2
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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 . . . . . . . . . . . . . . . . . . . 3
Components and Physical Data . . . . . . . . . . . . . . . . . . . . 4
START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternate Wire Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Verify Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Configure the VFD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Commissioning the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Check Internal Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting the Drive. . . . . . . . . . . . . . . . . . . . . . . . . 10
• CHILLER ALERT CODES
• CHILLER ALARM CODES
• TEST EQUIPMENT NEEDED TO TROUBLESHOOT
• VERIFYING THAT DC BUS CAPACITORS ARE
DISCHARGED
• HIGH TEMPERATURE ALARMS
• MAIN CONTROL BOARD (MCB) COMPONENTS
Checking Power Modules and Motor Input
with Input Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Servicing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
• REMOVING THE DRIVE
• RIGGING THE ENCLOSURE
• REPLACING THE GATEWAY
• CHILL PLATE FAN AND INTERNAL FAN REPLACE-
MENT
Part Identification and Location . . . . . . . . . . . . . . . . . . . 18
APPENDIX A — WIRING SCHEMATICS . . . . . . . . . . . 21
INTRODUCTION
The Carrier VFD option Start-Up and Service Manual is intended
for trained and qualified service personnel and is to be used during
start-up, operation, and maintenance of Rockwell/Allen-Bradley
PF755L drive.
WARNING
DO NOT ATTEMPT TO REMOVE fittings, covers, etc.,
while chiller is under pressure or while chiller is running. Be
sure pressure is at 0 psig (0 kPa) before breaking any refriger-
ant connection.
CAUTION
Failure to follow these procedures may result in personal inju-
ry or damage to equipment.
TO AVOID an electric shock hazard, verify that the voltage on
the bus capacitors has discharged completely before servicing.
Check the DC bus voltage at the power terminal block by mea-
suring between the +DC and -DC terminals, between the +DC
terminal and the chassis, and between the -DC terminal and the
chassis. The voltage must be zero for all 3 measurements.
THE USER is responsible to conform with all applicable local,
national, and international codes. Failure to observe this pre-
caution could result in damage to, or destruction of, the equip-
ment.
THIS DRIVE contains ESD (electrostatic discharge) sensitive
parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are
not followed. For static control procedures, reference Rock-
well publication Guarding Against Electrostatic Damage, or
any other applicable ESD protection handbook.
DO NOT alter the setting of any jumper. Failure to observe
this precaution could result in damage to, or destruction of, the
equipment.
USE OF power correction capacitors on the output of the drive
can result in erratic operation of the motor, nuisance tripping,
and/or permanent damage to the drive. Remove power correc-
tion capacitors before proceeding. Failure to observe this pre-
caution could result in damage to, or destruction of, the equip-
ment.
MOST CODES require that upstream branch circuit protection
be provided to protect input power wiring. If fuses are chosen
as the protection method, refer to the PowerFlex 750 user man-
ual. Failure to observe this precaution could result in damage
to, or destruction of, the equipment.
DO NOT route signal and control wiring with power wiring in
the same conduit. This can cause interference with drive opera-
tion. Failure to observe this precaution could result in damage
to, or destruction of, the equipment.
DISTRIBUTION SYSTEM short circuit capacity shall not ex-
ceed the rating of the drive. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.
DO NOT STEP on refrigerant lines. Broken lines can whip
about and release refrigerant, causing personal injury.
DO NOT climb over a chiller. Use platform, catwalk, or stag-
ing. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift
or move inspection covers or other heavy components. Even if
components are light, use mechanical equipment when there is
a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements CAN
ENGAGE THE VFD, TOWER FAN, OR PUMPS. Open the
disconnect ahead of the VFD, tower fans, or pumps.
(Cautions continued in next column.)
CAUTION
USE only repair or replacement parts that meet the code re-
quirements of the original equipment.
PERIODICALLY INSPECT all valves, fittings, and piping for
corrosion, rust, leaks, or damage.
DO NOT re-use compressor oil or any oil that has been ex-
posed to the atmosphere. Dispose of oil per local codes and
regulations.
DO NOT leave refrigerant system open to air any longer than
the actual time required to service the equipment. Seal circuits
being serviced and charge with dry nitrogen to prevent oil con-
tamination when timely repairs cannot be completed.
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