 RMS Current L3 RMS Current Current Imbalance % 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: Power Factor 13: KW

14: KVA 15: KWh 16: MWh 17: Phase Rotation 18: Line Frequency 19: Analog Input

Display Output for the Standard Keypad The display will output different information depending on the operation of the starter. See Table 8, LED Special Characters Displayed.

Power Up The software version will be displayed as a series of blinking digits once power has been applied to the D3 control. If the parameters were being reset on power up, “dFLt” will be flashed on the display for three seconds, then the software version will be displayed.

Stopped When the starter is not in the run mode, the display will show the status condition of the starter, such as “rdY” (ready), “L OL” (Overload Lockout), “noL” (No Line).

Running When running, the display will show the user selected meter function. 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 between displaying the selected meter and the alarm code. The alarm code is displayed as “A XX”, where XX is the alarm code. • When a thermal overload alarm condition exists, “A OL” will be displayed. • When a no line alarm condition exists, “noL” will be displayed. When the starter is stopped, the selected meter is not displayed.

Lockout Condition When a lockout condition exists, the display shows the lockout code. The lockout code is displayed as “L XX: where XX is the lockout code. Following are the defined lockout conditions and their codes: • When a motor thermal overload lockout condition exists, “L OL” will be displayed. •

When a power stack thermal overload lockout condition exists, “L Ot” will be displayed.

• When a low control power lockout condition exists, “L CP” will be displayed. When there are multiple lockout codes, each will be displayed at 2 second intervals.

IOMM Starter

35

Faulted Condition When a fault condition exists, the display shows the fault code Fxx. The exceptions to this are as follows: • When the fault is thermal overload trip, “F OL” will be displayed. •

When the fault is Instantaneous over current, ioc will be displayed.

Quick Meters Although any meter may be viewed by changing the meter parameter, there are 3 “Quick Meters” that are always available with a single key press. When the starter is in the normal display mode, the display may be toggled between the information currently displayed and the following quick meters. Status Meter

Toggle between the programmed meter display and the starter operational status display (rdY, run, utS, dcL, etc) by pressing the ENTER key.

Overload Meter

Toggle between the programmed meter display and the overload content by pressing the DOWN key. The overload will be displayed as “oXXX” where XXX is the overload content. For example if the overload content is 76 percent, it will be displayed as “o 76”.

Phase Order Meter

Toggle between the programmed meter display and the phase order by pressing the UP key. The phase order will be displayed as “AbC” or “CbA”. The phase order must be AbC to operate.

Restoring Factory Parameter Settings 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, press RESET and DOWN. This will set the motor thermal overload content to 0.

Wye Delta When the D3 control is provided for Wye-Delta – there is Wye-Delta specific software and the D3 control is configured to operate an electromechanical closed transition Wye-Delta (Star-Delta) starter. When equipped with Wye-Delta software, all D3 motor and starter protective functions, except bad SCR detection and power stack overload, are available to provide full motor and starter protection. There is an additional specific parameter for Transition Time. This sets the time when the Wye to Delta transition occurs during starting. A closed transition starter uses resistors that are inserted during the transition so that the motor is never completely disconnected from the input line. The presence of these resistors in a closed transition starter smoothes the transition from Wye to Delta operation mode. A typical closed transition Wye-Delta starter schematic is shown in Figure 10, Wye Delta Motor Connection to the D3 Control.

36

IOMM Starter

Figure 10, Wye Delta Motor Connection to the D3 Control L1

L2

L3 T o T B 3, C1+ (W hite W ire) T o T B 3, C 1- (B lack W ire) T o T B3, C 2+ (W hite W ire ) T o T B 3, C 2- (B lack W ire)

C urrent F eedbacks to M X

To TB8 (SCR 3) K3

To TB6 (SCR 2) K2

To TB4 (SCR 1) K1

T o T B3, C 3+ (W hite W ire ) T o T B 3, C 3- (B lack W ire)

1M

2M

2S R esistor

Line Voltage & Frequenc y to MX

R esistor R esistor

T3

T6

T2

T5

T1

T4

1S

C ontrol P ow er

2M C onfirm Input C om m on 2M

MX 2S UTS MX

R un MX

2M

1S 2S 1M

M echanical Interlock

1S 2M 1M

1S

The closed transition resistors generally are sized to be in the circuit for a short period of time. To protect the resistors from over heating, one input should be programmed as a Bypass/2M contact feedback input and the Bypass/2M confirm parameter must be set. For the Wye-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-Delta (Star-Delta) starter. When in Wye-Delta mode, all D3 motor and starter protective functions except bad SCR detection and power stack overload, are available to provide full motor and starter protection. The D3 control utilizes an intelligent Wye to Delta transition algorithm. If during starting the measured motor current drops below 85% of FLA and more than 25% of the UTS / Transition Time (QST 09, P9) has elapsed then a Wye to Delta transition will occur. The intelligent transition algorithm prevents unnecessarily prolonged motor starts thereby

IOMM Starter

37

reducing motor heating. If a Wye to Delta transition has not already occurred, a transition will always occur when the complete UTS / Transition Time (QST 09, P9) expires. The D3 control can operate two configurations of Wye-Delta starters, open transition and closed transition. An open transition starter momentarily disconnects the motor from the input line during the transition from Wye to Delta operating mode. A closed transition starter uses resistors that are inserted during the transition so that the motor is never completely disconnected from the input line. The presence of these resistors in a closed transition starter smoothes the transition from Wye to Delta operating mode. A typical closed transition WyeDelta starter schematic is shown in Figure 10. For the Wye-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.) Based on the typical closed transition schematic shown in Figure 10, Wye Delta Motor Connection to the D3 Control, when a start command is given the starter will enter the Wye starting 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 or The measured motor current is less than 85% of FLA and at least 25% of the Transition Time (QST 09, P9) has elapsed. 3. A fault occurs. When the Transition Time (QST 09, P9) expires, the starter will change from Wye starting mode to the Delta or normal running mode by energizing the relay programmed as UTS. In Delta mode, the RUN and UTS relays are both energized and the motor is connected in the normal running Delta configuration. The transition to Delta (Run) mode occurs as follows: 1. The Transition Time (QST 09, P9) expires or The measured motor current is less than 85% of FLA and at least 25% of the Transition Time (QST 09, P9) has elapsed. 2. The UTS relay is energized which energizes the 2S contactor. 3. When the 2S contactor pulls in, resistors are inserted in the circuit and the 1S contactor is DE-energized. 4. When the 1S contactor drops out the 2M contactor is energized. 5. When the 2M contactor is pulled in, feedback can be sent to the D3 control board to confirm that the transition sequence to Delta is complete.

38

IOMM Starter

The starter will remain in the Delta or running mode until the start command is removed or a fault occurs. Usually the D3 intelligent Wye to Delta transition algorithm provides an optimal transition point that minimizes the transient current and torque surges that can occur. However sometimes, based on the motor and loading, the Wye to Delta transition will occur only after the Transition Time has expired. In order to reduce the current surge that can take place during the transition from Wye to Delta mode, the Transition Time parameter (QST 09, P9) should be adjusted so that the transition occurs as close to full speed as possible within the constraints of the load. If the transition time is set too short, a large current and torque surge may occur during the transition. If the transition time is set too long, the motor may not have sufficient torque to continue accelerating 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 Wye-Delta Closed Transition Current Profile 600%

500%

% Full Load Motor Current

400%

300%

200%

100%

0%

% speed

100%

Transition from Wye to Delta mode

A digital input (I/O 01-03, P39-41) can be programmed as a 2M contactor feedback input. This input provides verification that the 2M contactor has fully closed preventing operation when the transition resistors are still connected in the motor circuit. The use of this feedback is recommended to prevent the overheating of the transition resistors if the 2M contactor does not close properly. The 2M confirmation trip time can be adjusted by modifying the Bypass / 2M Confirm parameter (I/O 16, P54). Note: When in Wye-Delta mode, the acceleration ramp, kick, and deceleration settings have no effect on motor operation and the SCR gate outputs are disabled.

IOMM Starter

39

Fault Code Troubleshooting Chart The following is a list of possible fault messages that can be generated by the D3 starter control. Code

Description

Detailed Description of Fault / Possible Solutions Motor did not achieve full speed before the UTS timer (QST 09, P9) expired. Check motor for jammed or overloaded condition.

UTS Time F01

Limit Expired

Verify that the combined kick time (CFN11, P14) and acceleration ramp time (QST 08, P8) is shorter than the UTS timer setting. Evaluate acceleration ramp settings. The acceleration ramp settings may be too low to permit the motor to start and achieve full speed. If so, revise acceleration ramp settings to provide more motor torque during starting. Evaluate UTS timer setting and, if acceptable, increase UTS timer setting (QST 09, P9). The D3 motor thermal overload protection has tripped. Check motor for mechanical failure, jammed, or overloaded condition. Verify the motor thermal overload parameter settings (QST 03, P3 and PFN 12-16, P3538) and motor service factor setting (QST 02, P2).

Motor

Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch

F02

Thermal

settings are correct.

(F OL)

Overload Trip

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. Reset overload when content falls below 15%.

Phase F10

Rotation Error, not ABC

Phase F11

Rotation Error, not CBA

Input phase rotation is not ABC and Input Phase Sensitivity parameter (FUN 04, P67) is set to ABC only. Verify correct phase rotation of input power. Correct wiring if necessary. Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67). Input phase rotation is not CBA and Input Phase Sensitivity parameter (FUN 04, P67) is set to CBA only. Verify correct phase rotation of input power. Correct wiring if necessary. Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67). Line frequency below 23 Hz was detected. Verify input line frequency.

F12

Low Line Frequency

If operating on a generator, check generator speed governor for malfunctions. Check input supply for open fuses or open connections Line power quality problem / excessive line distortion.

40

IOMM Starter

Code

Description

Detailed Description of Fault / Possible Solutions Line frequency above 72 Hz was detected.

F13

High Line

Verify input line frequency.

Frequency

If operating on a generator, check generator speed governor for malfunctions. Line power quality problem / excessive line distortion. Three-phase power has been detected when the starter is expecting single-phase power.

F14

Input power

Verify that input power is single phase.

not single

Verify that single-phase power is connected to the L1 and L2 inputs. Correct wiring if

phase

necessary. Verify that the SCR gate wires are properly connected to the D3 control board. Single-phase power has been detected when the starter is expecting three-phase power.

Input power F15

Verify that input power is three phase. Correct wiring if necessary.

not three phase

Verify that the SCR gate wires are properly connected to the D3 control board. On medium voltage systems, verify wiring of the voltage feedback measurement circuit. Low voltage below the Undervoltage Trip Level parameter setting (PFN 08, P31) was detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).

F21

Low Line L1L2

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. On medium voltage systems, verify wiring of the voltage measurement circuit. Low voltage below the Undervoltage Trip Level parameter setting (PFN 08, P31) was detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).

F22

Low Line L2L3

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. On medium voltage systems, verify wiring of the voltage feedback measurement circuit. Low voltage below the Undervoltage Trip Level parameter setting (PFN 08, P31) was detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).

F23

Low Line L3L1

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. On medium voltage systems, verify wiring of the voltage feedback measurement circuit.

IOMM Starter

41

Code

Description

Detailed Description of Fault / Possible Solutions High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was

F24

High Line L1-L2

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. Line power quality problems/ excessive line distortions. High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was

F25

High Line L2-L3

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. Line power quality problems/ excessive line distortions. High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was

F26

High Line L3-L1

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. 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.

F27

Phase Loss

Check power supply wiring for open or intermittent connections. Check motor wiring for open or intermittent connections. On medium voltage systems, verify wiring of the voltage feedback measurement circuit. Check Gate and Cathode connections to D3 board No input voltage was detected for longer than the Inline Configuration time delay parameter setting (I/O 15, P53) when a start command was given to the starter. If an inline contactor is being used, verify that the setting of the Inline Configuration time delay parameter (I/O 15, P53) allows enough time for the inline contactor to completely

F28

No Line

close before the No Line fault occurs. Check input supply for open disconnects, open fuses, open circuit breakers, or disconnected wiring. Verify that the SCR gate wires are properly connected to the D3 control board. On medium voltage systems, verify wiring of the voltage feedback measurement circuit.

42

IOMM Starter

Fault Code

Description

Detailed Description of Fault / Possible Solutions During operation, the D3 controller detected a very high level of current in one or more phases.

I.O.C. F30

(Instantaneous

Check motor wiring for short circuits or ground faults. Check motor for short circuits or ground faults.

Overcurrent Current)

Check if power factor or surge capacitors are installed on the motor side of the starter. Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch settings are correct. Motor current exceeded the Over Current Trip Level setting (PFN 01, P24) for longer

F31

Overcurrent

than the Over Current Trip Delay Time setting (PFN 02, P25). Check motor for a jammed or an overload condition. Motor current dropped under the Under Current Trip Level setting (PFN 03, P26) for

F34

Undercurrent

longer than the Under Current Trip Delay time setting (PFN 04, P27). Check system for cause 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.

F37

Current

Check motor wiring for cause of imbalance. (Verify dual voltage and 6 lead motors for

Imbalance

correct wiring configuration). Check for large input voltage imbalances that can result in large current imbalances. Check motor for internal problems. Ground current above the Ground Fault Trip level setting (PFN 06, P29) has been detected for longer than 3 seconds. Check motor wiring for ground faults. Check motor for ground faults.

F38

Ground Fault

Megger motor and cabling (disconnect from starter before testing). Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch settings are correct. Verify that the CTs are installed with all the White dots towards the input line.

F39

No Current at Run

Motor current went below 10% of FLA while the starter was running. Verify Motor Connections. Verify the CT wiring to the D3 control board. Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch settings are correct.

IOMM Starter

43

Fault Code

Description

Detailed Description of Fault / Possible Solutions

Check if load is still connected to starter

F39

No Current at

Check if motor may have been driven by the load (a regeneration condition)

Run (Cont’d)

Check Gate and Cathode connections to D3 for loose connections. Check for inline contactor or disconnect. A shorted or open SCR condition has been detected. Verify that all SCR gate leads wires are properly connected at the SCR devices and the D3 control board.

F40

Shorted / Open

Check all SCRs with ohmmeter for shorts.

SCR Verify that the Input Phase Sensitivity parameter setting (FUN 04, P67) is correct. Verify that the Starter Type parameter setting (FUN 07, P64) is correct. Verify the motor wiring. (Verify dual voltage motors for correct wiring configuration). Motor current was detected while the starter was not running. Examine starter for shorted SCRs.

F41

Current at Stop

Examine bypass contactor (if present) to verify that it is open when starter is stopped. 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.

Stack Protection F47

Fault (stack thermal overload)

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 correct. Motor load exceeds power stack rating. Consult factory A digital input has been programmed as a Bypass/2M Contactor Feedback input and an incorrect bypass feedback has been detected for longer than the Bypass Confirm time parameter setting (I/O 16, P54). Verify that the bypass/2M contactor coil and feedback wiring is correct.

F48

Bypass /2M

Verify that the relay output that is connected to the bypass/2M contactor(s) is

Contactor

programmed to the UTS function.

Fault Verify that the bypass/2M contactor power supply is present. Verify that the appropriate Digital Input Configuration parameter has been programmed correctly. Verify that the bypass contactor(s) are actually not damaged or faulty.

Continued on next page.

44

IOMM Starter

Fault Code

Description

Detailed Description of Fault / Possible Solutions Low control power (below 90V) has been detected while running, by the D3 controller. Verify that the control power input level is correct especially during starting when there may

F50

Control Power Low

be significant line voltage drop. Check control power transformer tap setting (if available). Check control power transformer fuses (if present). Check wiring between control power source and starter. Indicates that the D3 control board self-diagnostics have detected a problem with one or more of the current sensor inputs.

F51

Current

Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch

Sensor

settings are correct.

Offset Error

Verify that no actual current is flowing through any of the starter’s CTs when the starter is not running. Consult factory if fault persists.

F52

Burden

The burden switch settings were changed when starter was running. Only change burden

Switch Error

switches when starter is not running. DI#1 has been programmed as a fault type digital input and the input indicates a fault

External F60

condition is present.

Fault on

Verify that the appropriate Digital Input Configuration parameter has been programmed

DI#1 Input

correctly. Verify wiring and level of input. DI#2 has been programmed as a fault type digital input and input indicates a fault condition

External F61

is present.

Fault on

Verify that the appropriate Digital Input Configuration parameter has been programmed

DI#2 Input

correctly. Verify wiring and level of input. DI#3 input has been programmed as a fault type digital input and input indicates a fault

External F62

condition is present.

Fault on

Verify that the appropriate Digital Input Configuration parameter has been programmed

DI#3 input

correctly. Verify wiring and level of input.

IOMM Starter

45

Fault Code

Description

Detailed Description of Fault / Possible Solutions Based on the Analog Input parameter settings, the analog input level has either exceeded or dropped below the Analog Input Trip Level setting (I/O 08, P46) for longer than the Analog Input Trip Delay time (I/O 09, P47). Measure value of analog input to verify correct reading.

F71

Analog Input Level Fault Trip.

Verify settings of all Analog Input parameters (I/O 07-11, P45-49). Verify correct positioning of input jumper JP3 (Voltage or Current) on the D3 control card. Verify correct grounding of analog input connection to prevent noise or ground loops from affecting input. Indicates that communication has been lost with a remote device such as a remote keypad. (This fault will normally occur if the remote keypad is disconnected while the D3 control board is powered up. Only connect and disconnect a remote keypad when the

SPI F81

control power is off.)

Communication

Verify that the remote keypad cable has not been damaged and that its connectors are

Fault

firmly seated at both the keypad and the D3 Control board. Verify that the display interface board (when present) is firmly attached to D3 control card. 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) defined time.

F82

Modbus Timeout Fault

Verify communication parameter settings (FUN 10-12, P59-P61). Check wiring between the remote network and the D3 control card. Examine remote system for cause of communication loss. Typically occurs when attempting to run a version of control software that is incompatible with the D3 control board hardware being used. Verify that the software

F94

CPU Error –

is a correct version for the D3 control board being used. Consult factory for more

SW fault

details. Fault can also occur if the D3 control has detected an internal software problem. Consult factory.

F95

CPU Error –

The non-volatile user parameter values have been found to be corrupted. Typically

Parameter

occurs when the D3 control is re-flashed with new software.

EEPROM Checksum Fault

46

Perform a Factory Parameter reset and then properly set all user parameters before resuming normal operation.

IOMM Starter

Fault Code

Description

Detailed Description of Fault / Possible Solutions If fault persists after performing a Factory Parameter reset, consult factory.

F96

CPU Error

The D3 control has detected an internal CPU problem. Consult factory.

CPU Error – F97

SW Watchdog

The D3 control has detected an internal software problem. Consult factory.

Fault F98

F99

IOMM Starter

CPU Error

The D3 control has detected an internal CPU problem. Consult factory.

CPU Error –

The non-volatile program memory has been corrupted.

Program EPROM

Consult factory. Control software will need to be reloaded in to the D3 control card

Checksum Fault

before normal operation can resume.

47

General Troubleshooting Chart The following troubleshooting charts can be used to help solve many of the more common problems that may occur. Motor does not start, no output to motor Condition Display Blank, CPU Heartbeat LED on D3 board not blinking. Fault Displayed.

Start command given but nothing happens.

Cause Control voltage absent. D3 control board problem. Fault Occurred. Start/Stop control input problems.

Solution Check for proper control voltage input. Verify fuses and wiring. Consult factory. See fault code troubleshooting table for more details. Verify that the start/stop wiring and start input voltage levels are correct.

Control Source parameters ( P4-5)

Verify that the parameters are set

not set correctly.

correctly. Check input supply for inline contactor, open disconnects, open fuses, open circuit breakers, or disconnected wiring. Verify that the SCR gate wires are

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.

properly connected to the D3 control board. On medium voltage systems, verify wiring of the voltage feedback measurement circuit. See fault code troubleshooting table for more details.

During starting, motor rotates but does not reach full speed Condition Fault Displayed.

Cause Fault Occurred. Maximum Motor Current setting ( P7) set too low.

Solution See fault code troubleshooting table for more details. Review acceleration ramp settings.

Motor loading too high and/or current not dropping below 175% FLA indicating that the motor has Display shows Accel or Run.

Motor Hums before turning

48

Reduce load on motor during starting.

not come up to speed. Motor FLA ( P1) or CT ratio ( P1 &

Verify that Motor FLA and CT ratio

P15) parameter set incorrectly.

parameters are set correctly.

Abnormally low line voltage.

Fix cause of low line voltage.

A mechanical or supplemental brake

Verify that any external brakes are

is still engaged.

disengaged.

Initial current to low

Increase initial current

FLA or CT incorrect

Verify FLA or CT’s

IOMM Starter

Acceleration not operating as desired Condition

Motor accelerates too quickly.

Cause Ramp time ( P8) too short.

Increase ramp time.

Initial current ( P6) set too high.

Decrease Initial current.

Maximum current ( P7) set too high.

Decrease Maximum current.

Kick start current ( P13) too high.

Decrease or turn off Kick current.

Kick start time ( P14) too long.

Decrease Kick time.

Motor RLA ( P1) or CT ratio ( P15)

Verify that Motor FLA and CT ratio

parameter set incorrectly.

parameters are set correctly.

Starter Type parameter ( P64) set

Verify that Starter Type parameter is

incorrectly.

set correctly.

Maximum Motor Current setting ( P7) set too low. Motor loading too high. Motor accelerates too slowly

Solution

Motor RLA ( P1) or CT ratio ( P15)

Review acceleration ramp settings. Reduce load on motor during starting. Verify that Motor FLA and CT ratio

parameter set incorrectly.

parameters are set correctly.

Abnormally low line voltage.

Fix cause of low line voltage.

Ramp time to long

Decrease ramp time

Motor stops unexpectedly while running Condition Fault Displayed.

Cause Fault Occurred.

Solution See fault code troubleshooting table for more details. Verify start command input signal is present or serial communications

Ready Displayed.

Start command lost.

start command is present. Check any permissives that may be wired into the run command (Start/Stop)

Display Blank, Heartbeat LED on D3 board not blinking.

IOMM Starter

Control voltage absent. D3 control board problem.

Check for proper control voltage input. Verify wiring and fuses. Consult factory.

49

Metering incorrect Condition

Cause

Solution Verify correct CT wiring and verify

CTs installed or wired incorrectly. Power Metering not reading correctly.

that the CTs are installed with all the White dots towards the input line side.

CT ratio parameter (FUN 03, P68)

Verify that the CT ratio parameter is

set incorrectly.

set correctly.

Burden switches set incorrectly.

Verify that the burden switches are set correctly. Verify correct CT wiring and verify

PF Meter not reading correctly.

CTs installed or wired incorrectly.

that the CTs are installed with all the White dots towards the input line side.

Energy Saver active. Loose connections.

Turn off Energy Saver if not desired. Shut off all power and check all connections. Verify that the SCRs gate leads are

SCR fault.

connected properly and the SCRs are

Motor Current or Voltage meters

ok.

fluctuating with steady load.

Verify that the load is actually steady Load actually not steady.

and that there are not mechanical issues.

Other equipment on same power feed causing power fluctuations and/or distortion. Voltage Metering not reading correctly.

Current Metering not reading

In medium voltage systems, Rated Voltage parameter (FUN 05, P66) set incorrectly.

Fix cause of power fluctuations and/or distortion. Verify that Rated Voltage parameter is set correctly.

CT ratio parameter (FUN 03, P68)

Verify that the CT ratio parameter is

set incorrectly.

set correctly.

Burden switches set incorrectly.

correctly.

Verify that the burden switches are set correctly. Verify correct CT wiring and verify

CTs installed or wired incorrectly.

that the CTs are installed with all the White dots towards the input line side.

Ground Fault Current Metering not

CT ratio parameter (FUN 03, P68)

Verify that the CT ratio parameter is

set incorrectly.

set correctly.

Burden switches set incorrectly.

reading correctly.

Verify that the burden switches are set correctly. Verify correct CT wiring and verify

CTs installed or wired incorrectly.

that the CTs are installed with all the White dots towards the input line side.

50

IOMM Starter

Other Situations Condition

Cause

Solution If input phasing correct, exchange

Motor Rotates in Wrong Direction

Phasing incorrect

any two output wires. If input phasing incorrect, exchange any two input wires.

Erratic Operation

Loose connections Motor overloaded

Shut off all power and check all connections. Reduce motor load. Allow for adequate motor cooling

Too many starts per hour

between starts. Set Hot/Cold ratio higher or lengthen cooling time. Reduce ambient temperature or

High ambient temperature Motor Overheats

Incorrect motor OL settings Motor cooling obstructed/damaged

(When Present)

Fan power supply lost

Reduce starting load and/or review acceleration ramp settings. Review and correct if necessary motor OL settings. Remove cooling air obstructions. Check motor cooling fan. Verify fan power supply, check fuses.

Fan wiring problem

Check fan wiring.

Fan failure

Replace fan

Voltage/Current output jumper (JP1) not set correctly.

Analog Output not functioning

class lower to compensate for ambient temperature.

Acceleration time too long

Starter cooling fans do not operate

provide for better cooling. Set OL

Set jumper to give correct output.

Wiring problem

Verify output wiring.

Analog Output Function parameter

Verify that the Analog Output

(I/O 12, P50) set incorrectly.

Function parameter is set correctly.

Analog Output Offset and/or Span

Verify that the Analog Output Span

parameters (I/O 13-14, P51-52) set

and Offset parameters are set

incorrectly.

correctly.

properly

Verify that load on analog output Load on analog output too high.

meets D3 control analog output specifications. Verify correct grounding of analog

Ground loop or noise problems.

output connection to prevent noise or ground loops from affecting output.

IOMM Starter

51

Operation, Medium/High Voltage Starters, 2300V – 7.2KV Introduction This section contains information on medium voltage, across-the-line and solid state starters as manufactured by Benshaw Inc. for McQuay centrifugal Chillers. Medium voltage starters have similar software (Micro II Control) and are grouped together in this manual. Model numbers are as follows: Description Model Number MVSS36 to MVSS30 Solid State, 2300V, Free-standing MVSS50 to MVSS21 Solid State, 3300V, Free-standing MVSS40 to MVSS20 Solid State, 4160V, Free-standing HVSS42 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 Menu button to enter the menu system. • Press the Up or Down buttons to get the desired menu on the display. • Press the Enter button to go into the menu. • Press the Up or Down button to get to the desired sub-menu, if necessary. • Press the Enter button to go into the sub-menu, if necessary. • Press the Up or Down arrow buttons until the parameter is displayed.

52

IOMM Starter

Changing Parameters The starter’s setpoint parameters are factory-set and subsequently reviewed during commissioning by the McQuay startup technician. They should not be changed unless authorized by McQuay. The programming procedure is explained below and the following table shows the range of values and defaults.

Menu Buttons General:

The Micro II starter controller has a display/keypad (see Figure 12) that allows the user to set the starter parameters using a plain English interface. The functions of the display buttons are as follows.

MENU

ENTER

Press to enter a menu. Press to enter a sub-menu. Press to change the parameter displayed. Press to store the new value entered.

ž

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 when in a specific menu or sub-menu. Decrease a parameter value. Press to view the meters when the main display is shown.

START

STOP

IOMM Starter

Press to enter the menu system. Press to abandon changes made to a parameter (before pressing the Enter key). Press to exit a sub-menu. Press to exit the menu system.

Press to start the motor when the starter is connected for local display control. Press to activate the BIST (Built-In Self test) If 2-wire control is used or the Start button is disabled, this button is inoperative. Press to stop the motor when the starter is connected for local display control. If 2-wire control is used or the Stop button is disabled, this button is inoperative.

53

Menu Structure The Micro II control has a 2 level menu structure. There are eight main menus that contain parameters related to the different functions of the starter and five of the main menus contain additional sub-menus that divide the parameters into functional groups. The following shows the structure of the menu structure. Table 14, Main Menu Quick Start

Motor Nameplate

Starter Setup

Motor Protection

Starter Modes

Overload Class

Forward1 Profile

Line Current

Forward2 Profile

Line Voltage

Tachometer Setup Decel Setup Port Ctl Setup True Torque Ramp

Line Frequency Ground Fault Shorted Scr Over Curr. Trip Under Curr. Trip Start Lockouts Starting Timers Permissive Input Misc. Fault Classes

Meters & Relays Meters Setup Standard Relays Extended Relays

Continued Event Recorder

Control Config System Clock System Password Comm. Settings Options List Software Part#

Factory Setup Hardware Setup Bist Setup/Run Factory Control

RTD Setup Rtd Module Setup Rtd Setpnts 1-8 RTD Setpnts 9-16

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 the new value.

Example The ramp time is set to 30 seconds and it is to be changed to 20 seconds. The following steps must be taken to change the ramp time. • Press the Menu button to enter the menu system. • Press the Down button twice to get to the Starter Setup screen. • Press the Enter button to access the Starter Setup menu. • Press the Down button once to display the Forward1 Profile. • Press the Enter button to access the Forward1 Profile sub-menu. • Press the Down button twice to display the Ramp Time parameter. • Press the Enter button to allow a change to the ramp time. • Press the Down button repeatedly to change the Ramp Time to the desired value. • Press the Enter button to store the value. 54

IOMM Starter

• Press the Menu button repeatedly to return to the main display.

Quick Start Motor FLA Parameter Description

The motor FLA parameter must be set to the full load amps of the motor connected to the starter for the starter to function correctly. NOTE: The starter uses the entered motor FLA for 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 parameter should be set to the service factor of the motor. The service factor is used for the overload calculations. The service factor is factory set, will be checked by the start-up technician 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 the service factor is 1.15.

Start Mode Description

The Start Mode parameter allows for an optimal start of the motor based on the application. For a description of the possible Start Mode parameters, refer to page 31 in the Operations chapter. Values

The Start Mode Parameter can be set to Curr, TT, or Tach. Default

The default value for the Start Mode is Curr.

Stop Mode Description

The Stop Mode parameter allows for the most suitable stop of the motor based on the application. For a description of the possible Stop Mode parameters, refer to page 31 in the Operations chapter of the starter manual. Values

The Stop Mode can be set to Coas, VDCL, or TT. Default

The default value for the Stop Mode is Coas.

IOMM Starter

55

Int. Curr. (initial current) Description

The initial current parameter is set as a percentage of the motor FLA parameter setting. The initial current parameter sets the current that will initially reach the motor when a start is commanded. If the motor does not rotate within a few seconds after a 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

The default value for the initial current is 100%.

Max. Curr. (maximum current) Description

The maximum current parameter is set as a percentage of the motor FLA parameter setting. The maximum current parameter performs two functions. It sets the 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 power system or load dictates the setting of a lower maximum current. Values

The maximum current is adjustable from 100% to 600% in 1% intervals. Default

The default value for the maximum current is 600%.

Ramp Time Description

The ramp time sets the amount of time that it takes for the starter to linearly increase the current from the initial current level to the maximum current level. A typical ramp time setting is from 15 to 30 seconds. Settings

The ramp time is adjustable from 0 to 120 seconds in 1 second intervals. Default

The default value for the ramp time is 15 seconds.

Overload Description

If there is more than one motor connected, the motor FLA should be set to the sum of the connected motor full load. amps.Values Class 1 to 40 in steps of 1.

56

IOMM Starter

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 is attempted. Values

The line phasing can be set to: • INS - will run with either phase sequence • ABC - will only run with ABC phase sequence • CBA - will only run with CBA phase sequence Default

The default value for the phase sensitivity parameter is INS.

Troubleshooting The following troubleshooting charts can be used to help solve some of the more common problems that occur. Table 15, Motor will not start, no output to motor. Display Fault Displayed. Watchdog LED on.

Cause Shown on display. CPU card problem. Control voltage is absent. FU1 on power card. Ribbon Cables. Control Devices Display buttons disabled. Missing at least one phase of main po

Display is blank. Stopped No line

Solution See fault code table. Consult McQuay Factory Service. Check for proper control voltage. Replace FU1. Check ribbon cables. Check control devices Enable display buttons. Check power system.

Table 16, Motor rotates but does not reach full speed. Display Fault displayed. Accel or Running

Cause Shown on display Mechanical problems. Abnormally low line voltage.

Solution See fault code table. Check for load binding. Check motor. Fix line voltage problem

Table 17, Deceleration profile not operating correctly. Display Motor stops too quickly. Time seems correct but motor surges at start of decel. Time seems correct but motor stops before cycle complete. Time seems correct but water hammer occurs at end of cycle.

Cause Time setting. or improper level setting. Decel level 1 Decel level 2. TruTorque DCL End Torque Decel level 2. TruTorque DCL End Torque

Solution Contact McQuay Factory Service Contact McQuay Factory Service Contact McQuay Factory Service Contact McQuay Factory Service

Table 18, Motor stops while running. Display Fault displayed. Display is blank. Stopped

IOMM Starter

Cause Shown on display. Control voltage is absent. FU1 on power card Control devices.

Solution See fault code table. Check control wiring and voltage. Replace fuse. Check control system.

57

Table 19, Other situations. Display Power Metering not working. TruTorque Ramp not working.

Cause CT installed wrong. CT installed wrong. Motor Motor current or voltage fluctuat Energy saver load. Power connection. Erratic operation. Loose connections. Ramp time. Initial current. Maximum current setting. Kick Start. Accelerates too quickly. Improper FLA setting. Initial torque. Maximum torque. Ramp time. Initial current. Maximum current setting. Kick Start. Accelerates too slowly Improper FLA setting. Initial torque. Maximum torque. Duty cycle. High ambient. Too long acceleration time. Motor overheats. Wrong overload setting. Too long jog cycle.

Motor short circuit.

Fans do not operate Display buttons don’t work.

58

Solution Fix CT installation. White dot to line side. Fix CT installation. White dot to line side Verify motor is operating correctly. Set energy saver to off. Shut off power and check connections Shut off all power and check connections.

Contact McQuay Factory Service

Contact McQuay Factory Service

Cool between starts. Provide better ventilation. Reduce motor load. Select correct overload setting. Jog operation reduces motor cooling current. Shorten jog cycle. Identify fault and correct. Wiring fault. Power factor correction capacitors (P Move PFCC to line side of starter. starter output. Check wiring and correct. Wiring. Replace fuse. Fuse. Replace fan. Fan failed. Display ribbon cable. Check cable on back of display. Display faulty. Replace display.

IOMM Starter

Fault/Log Codes The following is a list of the possible fault and log codes that can be generated depending on the type of starter. The fault class lists the default setting for each fault; either critical or non-critical. NonC = Non-critical Crit = Critical Table 20, Fault/Log Codes Fault/ Log No. 1 2

Fault Class NonC NonC

Fault/Event Recorder Text Sequence Not CBA Sequence Not ABC

3

NonC

No Phase Order

4

NonC

High Freq. Trip

5

NonC

Low Freq. Trip

6

NonC

Jog Not Allowed

7

NonC

100% Not Allowed

9

NonC

Dir Change Fault

15 16 17 18 19 20 21 22 23 24 25 26 27 28

Crit Crit NonC NonC NonC NonC NonC NonC NonC NonC NonC NonC NonC NonC

Phase Order Err Bad OP Code Err Over voltage L1 Over voltage L2 Over voltage L3 Low line voltage#1 Low line voltage#2 Low line voltage#2 Curr. Imbal. HL1 Curr. Imbal. HL2 Curr. Imbal. HL3 Curr. Imbal. LL1 Curr. Imbal. LL2 Curr. Imbal. LL3

29

Crit

Bad RAM Battery

30

Crit

Def Param Loaded

31

NonC

REV Not Allowed

46

NonC

BIST Canceled

NonC

Tach Loss

49

Description/Possible Solutions Incoming phase sequence is actually ABC but starter is set to CBA Incoming phase Sequence is actually CBA but starter is set to ABC No phase order detected. Line frequency went above the high freq. trip setting Line power quality problem. Low control power problem. Generator governor is malfunctioning Line frequency went below the low freq. trip setting Line power quality problem. Low control power problem. Generator governor malfunctioning. Jog input (JC13-4) was energized while the starter was running. Stop the starter by removing the run command before requesting a jog (JC13-4). The jog input (JC13-4) was de-energized while the starter was operating in the jog mode. Stop the starter by removing the run command before removing the (JC13-4). The jog direction was changed while the starter was operating in the jog mode. Stop the starter by removing the run command before changing the reversing input (JC13-6). Phase order error. Bad operating-code error The voltage on line 1 went above the high/low voltage setting The voltage on line 2 went above the high/low voltage setting The voltage on line 3 went above the high/low voltage setting The voltage on line 1 went below the high/low voltage setting The voltage on line 2 went below the high/low voltage setting The voltage on line 3 went below the high/low voltage setting The current on line 1 went above the current imbalance setting The current on line 2 went above the current imbalance setting The current on line 3 went above the current imbalance setting The current on line 1 went below the current imbalance setting The current on line 2 went below the current imbalance setting The current on line 3 went below the current imbalance setting Bad RAM battery. Replace IC16 or computer card to correct problem. To clear fault, hold the down arrow key and perform a computer reset. Co the down arrow key until fault 30 appears on the display The factory defaults for the parameters have been loaded. Reset the computer to clear the fault. All parameters have to be re-programmed as necessary. Starter is not a reversing unit. Remove reverse command from reverse input (JC13-6). The Built-in Self Test was canceled. The disconnect was closed. Line power was applied to the starter. There was no tachometer feedback signal detected when a start was com

Continued on next page.

IOMM Starter

59

Fault/ Log No.

Fault Class

Fault/Event Recorder Text

50

Crit

Key Pad Failure

51

Crit

TT Overcurrent Limit

52

Crit

Curr. At Stop

53

NonC

No Curr. At Run

56 64 65

NonC Dis NonC

Phase Detection Bad RTD Detected RTD Alarm Limit

66

NonC

RTD Comm Loss

67

NonC

PWR DIP data Lost

68

NonC

Jog Timer Limit

69

NonC

Zero Speed Timer

70

NonC

Low Control PWR

71

NonC

Ground Fault

72

Crit

DIP SW set Wrong

73

NonC

Bypass Fault

74

NonC

UTS Timer Limit

75

NonC

External Trip

76

Crit

Disconnect Open

77

NonC

In-line Fault

78 79

NonC NonC

Over Curr Trip Under Curr Trip

80

NonC

High Field Curr.

81

NonC

Field Loss

82

NonC

Loss of SYNC

83 84 87 90

NonC NonC NonC Crit

High PF Trip Low PF Trip Incomplete Seq. OL Lock

Description/Possible Solutions The door mounted keypad has failed. The Stop or Start button was held down while a computer reset was while power was applied to the unit. During TruTorque ramping, the motor current exceeded the TruTorqu Trip level Current flow above the no current at run setting was detected while the starter was stopped. Examine starter for shorted SCRs. The motor current went below the no current at run setting while the starter was running. The load was disconnected while running. The motor is being driven by the load. A bad RTD was detected (open or shorted lead). A RTD alarm set point was exceeded. Communications with the RTD module was lost. Check RS-485 wiring between the RTD module and card. Check 24VDC RTD module power supply. PWR DIP data lost The jog timer expired. Examine reason for extended jog operation. The zero speed timer expired. • Check motor for jammed or overloaded condition Control power is too low. Examine control power transformer input and output voltages. Check wiring between control power source and starter. A ground fault current above the ground fault setting was detected. CT burden DIP switch set incorrectly. Set switches correctly. The bypass contactor failed to stay energized. Check separate bypass for proper wiring. Check integral bypass (RSxB units) control card fuses. The motor was not at full speed before the UTS time expired. Check motor for jammed or overloaded condition. Power was removed from the external trip input on the computer card (JC13-1). Trip input delay is set to short A start was commanded while the disconnect was open. The in-line contactor did not close. Check wiring to coil of contactor. Check feedback wiring from auxiliary contactor to JC13-4 terminal. check in-line fault delay The current went above the over-current trip setting

The current went below the under-current trip setting The field current was above the maximum field current setting. • Examine parameter settings for improper adjustment. • Examine field for problem causing the high field current There was no synchronous field current. Check wiring and motor for open field circuit. The motor came out of synchronization while it was operating. Examine the motor load for an overload. Increase the field current up to the maximum for the motor. Change from power factor control to current control mode for a varying l

The motor power factor went above the high power factor trip se The motor power factor went below the low power factor trip sett The motor was not synchronized before the sequence timer exp Used to set the operation of the overload.

Continued on next page.

60

IOMM Starter

Fault/ Log No

Fault/Event Recorder Text

Description/Possible Solutions

91

Crit

Unauthorized RUN

The start/stop circuitry has failed. A fast start/stop sequence was performed. Check wire connected to terminal JC13-3.

92

Crit

Shorted SCR

A shorted SCR on line 1 was detected • Check all 3 SCRs for shorts

93

Crit

Shorted SCR

A shorted SCR on line 2 was detected. Check all 3 SCRs for shorts

94

Crit

Shorted SCR

A shorted SCR on line 3 was detected Check all 3 SCRs with ohmmeter for shorts.

95

Crit

Shorted SCR

Shorted SCRs on line 2 and 3 were detected Check all 3 SCRs with ohmmeter for shorts.

96

Crit

Shorted SCR

Shorted SCRs on line 1 and 3 were detected Check all 3 SCRs with ohmmeter for shorts.

97

Crit

Shorted SCR

98

NonC

No Mains Power

Shorted SCRs on line 1 and 2 were detected Check all 3 SCRs with ohmmeter for shorts. A start was commanded while no line power was detected.

99

Crit

I. O. C. Blank Log Log:Disconnect O Log:DIR Change Start Commanded Stop Commanded Stop Complete Log: System UTS Log:BIST Entered Log:BIST Passed Log:Password CLR Log:Events CLR

A very high current was detected. Check the motor and wiring for short circuits. Blank Log. Log:Disconnect open. The direction of the starter was changed. A start command was given. A stop command was given. The stop sequence is complete and the starter has removed power fro Log: System UTS (up to speed). Log:BIST entered. Log:BIST passed. Log:Password cleared. Log:Event log cleared.

156

Log:System Reset

Log:System Reset.

157 158

Log:Hardware PWR U Log:Emerg Reset

Log:Hardware PWR UP. Log:Emergency reset.

159

Log:Time Changed

Log:Time changed.

160 161 162 163 164 165 169 185 186

PWR Ret BYP IN PWR Ret BYP OUT PWR Loss Voltage PWR Loss Current PORT BYP Open Log:System Reset RTD Warn Limit Log:Loss of SYNC Log:If Ctrl Mode

Line power returned while the bypass contactor was in. Line power returned after the bypass contactor was dropped out. PORT mode was entered due to low line voltage. PORT mode was entered due to loss of current. Bypass contactor was dropped out while in PORT mode. The unit was reset. One of the RTD warning set points was exceeded. Log:Loss of SYNC. Log:If Ctrl Mode.

188

Log:By-Pass Drop

189

Log:OL Warn

The integral bypass contactors dropped out and were re-energized. Possible short term drop in line voltage. The thermal overload went above 90% thermal content.

190

Log:OL Lock

101 102 103 104 105 106 107 147 148 154 155

IOMM Starter

Fault Class

The thermal overload tripped. Check motor and load for cause of overload.

61

LED Diagnostics There are several LEDs located on the Micro II circuit cards. These LEDs can be used to help troubleshoot problems with the starter. Refer to the circuit card layouts for LED locations. Table 21, LED Diagnostics CARD

Computer

Local I/O Controller Card

LED #

NAME

INDICATION

LEDC1

Watch Dog/Power Fail/Reset

On when reset/CPU failure/control voltage failure.

LEDC2

Control power

On if control voltage is present.

NS

DeviceNet Network Status

See DeviceNet manual.

MS

DeviceNet Module Status

See DeviceNet manual.

DE

Data Enable

On when card is transmitting data.

TXD

Transmit Data

On when card is transmitting data.

RXD

Receive Data

On when card is receiving data.

LED1

Operation

Flashes when card is operating.

LED2

Communication

On when valid data is received over the master link. Indicates forward SCR condition;

Power

SCR Status

L1 - L6

Condition of SCR’s L1 and L2 - SCR’s A and B L3 and L4 - SCR’s C and D L5 and L6 - SCR’s E and F

Indicates SCR condition; Stop - LEDs will be off when stopped. Start - LEDs will be bright when the in-line is energized. LED’s will go progressively dimmer as motor accelerates. Run - LED’s will be off when motor reaches full voltage.

A-F

SCR gate voltage

These LEDs will be on, while ramping, to indicate that gate power is reaching the SCR’s.

Pulse Generator

62

Stop - LEDs must be on or the SCR is shorted

LEDP1 LEDP2 LEDP3

Start - LEDs will become dimmer as motor accelerates. Run - LEDs must be fully off or the SCR is open or misfiring.

IOMM Starter

Maintenance Preventive Maintenance During Commissioning

•

Torque all power connections during commissioning, including prewired equipment.

•

Check all control wiring for loose connections.

•

If fans are installed, 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

IOMM Starter

•

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 filters every three months.

63

64

IOMM Starter

Index of Figures & Tables FIGURES Figure 1, Wye-Delta Starter .................................................................................. 3 Figure 2, Solid State Starter, Wall Mounted ......................................................... 4 Figure 3, Starter Panel ........................................................................................ 14 Figure 4, Field Wiring for Optional D3 Communication.................................... 15 Figure 5, Control and Power Field Wiring.......................................................... 16 Figure 6, Optional Starter View Screen .............................................................. 27 Figure 7, Expanded Starter View Screen ............................................................ 28 Figure 8, Optional Starter Setpoint Screen ......................................................... 29 Figure 9, Starter-mounted LED .......................................................................... 30 Figure 10, Wye Delta Motor Connection to the D3 Control............................... 37 Figure 11, Wye Delta Profile .............................................................................. 39 Figure 12, LED Display/Keypad ........................................................................ 52

TABLES Table 1, Starter/VFD Mounting Arrangements ..................................................... 6 Table 2, Solid State Connection Sizes, Power Block.......................................... 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, Status Messages, Wye-Delta Starter.................................................... 34 Table 12, Status Messages, Solid State Starter ................................................... 34 Table 13, Default Meter Display......................................................................... 35 Table 14, Main Menu.......................................................................................... 54 Table 15, Motor will not start, no output to motor.............................................. 57 Table 16, Motor rotates but does not reach full speed. ....................................... 57 Table 17, Deceleration profile not operating correctly. ...................................... 57 Table 18, Motor stops while running. ................................................................. 57 Table 19, Other situations. .................................................................................. 58 Table 20, Fault/Log Codes.................................................................................. 59 Table 21, LED Diagnostics................................................................................. 62

IOMM Starter

65

This document contains the most current product information as of this printing. For the most up-todate product information, please go to www.mcquay.com.

Post Office Box 2510, Staunton, Virginia 24402-2510 USA • (800) 432-1342 • www.mcquay.com

IOMM Starter (09/05)