Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53190096-01 Printed in U.S.A. Form 19-CLT-1SS Pg 1 4-24 Replaces: New
Start-Up and Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . 3
Required Publications . . . . . . . . . . . . . . . . . . . . . . . . 3
Getting Assistance from Rockwell Automation . . . . 3
IDENTIFYING DRIVE COMPONENTS . . . . . . . . . . . . . 3
Opening the VFD Access Door . . . . . . . . . . . . . . . . . 3
Drive Assembly Catalog Number . . . . . . . . . . . . . . . 4
Components and Physical Data . . . . . . . . . . . . . . . . 5
• LAYOUT AND DIMENSIONS FOR 19MV CHILLERS
• LAYOUT AND DIMENSIONS FOR 19XR6 CHILLERS
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Alternate Wire Lugs . . . . . . . . . . . . . . . . . . . . . . . . . 10
Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Configure the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Commissioning the Unit . . . . . . . . . . . . . . . . . . . . . . 12
Check Internal Jumpers . . . . . . . . . . . . . . . . . . . . . . 12
Power Jumper Configuration (Head Line) . . . . . . . 14
• FRAME 7 (19MV PRODUCT)
• FRAME 9, 10 AND LARGER (19XR PRODUCT)
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting the Drive . . . . . . . . . . . . . . . . . . . . 16
• CHILLER ALERT CODES
• CHILLER ALARM CODES
• CONNECTED COMPONENTS WORKBENCH (CCW)
• TEST EQUIPMENT NEEDED TO TROUBLESHOOT
• VERIFY THAT DC BUS CAPACITORS ARE
DISCHARGED
• MAIN CONTROL BOARD (MCB) COMPONENTS
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Checking Power Modules and Motor Input
with Input Power Off . . . . . . . . . . . . . . . . . . . . . . . 64
Servicing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 65
• RIGGING THE ENCLOSURE
• TYPICAL SERVICE PROCEDURES
• LCL FILTER MODULE AND POWER MODULE
REPLACEMENT
• UNIT MOUNT DRIVES (19MV PRODUCT):
• FREESTANDING DRIVES (19XR PRODUCT)
• PREVENTIVE MAINTENANCE
APPENDIX A — WIRING SCHEMATICS . . . . . . . . . . 72
SAFETY CONSIDERATIONS
Centrifugal and screw compressor liquid chillers are designed to
provide safe and reliable service when operated within design
specifications. When operating this equipment, use good judg-
ment and safety precautions to avoid damage to equipment and
property or injury to personnel.
Be sure you understand and follow the procedures and safety pre-
cautions contained in the chiller instructions as well as those listed
in this guide.
DANGER
Failure to follow these procedures will result in severe personal
injury or death.
ONLY QUALIFIED electrical personnel familiar with the
construction and operation of this equipment and the hazards
involved should install, adjust, operate, or service this
equipment.
READ AND UNDERSTAND this manual and other
applicable manuals in their entirety before proceeding. Failure
to observe this precaution could result in severe bodily injury
or loss of life.
DO NOT install modification kits with power applied to the
drive. Disconnect and lock out incoming power before
attempting such installation or removal. Failure to observe this
precaution could result in severe bodily injury or loss of life.
UNUSED WIRES in conduit must be grounded at both ends to
avoid a possible shock hazard caused by induced voltages.
Also, if a drive sharing a conduit is being serviced or installed,
all drives using this conduit should be disabled to eliminate the
possible shock hazard from cross-coupled motor leads. Failure
to observe these precautions could result in bodily injury.
DO NOT VENT refrigerant relief valves within a building.
Outlet from rupture disc or relief valve must be vented
outdoors in accordance with the latest edition of ANSI/
ASHRAE 15 (American National Standards Institute/
American Society of Heating, Refrigerating, and Air-
Conditioning Engineers). The accumulation of refrigerant in
an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/
ASHRAE 15, especially for enclosed and low overhead
spaces. Inhalation of high concentrations of vapor is harmful
and may cause heart irregularities, unconsciousness, or death.
Misuse can be fatal. Vapor is heavier than air and reduces the
amount of oxygen available for breathing. Product causes eye
and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a
chiller for any purpose. Oxygen gas reacts violently with oil,
grease, and other common substances.
(Dangers continued in next column.)
19XR, 19MV
with PIC6 Controls
Rockwell PowerFlex 755TL VFD Option
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