Carrier VFD Quick Reference

Instruction Manual D2-3466-1

The information in this manual is subject to change without notice.

Throughout this manual, the following notes are used to alert you to safety considerations:

ATTENTION: Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
!
Important: Identifies information that is critical for successful application and understanding of the product.

The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to
signify new or revised text or figures.

ATTENTION: 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.
ATTENTION: DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to
discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are
discharged before touching any internal components. Failure to observe this precaution could
result in severe bodily injury or loss of life.
ATTENTION: The drive can operate at and maintain zero speed. The user is responsible for
assuring safe conditions for operating personnel by providing suitable guards, audible or visual
alarms, or other devices to indicate that the drive is operating or may operate at or near zero
speed. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: 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.
ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of the
drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled
machine operation may result if this procedure is not followed. Failure to observe this precaution
could result in bodily injury.
ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.

Copyright © 2002 Rockwell Automation. All rights reserved.

 ATTENTION: When the level-sense start feature is enabled (P.054 = ON), the user must ensure
that automatic start up of the driven equipment will not cause injury to operating personnel or
! damage to the driven equipment. In addition, the user is responsible for providing suitable audible
or visual alarms or other devices to indicate that this function is enabled and the drive may start
at any moment. Refer to the LiquiFlo Software Start-Up and Reference manual (D2-3410)for
additional information. Failure to observe this precaution could result in severe bodily injury or
loss of life.
ATTENTION: When P.055 is set to ON, the STOP/RESET key is functional only from the selected
control source. As a safety precaution, Reliance recommends that an emergency stop input be
located near the equipment. As a further safety precaution, the user should post a warning on
the drive to alert personnel that the STOP/RESET key is not functional. Failure to observe this
precaution could result in severe bodily injury or loss of life.
ATTENTION: 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.
ATTENTION: The drive contains printed circuit boards that are static-sensitive. Anyone who
touches the drive components should wear an anti-static wrist band. Erratic machine operation
and damage to, or destruction of, equipment can result if this procedure is not followed. Failure
to observe this precaution can result in bodily injury.
ATTENTION: If a maintained start contact is used when the control source = rE, switching from
local to remote from the terminal strip will cause power to be applied to the motor if the remote
start contact is closed. Stay clear of rotating machinery in this case. Failure to observe this
precaution could result in bodily injury.
ATTENTION: The drive is not equipped with a coast-stop pushbutton. You must install a hardwired
operator-accessible pushbutton that provides a positive interrupt and shuts down the drive. See
the LiquiFlo AC Power Modules Hardware Reference, Installation, and Troubleshooting manual
(D2-3411) for wiring information. Failure to observe this precaution could result in bodily injury.
ATTENTION: The user is responsible for ensuring that driven machinery, all drive-train
mechanisms, and application material are capable of safe operation at the maximum operating
speed of the drive. In V/Hz regulation, overfrequency protection in the drive is provided by means
of H.022. Failure to observe this precaution could result in bodily injury.
ATTENTION: The setting of parameters H.001 (Motor Nameplate Base Frequency), and P.004
(Maximum Speed) determines the motor maximum speed. These parameters must be set by a
qualified person who understands the significance of setting them accurately. Failure to observe
this precaution could result in bodily injury.
ATTENTION: When switching from auto to manual, or manual to auto, the drive will ramp to the
reference level provided by the new source at the rate specified in P.001 (Accel Time 1), P.002
(Decel Time 1), P.017 (Accel Time 2), or P.018 (Decel Time 2). Be aware that an abrupt speed
change may occur depending upon the new reference level and the rate specified in these
parameters. Failure to observe this precaution could result in bodily injury.
ATTENTION: It is the user’s responsibility to determine how to distribute the passwords. Reliance
Electric is not responsible for unauthorized access violations within the user’s organization. Failure
to observe this precaution could result in bodily injury.
ATTENTION: Do not alter the setting of any jumper not described in LiquiFlo Hardware Reference
manual (D2-3411). Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
ATTENTION: For single-motor applications with no external thermal overload relay, P.040 (Motor
Overload Enable) should always be set to ON. Failure to observe this precaution could result in
damage to, or destruction of, the equipment.
 ATTENTION: 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
! correction capacitors before proceeding. Failure to observe this precaution could result in damage
to, or destruction of, the equipment.
ATTENTION: Most codes require that upstream branch circuit protection be provided to protect
input power wiring. Install the fuses recommended in table 3.7 of the LiquiFlo Hardware Reference
manual (D2-3411). Do not exceed the fuse ratings. Failure to observe this precaution could result
in damage to, or destruction of, the equipment.
ATTENTION: Do not route signal and control wiring with power wiring in the same conduit. This
can cause interference with drive operation. Failure to observe this precaution could result in
damage to, or destruction of, the equipment.
ATTENTION: Distribution system short circuit capacity shall not exceed the rating of the drive.
Failure to observe this precaution could result in damage to, or destruction of, the equipment.
ATTENTION: H.002 (Motor Nameplate Amps) must not exceed the rated amps found on the motor
nameplate. Overcurrent or excess heating of the motor could result if this is not done. Failure to
observe this precaution could result in damage to, or destruction of, the equipment.

The following ATTENTION statements do not apply to the default Carrier VFD configuration.
However, they do apply to the Reliance LiquiFlo AC Power Module.

ATTENTION: As a safety precaution, Reliance Electric recommends that you provide an audible
or visual alarm to indicate that the level sense start feature is enabled and the motor can start
when power is applied to the drive. You should also post warnings on the motor, the drive, and
any other applicable equipment to alert personnel that the application uses an automatic start-
up feature. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: Be aware of the following before enabling the level sense start function (P.054):
• Setting P.054 to ON immediately applies output power to the motor when all start conditions are
met.
• If the drive is running from the terminal strip, both the start and stop inputs are closed. If P.054 =
ON and a fault occurs, the drive coasts to rest and generates a fault. In this case, resetting and
clearing the fault immediately restarts the drive without any change to the start or stop input
states
• If P.026 (Function Loss Response) = 1, the control source is the terminal strip (start and stop
inputs are closed), and P.054 = ON, the drive coasts to rest if the function loss input is opened
and does not generate a fault. In this case, closing the function loss input immediately starts the
drive without any change to the start or stop input.
When this function is enabled, the user must ensure that automatic start up of the driven
equipment will not cause injury to operating personnel or damage to the driven equipment. In
addition, the user is responsible for providing suitable audible or visual alarms or other devices to
indicate that this function is enabled and the drive may start at any moment. Failure to observe this
precaution could result in severe bodily injury or loss of life.
ATTENTION: If P.062 (Option Port: Communication Loss Response) = 2 and P.054 (Level Sense
Start Enable) = ON and network communication is lost while the drive is running, the terminal
strip stop input will function as a STOP/RUN input. If the terminal strip stop input is opened, the
drive will stop. If the terminal strip stop input is closed, the drive will re-start. Failure to observe
this precaution could result in severe bodily injury or loss of life.
ATTENTION: When starting with search enabled (H.016 is set to any value but OFF), there will
be a several second delay, and the motor may drift in the forward and reverse direction, before
the motor begins operating in the desired direction even if reverse has been disabled in P.027.
Stay clear of rotating machinery. Failure to observe this precaution could result in bodily injury.
 ATTENTION: When connected to a non-regenerative common DC bus, regeneration may cause
a rise in DC bus voltage. Be aware that other drives on the bus may experience an unexpected
! speed increase due to the high bus voltage. Failure to observe this precaution may result in bodily
injury.
ATTENTION: The motor shaft can rotate in either direction by up to one (1) revolution, providing
minimum torque immediately after the identification procedure (initiated in H.020) has been
started. Stay clear of rotating machinery. Failure to observe this precaution could result in bodily
injury.
ATTENTION: In V/Hz regulation, if P.000 (Control Source) is set to OP (Option Port), and P.062
is set to 1 (Hold Last Reference), and the drive loses communication with the network, the drive
will maintain the last frequency command sent to it. Ensure that driven machinery, all drive-train
mechanisms, and application material are capable of safe operation at the maximum operating
speed of the drive. Failure to observe this precaution could result in bodily injury.
ATTENTION: Carrier Frequency (P.047) and Current Limit (P.005) must be set correctly before
activating the identification procedure (H.020) to avoid motor overloading and/or overheating.
Failure to observe this precaution could result in damage to, or destruction of, the equipment.
ATTENTION: The motor can rotate in the reverse direction during the identification procedure
(H.020) even if reverse disable has been selected in P.027. Uncouple the motor from any driven
machinery that could be damaged by reverse rotation. Failure to observe this precaution could
result in damage to, or destruction of, the equipment.
 CONTENTS
Chapter 1 Using This Manual
1.1 Required Publications...................................................................................... 1-1
1.2 Getting Assistance from Reliance Electric....................................................... 1-1

Chapter 2 Identifying Drive Components Using Reference Drawings and Parts Lists
2.1 VFD Chiller Installation Drawings .................................................................... 2-1
2.2 Front View of 500 and 643 Amp VFD with Parts List
(19XV04000601 rev 4.0) ................................................................................. 2-3
2.3 500 Amp and 643 Amp 19XRV Drive Module Component Locations
and Parts List................................................................................................... 2-4
2.4 Front View of 414 Amp VFD with Parts List (19XVR0414100 rev 2.0)............ 2-5
2.5 414 Amp 19XRV Drive Module Component Locations and Parts List............. 2-6
2.6 414 Amp 19XRV Drive Wiring Diagrams ......................................................... 2-7
2.7 VFD System Wiring Diagram (19XV05007901 rev A) ..................................... 2-9
2.8 500 Amp and 643 Amp 19XRV Drive Wiring Diagrams ................................ 2-14

Chapter 3 Using the Keypad/Display to Program, Monitor, and Control the Drive............ 3-1

Chapter 4 Identifying Parameter Defaults For Carrier Drives .............................................. 4-1

Chapter 5 Verifying the Installation ........................................................................................ 5-1

Chapter 6 Troubleshooting the Drive

6.1 Test Equipment Needed To Troubleshoot....................................................... 6-1
6.2 Verifying That DC Bus Capacitors Are Discharged ......................................... 6-1
6.3 Checking the Power Modules and Motor with Input Power Off ....................... 6-4
6.4 Troubleshooting the Drive Using Error Codes ................................................. 6-6
6.4.1 Identifying Alarm Codes and Recovering .............................................. 6-7
6.4.2 Identifying Fault Codes and Recovering ............................................... 6-8
6.4.3 Accessing, Reading, and Clearing the Faults in the Error Log............ 6-11
6.5 Identifying Fatal Fault Codes and Recovering............................................... 6-14
6.6 Indentifying PMC Board Fault Codes and Recovering .................................. 6-15
6.7 Resetting a Checksum (CHS) Fault .............................................................. 6-15

Contents I
II Carrier VFD Quick Reference
 List of Figures

Figure 3.1 – Keypad/Display..................................................................................... 3-1

Figure 6.1 – DC Bus Voltage Terminals (414 Amp Drives) ...................................... 6-2
Figure 6.2 – DC Bus Voltage Terminals (500 Amp and 643 Amp Drives)................ 6-3

Contents III
IV Carrier VFD Quick Reference
 List of Tables

Table 6.1 – Resistance Checks ................................................................................ 6-5

Table 6.2 – List of Alarm Codes ............................................................................... 6-7
Table 6.3 – List of Fault Codes ................................................................................ 6-8
Table 6.4 – Fatal Fault Codes That Can Be Reset................................................. 6-14
Table 6.5 – PMC Board Fault Codes...................................................................... 6-15

Contents V
VI Carrier VFD Quick Reference
 CHAPTER 1
Using This Manual

The Carrier VFD Quick Reference is intended for qualified Carrier service personnel,
and is to be used during start up, operation, and maintenance of the variable speed
drive.

1.1 Required Publications

The Carrier VFD Quick Reference must be used with the following manuals:

• D2-3410 LiquiFlo AC General Purpose (Volts/Hertz) and Vector Duty Drive

Software Start-Up and Reference Manual
• D2-3411 LiquiFlo AC Power Modules Hardware Reference, Installation, and
Troubleshooting
• D2-3341 Super Remote Meter Interface (RMI) Board for GV3000 and
LiquiFlo AC Drives
• D2-3448 Control and Configuration Software
• 531-982 19XR, XRV Start-Up, Operation, and Maintenance Instructions
(19XR-5SS)

1.2 Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this manual,
contact your local Reliance Electric sales office. For technical assistance, call
1-800-726-8112.

Before calling, have the following information available (from the Reliance label):
• Reliance model number
• Carrier part number
• Serial number
• Carrier drawing number and revision

Using This Manual 1-1

1-2 Carrier VFD Quick Reference
 CHAPTER 2
Identifying Drive Components Using Reference Drawings and Parts Lists

2.1 VFD Chiller Installation Drawing (500A and 643A VFD)

Note:

The VFD chiller is typically

pre-wired at the factory.

Identifying Drive Components Using Reference Drawings and Parts Lists 2-1
 VFD Chiller Installation Drawing (414A VFD)

2-2 Carrier VFD Quick Reference

 2.2 Front View of 500 and 643 Amp VFD with Parts List (19XV04000601 rev 4.0)

Notes:

Refer to section 2.3 for drive

module parts.

Replacement parts not in the

drive module are available from
Reliance Electric.

Call 1-888-DRIVES-0.

Note: Use this phone number only for

replacement parts listed on this
page.

Identifying Drive Components Using Reference Drawings and Parts Lists 2-3
 2.3 500 Amp and 643 Amp 19XRV Drive Module Component Locations and Parts List

Rockwell
Automation
Item # Description Part # Qty
1 Bus Bars (AC Input) n/a 6
16 2 SCR Module 22501-025-04 1
Power Module Adapter (PCB) 500 A Frame 179134 1
3
1 Power Module Adapter (PCB) 643 A Frame 179067 1
4 Power Interface Harness 179058
2 5 Bus Bars (AC Output) n/a 3
6 LEM Interface Harness 179061 1
3 7 DC Bus Control PCB 179069 1
17 8 Gate Driver PCB - Low Side 179065
4 9 DC Bus Laminate Assembly n/a 1
5
10 Current Feedback Devices 25503-011-01 3
11 IGBT Modules n/a 6
18
12 Chillplate (Heatsink) n/a 1

6 18
13 Capacitors n/a 36
14 Drive Baseplate n/a 1
7 19 15 Coolant Lines (not shown) n/a 2

19
16 Discharge Resistor (not shown) n/a 3
17 Control Panel Assembly n/a 1
18 Bus Control - PMA Harness 179057 1
8 19 Bus Control - Gate Driver Harness 179055 1
20
Note: When replacing the Regulator board, 20 Gate Driver PCB - High Side (not shown) 170065 1
verify that jumper J4 is on pins 1 and 2,
21 Membrane Switch Keypad/Bracket 410483-15B 1
as shown in the detail below. You also
9 21 may need to perform an initalization 22 Regulator PCB 179116 1
procedure. See section 6.7 of instruction
23 Remote Meter Interface (RMI) PCB 814.56.00 1
22 manual D2-3411 for more information.
24 Reactor (not shown) n/a 1
10 Regulator Board Detail
23 (not shown) Gate Driver Jumper Harness 179056 1
(not shown) SCR (S1, S2, S3) Gate Interface Harness 179059 1
11 Set jumper J4 to (not shown) SCR (S4, S5, S6) Gate Interface Harness 179060 1
pins 1 and 2. (not shown) Laminate PMA Interface Harness 179062 1
12
J17 J4 (not shown) Chillplate Interface Harness 179063 1

13 14 J7 J17 J4
Contact Reliance Electric at 1-440-646-6650 for replacement parts.
24
15 Note: Use this phone number only for replacement parts listed on
Regulator Board this page.

2-4 Carrier VFD Quick Reference

 2.4 Front View of 414 Amp VFD with Parts List (19XV04003001 rev 2.0)
Quantity

19XVR0414100
19XVR0414101
19XVR0414102
19XVR0414103
19XVR0414200
19XVR0414201
19XVR0414202
19XVR0414203
Item Description Component Number
1 Warning Label 179725-8 1 x 1 x 1 x 1 x
610293-201A x 1 x 1 x 1 x 1
2 Tube Assembly 19XR04021301 1 1 1 1 1 1 1 1
3 Tube Assembly 19XR04021401 1 1 1 1 1 1 1 1
4 Customer Ground 19XR05023001 1 1 1 1 1 1 1 1
5 Drive Unit 19XR04003201 1 1 1 1 1 1 1 1
6 Plate Assembly 19XR04003301 1 1 1 1 1 1 1 1
7 VFD Assembly 19XR05004801 1 x 1 x 1 x 1 x
VFD Assembly 19XR05004802 x 1 x 1 x 1 x 1
8 Terminal Strip 19XR05005001 1 1 1 1 1 1 1 1
9 Terminal Block 19XR05005101 1 x 1 x 1 x 1 x
Circuit Breaker 19XV05004901 x 1 x 1 x 1 x 1
10 Transformer, Current 19XR05005201 3 3 3 3 3 3 3 3
11 Fuse Assembly 19XR05005401 1 1 1 1 1 1 1 1
12 Relay Socket 19XR05005502 2 2 2 2 2 2 2 2
13 Relay Socket 19XR05005503 1 1 1 1 1 1 1 1
14 Disconnect Switch 19XR05005601 1 1 1 1 1 1 1 1
15 Cable Assembly 19XR05005701 1 1 1 1 1 1 1 1
16 Cable Assembly 19XR05005801 1 1 1 1 1 1 1 1
17 Cable Assembly 19XR05005901 1 1 1 1 1 1 1 1
18 Cable Assembly 19XR05006001 1 1 1 1 1 1 1 1
19 Label, Wiring 19XR05006301 1 1 1 1 1 1 1 1
20 Meter Kit 19XR05006601 x x 1 1 x x 1 1
21 Potential Transformer 19XR05007101 x x 2 2 x x 2 2
22 Transformer 19XR05007201 1 1 1 1 1 1 1 1
23 Circuit Breaker 19XR05007501 1 1 1 1 1 1 1 1
24 Cable - L1 19XV04003801_MU 1 1 1 1 1 1 1 1
25 Cable - L2 19XV04003802_MU 1 1 1 1 1 1 1 1
26 Cable - L3 19XV04003803_MU 1 1 1 1 1 1 1 1
27 Cable - L4 19XV04003804_MU 1 1 1 1 1 1 1 1
28 Cable - L5 19XV04003805_MU 1 1 1 1 1 1 1 1
29 Cable - L6 19XV04003806_MU 1 1 1 1 1 1 1 1
30 Ground Cable 19XV04003901_MU 1 1 1 1 1 1 1 1
31 Label 23XL05005303 1 1 1 1 1 1 1 1
32 Label 410267-12 1 1 1 1 1 1 1 1
33 Label - Torque (275 in-lb) 50D00032 1 x 1 x 1 x 1 x
Label - Torque (375 in-lb) 50D00033 x 1 x 1 x 1 x 1
34 Label - Conductors 50D00034 1 1 1 1 1 1 1 1
35 Nameplate, Data 616300-243 1 1 1 1 1 1 1 1
36 Label, Warning 616300-250 1 1 1 1 1 1 1 1
37 Label, VFD Order Code 616300-253 1 1 1 1 1 1 1 1
38 Label, Oil Pump 616300-251B 1 1 1 1 1 1 1 1
39 6 A Fuse 64676-75W 3 3 3 3 3 3 3 3
40 ISM CSE0130037 1 1 1 1 1 1 1 1
41 Edging GES144FA-C-08 1 1 1 1 1 1 1 1
42 Edging GSE144FA-C 1 1 1 1 1 1 1 1
43 O-Ring KK71EW016 2 2 2 2 2 2 2 2
44 Insulation QR09-47-625-28 1 1 1 1 1 1 1 1
45 Insulation QR09-47-625-40 1 1 1 1 1 1 1 1
46 Gland, Cable T_B-2522 1 1 1 1 1 1 1 1
47 Label - Z-417 Z-417 1 1 1 1 1 1 1 1

Identifying Drive Components Using Reference Drawings and Parts Lists 2-5
 2.5 414 Amp 19XRV Drive Module Component Locations and Parts List

Rockwell
Automation
Item # Description Part # Qty
1 Bus Bars (3) AC Output to motor n/a 3
1 2 Bus Bars (3) AC Input from supply n/a 3
2 3 IGBT Modules n/a 6

4 Output Laminate n/a 1

5 Capacitors n/a 24

6 Remote Meter Interface (RMI) PCB 814.56.00 1

3 12
7 Casting n/a 1
8 Membrane Switch Keypad/Bracket 410483-15B 1
9b
9 Coolant Lines - (a) Inlet, (b) Outlet n/a 2

10 Regulator PCB 179116 1

4
11 11 HP Power Module Control (PMC) PCB 179170 1

12 Current Feedback Devices (3) 25503-012-01 3

(not shown) Gate Driver PCB 179168 1

(not shown) LEM Harness 179215-8 1

10
(not shown) Laminate Harness 179216-8 1

(not shown) Chillplate Harness 179217-8 1

5
(not shown) SCR Gate Harness 179218-8 1
9a
(not shown) Internal Fan 179196 1

Contact Reliance Electric at 1-440-646-6650 for replacement parts.

Note: Use this phone number only for replacement parts listed on this page.
8
Note: When replacing the Regulator board,
verify that jumper J4 is on pins 1 and 2,
as shown in the detail below. You also
may need to perform an initalization
procedure. See section 6.7 or instruction
7 Set jumper J4 to pins 1 and 2. manual D2-3411 for more information.

6 J17 J4
J7 J17 J4

Regulator Board

2-6 Carrier VFD Quick Reference

 2.6 414 Amp 19XRV Drive Wiring Diagrams

For Reference Only

Refer to the 19XR, XRV Start-up, Operation,

and Maintenance manual for the VFD chiller
schematic.

Notes:
1.) Symbol designates pin 1 location of connectors.
2.) See sheet 2 for PC board pin designators and signal name.
3.) For S6 hookup: L1 is connected to L4
L2 is connected to L5
L3 is connected to L6
4.) For S12 hookup: AC power is attached individually to
L1 thru L6.

Identifying Drive Components Using Reference Drawings and Parts Lists 2-7
 For Reference Only

2-8 Carrier VFD Quick Reference

Identifying Drive Components Using Reference Drawings and Parts Lists

2.7
VFD System Wiring Diagram (19XV05007901 rev A)
CHILLER CONTROL SCHEMATIC
AUX AUXILIARY
ABBREVIATION LISTING
CAM SW CAM SWITCH MCB MODULE CONTROL BOARD
GV GUIDE VANE
CB CIRCUIT BREAKER
HGBP HOT GAS BYPASS N.C. NORMALLY CLOSED
CCM CHILLER CONTROL MODULE
HPR HIGH DISCHARGE PRESSURE RELAY N.O. NORMALLY OPEN
CCN CARRIER COMFORT NETWORK
HPS HIGH PRESSURE SWITCH RC REGULATOR CONTROLLER
COMM COMMUNICATIONS
HX HEAT EXCHANGER RMI REMOTE METERING INTERFACE
CT CURRENT TRANSFORMER ICVC INTERNATIONAL CHILLER VISUAL CONTROLLER
DL/DP DATALINK/DATAPORT ST SHUNT TRIP
IGBT INSULATED GATE BIPOLAR TRANSISTOR T TRANSFORMER
FD FUSED DISCONNECT IGV INLET GUIDE VANE
TB TERMINAL BLOCK
FR FAN RELAY ISM INTEGRATED STARTER MODULE
VFD VARIABLE FREQUENCY DRIVE
FU FUSE J JUNCTION
G CHASSIS GROUND 1C COMPRESSOR OIL HEATER CONTACTOR
LEM CURRENT DETECTOR
1M START CONTACTOR
MAB MODULE ADAPTER BOARD
2C OIL PUMP CONTACTOR
NOTES:
1. LINE NUMBERS ON THE RIGHT & LEFT-HAND SIDE INDICATE LOCATION OF CONTACTS. NUMBERS CONNECTED 3C HOT GAS BYPASS RELAY
WITH A LINE OVER THEM ARE CONTROLLED FROM THE SAME CONTACT COIL. AN UNDERLINED
NUMBER SIGNIFIES A NORMALLY CLOSED CONTACT. A NUMBER WITHOUT AN UNDERLINE SIGNIFIES
A NORMALLY OPEN CONTACT.
2. 230V CONTROL WIRING REQUIRES FIELD REWIRING.
3. VERTICAL BOLD LINES INDICATE COMMON POTENTIAL, NOT ACTUAL WIRES.

LEGEND
CARTRIDGE FUSE CURRENT
FIELD CONTROL WIRING CAM SWITCH
TRANSFORMER,
POLARIZED
FIELD POWER WIRING EARTH GROUND (DIRECTION DETERMINED BY)
COMPONENT TERMINAL
RESISTOR
FACTORY WIRING THERMISTOR
TRANSFORMER
CHASSIS GROUND
SHIELDED CABLE
TRANSDUCER
IGBT
LIGHT

TWISTED PAIR WIRING FUSIBLE LINK

TEMPERATURE SWITCH
DIODE
MALE/FEMALE CONNECTOR POTENTIOMETER
COMMON POTENTIAL SILICONE CONTROL
TERMINAL BLOCK CONNECTION PRESSURE SWITCH
RECTIFIER
DRY CONTACT

WIRE SPLICE OR JUNCTION COMPR OIL PUMP TERMINAL

VFD TERMINAL
19XV05007901 REV. -

POWER PANEL
2C 21 (WHT) (WHT) (BLK)

NOT USED IN 1C
VFD APPLICATION 230V 2C 22 (BLK) 21 11 (BLK) (BLK) (WHT)
COMPRESSOR 1500 WATTS-02XR2
VFD ENCLOSURE OIL HEATER 1800 WATTS-02XR3,02XR4
1C

TB6 LL1 (BLK) 22 12 (BLK)

1C
TB6 LL2 (WHT) 23 13 (WHT) (WHT) (BLK)
OPTIONAL
(RED)
TB6 G (WHT) (BLK)
OIL HEATER HGBP FRAME 7 HX
CONTACTOR
(GRN) 115V ONLY
(WHT) 2 HGBP ACTUATOR
HGBP FRAME 1 THRU 6 HX FRAME 7 HX ONLY
(BLK) 115V ONLY
(RED) HGBP SOLENOID
(WHT) T1
(BLK)
(ORN) (WHT)

(BLK)
(BLK) (RED) T3 (WHT)
T1
(SEE 24 VAC)
(BLK)
(RED) (RED) (WHT) (WHT) 23 1C
1C
ISOLATED
TERMINAL HGBP FRAME 1 THRU 7 HX 115V T1
(SEE 24 VAC)
(BLK) (BLK)
(RED) (WHT)
T1
COMMON

(BLK) T2
3C 2 (SEE 24 VAC) (WHT)

1C 22 MOTOR
CONTROL

L1 IGV L2
115V

SEE 24V
FOR CONTROLS
3C
1C 22 (BLK) (BLK) (BLK) (RED) (RED) 23 1C
F141
(YEL) (YEL) (BLU) (BLU) 23 1C
HGBP SOLENOID
(GRN)
FRAME 1 THRU 6 HX 115V ONLY (OPTIONAL)
7901-1
5-10-2002
2-9
2-10
24 VAC
CCM-J12 CB2 CHILLER CONTROL PANEL 60 VA
6 (BLK) (BLK) (BRN) (BRN) C1 1C
T1
3.2A
CCM-J12
24 VAC (BRN)
3 (BLK) 43
CB1 60 VA
1 (GRY) (GRY) (BRN) (BRN) (RED)
CCM-J1 T2
50 (YEL) 3.2A (RED)
4 (GRY) (RED)
ICVC-J1
(RED)

J1
5 ALARM
CB1 (GRY) 4
ICVC
(BLK) 3 -
CB1 (GRY) (CLR) 2
(RED) 1 + STOP
2 (SHIELD)
J7

J1
CCM
CB1 (GRY) 1 (GRN)
J8
AUTO DEMAND LIMIT 1 J6 SERVICE
(OPTIONAL) 6 T3
2 24 VAC 24 VAC
AUTO CHILLED 3 60 VA 60 VA
J7

J5
WATER RESET
(OPTIONAL) 4 (BLU) (BLU)
3

COMM
5
REFRIGERANT SW2 CB3 (RED) (RED)
2 2 1 SP G TB (BRN)
LEAK SENSOR 6 - +
(OPTIONAL) (SHIELD) 012 3 1 (RED)
(SHIELD) (BLK) (RED)
(RED) (BLK)
EVAPORATOR ENT. 1 SEE CHART BELOW (WHT) (BRN)
CB4 (ORN)
WATER TEMP. (BLK) (BLK)
2 J9
(RED) (RED) (SHIELD)
EVAPORATOR LVG. 3
WATER TEMP. (BLK) 4
J10 (CLR) CCN 1 2 3 1 2 3
(RED) 5
CONDENSER ENT. J5 J4
WATER TEMP. (BLK) 6 (BLK) 4

J4 (UPPER)
(RED) (BLK) 3
CONDENSER LVG. 7 J6 DL/DP
(BLK) (CLR) 2
WATER TEMP. 8 (OPTION)
(RED) 1
G.V. POSITION 9
FEEDBACK POWER PANEL 4
10
(RED) (RED) (RED) ISM J7-A 3
EVAP SATURATION 11 J7
2
TEMP. (BLK) 12 (BLK) (BLK) ISM J7-B 1
REMOTE TEMP. (WHT) 13
RESET (BLK)
(OPTIONAL) 14 (CLR) (CLR) ISM J7-C
J8
15
(SHIELD)
1 THRU 25

16
(RED) 17
COMPRESSOR
DISCHARGE TEMP. (BLK) 18
1 (CLR) FEED BACK
COMPRESSOR 19 8 POTENTIOMETER
THRUST BEARING
2 (BLK)
20 10K OHM
TEMP. 3 (SPARE) (CLR) 4
(RED) 21 (BLK) 7
COMPRESSOR OIL (SHIELD)
INPUT

SUMP TEMP. (BLK) 22

J4 (LOWER)

1 (CLR) J11 (CLR) X

23
COMPRESSOR 2 (BLK) 3
MOTOR TEMP. 24 INCREASE CCW
3 (SPARE) 2 (RED) 3
OUTPUT

(WHT) 25 1 DECREASE CW
SPARE TEMP. #1 (BLK)
(OPTIONAL) (BLK) 2
26
(WHT) 27
J12 (SHIELD)
SPARE TEMP. #2
(OPTIONAL) (BLK) 28 1 INTERNAL VARIABLE
CB2 (BLK) 6 GUIDE VANE CONTROL
SEE 115/230V FOR POWER
4
OUTPUT

5
CB2 (BLK) 3 (ORN) (BRN)
C2 1C C1 43
2
CB2 (BRN)
(BLK) (BLU) 3 3C
1
OIL SUMP (CLR) (BRN)
2
PRESSURE
(RED) 3
WHT WHT (WHT) C2 2C C1
(BLK) 4
OIL PUMP OIL PUMP MOTOR
(CLR) 5
DISCH. PRESSURE
(RED) 6 100 uf
7 J8
LOAD RESISTOR
8 4
4.3K 9
J3 (UPPER)

3
10
2
4-20mA kw
OUTPUT

11
4-20mA

LOAD RESISTOR 1 OUTPUT VFD ENCLOSURE

12 POWER PANEL
(WHT) TB5 VARIABLE FREQUENCY DRIVE
10 K
(SHIELD) (WHT) (RED) 51 6 4
13
14 1M
LOAD RESISTOR (YEL) (ORN) 50
15
(BLK)
4.3K
16
C NO (BLK) (BLK) (BLK) 17 7 HPR 8
8

17
JUMPER 2C AUX
18 HPS 24VAC
(BRN) 43
19
J3 (LOWER)

20 CLOSE:110±7 PSIG.
LOAD RESISTOR (758±48 kpa)
21
4.3K OPEN:165±5 PSIG.
22
0
TO OFF POSITION

(1,152±35 kpa)
ALL SWITCHES SET

23
JUMPER SW1 (BRN)
24 T1

(BRN) C1 1C
(BLK) 1
EVAPORATOR
REFRIGERANT (CLR) 2 CCM
PRESSURE (RED) 3 SWITCH POSITION
SW2 PIN
J2
INPUT

(BLK) 4 ON OFF
CONDENSER (CLR)
REFRIGERANT 5 1 J5-5 & J5-6 4-20mA 1-5 Vdc
PRESSURE (RED) 6
7901-2
2 J5-3 & J5-4 4-20mA 1-5 Vdc
5-10-2002 J5-1 & J5-2 4-20mA 1-5 Vdc
3
Carrier VFD Quick Reference
 VFD

TB6

G
G
COMPRESSOR
VFD
MOTOR
BRANCH CIRCUIT ENCLOSURE
DRIVE PROTECTION

Identifying Drive Components Using Reference Drawings and Parts Lists

FUSES OR 19XRV DRIVE MODULE
EQUIVALENT OPTIONAL
CIRCUIT BREAKER LINE REACTOR TB-MAIN CT1

L1 FU L1 R 1
C1 C11
L2 FU L2 S CT2 2 T6
T1
FU LEM U
L3 L3 T 3
C2 C22

CT3
LEM V T4
T3
0414 600A CLASS J TIME-DELAY 600V CIRCUT BREAKER CB1
0643 900A CLASS L TIME-DELAY 600V T2 T5
MAY BE FURNISHED C3 C33
0500 750A CLASS L TIME-DELAY 600V ISM COMPRESSOR
AS AN OPTION LEM W MOTOR
J4-1 THRU 6 4

COMPRESSOR OIL PUMP

OIL PUMP CONTACTOR 380/416/480V-3-60
FD1-OIL PUMP 2C (1 1/2 H.P.) 400-3-50
21 11 (YEL) YEL 3
FU1 OS1 6
(YEL) 2C
FU1 OS2
(BLK) 22 12 (BLK) BLK 1 4
FU1 OS3
(RED) 2C
5
23 13 (RED) RED 2
CLASS J TIME-DELAY 9
15A 600V POWER PANEL ENCLOSURE
7

OPTIONAL METERING
ANALOG AMP METER CIRCUIT
OFF 1 2 3
ISM J4-2 AM
(6) (5)
AMMETER
CT1 C11 (2) (1)
ISM J4-4
(10) (9)

CT2 C22 (12) (11)

ISM J4-6
(8) (7)

CT3 C33 (4) (3)

FU2

FU2
AMMETER SWITCH

FU2
INDICATES CONTACT CLOSURE
H1 H2 H1 H2
CLASS CC
TIME-DELAY 1PT 2PT
1A 600V AC INPUT VOLTS
X1 X2 X1 X2 1-2 2-3 VOLTMETER
OFF 3-1
VM
(1) (2)
(5) (6)
(3) (4)
(7) (8)
VOLTMETER SWITCH

CONTINUED ON SHEET 4

7901-3
5-10-2002
2-11
2-12
VFD
(CONTINUED FROM SHEET 3)
CONTINUED FROM SHEET 3

CB2-CONTROL & OIL HEATER

L1

L2

L3

346V 380V 400V 416V

COMM 460V

TB6 FU6 +10% 115V -10% TB6

LL1 LL2
CONTROL POWER TRANSFORMER
115V
(CONNECT TO APPROPRIATE
TERMINAL FOR LINE VOLTAGE)
CLASS M TIME-DELAY
J3
30A 250V
VL3
L3
FU5
VL2
L2
10A 250V VL1
L1
LINE VOLTAGE

HPR F147 J9
4 6 1 C165 E146
VFD PILOT RELAY
1CR

2 7 1M 8
3A

J2

SPARE SAFETY 1
3
SPAR
SFTY

(JUMPER) 2
4
TRANS

ICE BUILD 3
ICE
BLD

CONTACT 4

(SHIELD) REMOTE 5
REM
STRT

START CONTACT 6
5 C163
RMI-54 7 SHUNT TRIP
6 7 ST 8
FLT
SHUNT

STRT

RMI-55 8
CONTACT INPUTS

7
RC-30 9
EVAP WATER PUMP
1M
AUX
EVAP

RC-31 10 8

RMI-52 11 9
2M
AUX

12 COND WATER PUMP

COND

RMI-53 10
DISCRETE OUTPUTS

(SHIELD) (SHIELD) OPTIONAL

CT1 ANALOG METER J4 11
C1 TOWER FAN
C1 C11 1 12
1L1

C11
CT2 2
13
C2
C2 C22 3 TOWER FAN
14
1L2

C22
CT3 4
C3 15
C3 C33 5
TRIP ALARM
1L3

C33
TRIP

6 16
(SHIELD)
J5
COMMON

J8
1
115V CONTROL

1 RC-14 CONTROL SPEED

1/4

GROUND FAULT 2
VFD
- +

FUNCTION PROVIDED 2 RC-15 SIGNAL

3
3 4-20mA
2/5

BY VFD DRIVE
4 HEAD PRESSURE OUTPUT
4-20mA OUT
- +
SPARE

MODULE CONTROLLER 4
5 REFERENCE TO DEVICE CHOICE
GROUND FAULT CURRENT LINE CURRENTS

(SHIELD) (NOT BY CARRIER)

3/6

(SHIELD) 6 EXAMPLES - TOWER BYPASS VALVE

ISM
J6 - TOWER SPEED CONTROL
- CONDENSER PUMP
RMI-65 1
SPEED CONTROL
0-5
-Vdc+

RMI-68 2
VFD HZ

POWER PANEL
J7
STAT COMM

(RED)
+

CCM J7-3 (RED) A A

CCM J7-2 (BLK) B (BLK) B

GND
COMM

(CLR)
-

CCM J7-1 (CLR) C C

(SHIELD) (SHIELD)
J1
LL1
115V
POWER

LL2

FR
4 6
500 & 643
FAN FRAME VFD
ONLY
ENCLOSURE

7901-4
5-10-2002
Carrier VFD Quick Reference
 VFD
(CONTINUED FROM SHEET #4)
RMI
41 1 RS-232 CONNECTION

42 2
DIGITAL INPUTS
1-4 AND 24V 43 3 RC
INPUT POWER
44 4

45 5

Identifying Drive Components Using Reference Drawings and Parts Lists

46 6 ENCODER

47 DIGITAL 7
OUTPUTS
48 8
1-4
49 9

50 10 ANALOG OUT

51 11
VFD RUN
ISOLATED
(RELAY #1) 52 ISM J2-11 12
REFERENCE VOLTAGE
DRIVE MODULE 13
53 ISM J2-12
CONTROL
54 ISM J2-7 ISM J8-1 14
VFD FAULT SPEED
(RELAY #2) ISM J8-2 15 SIGNAL
55 ISM J2-8
DRIVE MODULE
FAULT 56 16 +24Vdc
RUN 17
57 DIGITAL INPUTS
1
FAN CONTROL 58 FAN RELAY B152 18
500 & 643 ST
59 7 FR 8 TB6-LL2 19
FRAME VFD
ONLY 60 TB6-LL1 5 20 FUNCTION LOSS

61 NOT USED 21 RUN/JOG

62 ANALOG INPUT 22 RESET

0-10V 1M
63 ANALOG INPUT 3 5 23 STOP
4-20mA
64 ANALOG INPUT 24 START
SPEED COMMON TEST/RUN
FEEDBACK 65 ISM J6-1 25
OUTPUT
0-5Vdc 66 26

67 27
SPEED
FEEDBACK 68 ISM J6-2 28
COMMON
69 29

ISM J2-9 30 DRIVE

MODULE
ISM J2-10 31 START

TEMP. TEMP.
SWITCH J2 SWITCH J3
#1
MAB #1
MCB
10 3

11 4

TEMP. TEMP.
SWITCH SWITCH
#2 #2
J7 J1

9 - 1

LEM-W 8 LEM-W M 2

7 + 3

6 - 4

LEM-V 5 LEM-V M 5

4 + 6

3 - 7

2 LEM-U M 8
LEM-U
1 + 9

MODULE ADAPTER BOARD MODULE CONTROL BOARD

500 & 643 FRAME 7901-5 414 FRAME VFD ONLY
VFD ONLY
5-10-2002
2-13
 2.8 500 Amp and 643 Amp 19XRV Drive Wiring Diagrams

PART OF REGULATOR 179116

60 WIRE
REMOTE I/O
CONNECTIONS
For Reference Only
1 TO 1 RIBBON CABLE

J1 J7 J8

1 RS-232 TX
J3 J16 OIM RS232 Refer to the 19XR, XRV Start-up, Operation,
2
3
4
RS-232 RX
RS-232 REGULATOR COMMON J1 and Maintenance manual for the VFD chiller
+15 VDC
5
6
PHASE A
PHASE A NOT REGULATOR
schematic.
7 USER
PHASE B SEE DETAIL A
BUS TERMINAL
8 PHASE B NOT REGULATOR CONTROL
179116 FOR USER
BLOCK
9 REGULATOR COMMON BUS CONTROL ASSEMBLY INTERFACE INTERFACE CONNECTIONS
(31 POS.)
10 ANALOG METER OUTPUT
179069
11 REGULATOR COMMON
12 ISOLATED REFERENCE VOLTAGE
13 VDC SPEED REFERENCE KEYPAD #410483-15B
14 mA SPEED REFERENCE NOTES:
15 ISOLATED REFERENCE GND
16 +24 VDC LOCAL 1.) SYMBOL DESIGNATES PIN 1
DC BUS/
17 DIGITAL INPUT 8 (REMOTE/LOCAL)
GATE DRIVER POWER MODULE GATE DRIVER OPTION CARD LOCATION OF CONNECTORS.
18 DIGITAL INPUT 7 (RAMP1/RAMP2) 25KHz PS ADAPTER INTERFACE INTERFACE INTERFACE
19 DIGITAL INPUT 6 (FORWARD/REVERSE) 2.) SEE SHEET 2 FOR PC BOARD PIN
20
21
FUNCTION LOSS J1 J4 J5 J3 34-WIRE RIBBON CABLE DESIGNATORS AND SIGNAL NAMES.
FACTORY RUN / JOG 179058 TO OPTION CARD
22 RESET
JUMPER J8 J6
23 STOP 179057
24 START 179055
25 BUS CONTROL INTERFACE 20
+24 VDC COMMON
26 NO CONNECTION
27 +24 VDC COMMON SCR GATE-
28 CATHODE 179063
N.C. RELAY CONTACT J2
29 INTERFACE 4
N.C. RELAY COMMON 25KHZ/
30 S1,S2,S3
N.O. RELAY CONTACT BLEEDER/
31 N.O. RELAY COMMON
J1 POWER MODULE TEMP SW/
FAN POWER
ADAPTER ASSEMBLY R1 R2
J3 4 2
DETAIL A SCR GATE-
179134
179067 - 450
600 HP MOTOR
VOLTAGE/ J1
CATHODE
REGULATOR USER CONNECTIONS DC BUS/
INTERFACE J3
CAP BANK 25 KHz P.S.
S4,S5,S6 MID-POINT TEMP SWITCH 1 TEMP SWITCH 2
LEM 66012-16B 66012-16B
J4 INTERFACE GATE
GATE DRIVER GATE
DRIVE I/F ASSEMBLY DRIVE I/F
J7
179059 179065

179060 179061
J2
SWITCHED DISCHARGE 179056
RESISTORS - 10K Ohms
63481-105SFY
9 6 3

BUSBARS 179031, BUSBAR 179012

179035, & 179037 179040 LAMINATED BUS ASSY
SCR1 SCR2 SCR3
AC POWER
INPUT LEADS
BUSBAR CAPACITORS
179033 2700 uF, 420 VDC
SCR6 SCR5 SCR4 (QTY. 30 = 450 HP)
(QTY. 36 = 600 HP) C C C
179025 REACTOR
L1 BUSBARS 179031, BUSBAR R3 184698
50 uh 179039 G G G
179035, 179036, + + + + + +
179023 L1P L2P L3P & 179038 179000 E E E
L2
(6-Pulse Configuration)
179022
L3 L6P L5P L4P
LEM
BUS QTY. 3 BUS BUS
179022 W 25503-011-01 V U
+ + + + + + LEM-W LEM-V LEM-U
L6
179024 20
L5
C C C
179026
L4 L1N L2N L3N L6N L5N L4N
BUSBARS G G G
179027 & E E E
GND 179034

IGBT
22501-025-04 QTY. 6
QTY. 6 179050 - 450
179133 600 HP
179012
LAMINATED BUS ASSY UNSWITCHED DISCHARGE
RESISTOR - 10K Ohms
63481-105SFY

REACTOR MOTOR LEADS

50 uh
J3 J2
179000
179042
(12-Pulse Configuration) W
179042 GATE GATE DRIVER GATE
V DRIVE I/F DRIVE I/F
ASSEMBLY
179042 179065
U
25 KHz P.S.
J1

2-14 Carrier VFD Quick Reference

 J16 J3
J1 1 GND 1
J5 J2 J31
For Reference Only
1 CHGND 1 CHGND
2 GND 2
2 CHGND 2 2 CHGND
3 VL1-VL2 3
REGULATOR 4
5
GND
VL2-VL3
4
5
3
4
5
UHI+
UHI-
ULO+
3
4
5
GATE
DRIVE
GATE
DRIVE
3
4
5
WLO+
WLO-
NC
6 GND 6
6 ULO- 6 6 NC
BOARD 7
8
V47-V45
GND
7
8
7
8
CHGND
CHGND
7
8
I/F IN I/F OUT
7
8
CHGND
CHGND
9 IPHV 9

179116 10
11
GND
IPHU
10
11
9
10
11
VHI+
VHI-
VLO+
9
10
11
RIGHT 9
10
11
VLO+
VLO-
NC
12
13
14
GND
IPHW
GND
12
13
14
GATE 12
13
VLO-
CHGND
12
13
GATE DRIVER 12
13
NC
CHGND
DRIVER 14 CHGND 14 14 CHGND
SEE SHEET 1 USER
15
16
GNDFLT
GND
15
16
INTERFACE
15
16
WHI+
WHI-
15
16
BOARD 15
16
ULO+
ULO-
17 VCC 17
DETAIL A FOR
CONNECTIONS
TERMINAL 18
19
VCC
VCC
18
19
17
18
WLO+
WLO-
17
18 179065 17
18
NC
NC
BLOCK 20 GND 20
19
20
CHGND
CHGND
19
20
19
20
CHGND
CHGND
21 VDD 21
22 VDD 22
25KHz
(31 POS.) 23 VSS 23 PWR SUPPLY
24 VSS 24 INTERFACE
25 ASYM_ERR 25
26 PUID0 26
27 PUID1 27
BUS 28 PUID2 28
REGULATOR J1
29 PUID3 29

4
30 VCC 30
CONTROL INTERFACE

25KHz PWR
31 VU-V49 31

25KHz RTN
BUS CONTROL BOARD

25KHz PWR

25KHz RTN
32 GND 32
INTERFACE 33 VV-V49 33
34 GND 34
35 VW-V49 35
1 36 GND 36 179069

1
XMIT 2 37 PHUPOS 37
RECV 3 38 GND 38 J1
4 39 PHUNEG 39
GND 5 40 GND 40
6 RS232 41 PHVPOS 41 25KHz
7 42 GND 42 PWR SUPPLY 20 CHGND
8 43 PHVNEG 43 19 CHGND
44 GND 44
INTERFACE
9 18 NC
45 PHWPOS 45 17 NC
SERIAL 46 GND 46 16 ULO-
47 PHWNEG 47 15 ULO+
I/O KEYPAD 48 GND 48
CONNECTIONS J8
410483-15B
49
50
DT3
DT2
49
50 J1 LEFT 14
13
12
CHGND
CHGND
NC
VCC
VCC
1
2
51
52
53
DT1
DT0
15VI2
51
52
53
GATE DRIVER
6
5
25KHz RTN
25KHz PWR GATE DRIVER 11
10
NC
VLO-
12VDC 4 9 VLO+
XMIT
GND
3
4
54
55
0VI2
PCHRGSTAT
54
55
25KHz P.S./ 3
2
LOCAL DC- BOARD 8
7
CHGND
CHGND
5 56 24VCOM 56 LOCAL DC 6 NC
RECV
GND
VSS
6
7
OIM 57
58
OVERTEMP
24VCOM
57
58 BUS
1 LOCAL DC+
GATE
DRIVE
179065 GATE
DRIVE
5
4
NC
WLO-
8 59 PCHRGRLY 59 3 WLO+
DTR
-12VDC
9
10
OPTION 60 24VDC 60 I/F OUT I/F IN 2 CHGND
1 CHGND
CARD
INTERFACE POWER MODULE ADAPTER INTERFACE
J7 J3 J2
J3 J4

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
1
2
3
4
5
6
7
8
9
GTPWR T456N

GTPWR T123N
GTPWR T456P

GTPWR T123P
34-WIRE RIBBON CABLE
TO OPTION CARD

BR CNTRL

FSL3 REG
FSL2 REG
FSL1 REG
FSDCMID
24VCOM

20VCOM

20VCOM
N20VDC
N20VDC
P24VDC
P24VDC

P20VDC
P20VDC
GND PS

VWFBK
P5VDC
VUFBK
TEMP1

FSDC+
VVFBK

IWFBK

FSDC-
IUFBK
IVFBK
TH6N
TH5N
TH4N

TH3N
TH2N
TH1N

CT1N
TH6P
TH5P
TH4P

TH3P
TH2P
TH1P

CT1P

FSL6
FSL5
FSL4
FSL3
FSL2
FSL1
GND

GND

GND

GND

GND

GND

GND

GND

GND
AC POWER

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
INPUT LEADS
1
2
3
4
5
6
7
8
9
G J6 TEMP
SWITCH
TEMP
SWITCH
K
SCR1 L1P
J1 NO. 2 NO. 1
J8
L1 BUS
1
2 1 LOCAL DC+ LEM-W
G L1 3 BUS CONTROL INTERFACE LOCAL DC 2
R1 & R2
L1 SCR2 L2P K 4
BUS / GATE
3
4
LOCAL DC-
10K Ohm
5
5 25KHz PWR W SWITCHED
L2 BUS 6
DRIVER 25KHz 6 25KHz RTN BLEEDERS
L2 7 BUS
L2 G 8 SCR PWR SUPPLY -M+ LEM-V
K 9
L3 BUS
SCR3 L3P
10 GATE-CATHODE J21
L3 11
L3 12 INTERFACE 2
25KHz PWR
25KHz RTN V
TH1P-G
TH1P-K
13
14
S1, S2, S3 3 25KHz PWR
BUS
4 25KHz RTN
TH2P-G 15
L6 BUS G TH2P-K 16 25KHz/ 5
-M+ LEM-U
6 BLEEDER (+)
K TH3P-G 17
SCR6
L6 L6P
BLEEDER/ 7
TH3P-K 18
POWER MODULE 8
9
BLEEDER (-)
U
L5 BUS TEMP SW/ 10 TEMPSW1
L5 SCR5 L5P
G
K J4
1
ADAPTER BOARD FAN PWR 11
12
TEMPSW2
FANPWR (+)
BUS
-M+
2 13 FANPWR (-)
L4 BUS
L4 G
L6 3
4 450 HP - 179134
5
SCR4 L4P
K

L5
6
7
600 HP - 179067 J7 N20VDC
9
GND 8
9
8 IPHW

10 SCR 7
6
P20VDC
N20VDC
L4 11
GATE-CATHODE 5 IPHW
12 LEM 4 P20VDC
TH6P-G 13 INTERFACE MOTOR 3 N20VDC
TH6P-K
TH5P-G
14
15 S4, S5, S6 INTERFACE 2 IPHU

TH5P-K 16 VOLTAGE/ 1 P20VDC

TH4P-G 17
TH4P-K 18 CAP BANK
DC- BUS MID-POINT
R3-10K Ohm
UNSWITCHED
BLEEDER DC MIDPT MV_W
RESISTOR
J3
11
10
9
8
7
6
5
4
3
2
1

DC- MV_V
DCMID MV_U
DC+ BUS DC+

Identifying Drive Components Using Reference Drawings and Parts Lists 2-15
2-16 Carrier VFD Quick Reference
 CHAPTER 3
Using the Keypad/Display to Program,
Monitor, and Control the Drive

If you are unfamiliar with the detailed operation of the keypad/display, refer to chapter
3 of the LiquiFlo Software Start-Up and Reference Manual (D2-3410).

Display Drive Status Keypad

LEDs

P.--- AUTO Forward

SPEED RUNNING MAN Reverse
Monitor Mode VOLTS REMOTE
AMPS JOG
LEDs Hz AUTO PRO G RAM
RUN
Kw FORWARD
JOG
TORQUE REVERSE
Password LED Password PROGRAM ENTER

STOP
START RELIANCE
RESET
ELECTRIC

Stop / Reset Key Start Key

Figure 3.1 – Keypad/Display

ATTENTION: When switching from auto to manual, or manual to auto,

the drive will ramp to the reference level provided by the new source at
! the rate specified in P.001 (Accel Time 1), P.002 (Decel Time 1), P.017
(Accel Time 2), or P.018 (Decel Time 2). Be aware that an abrupt speed
change may occur depending upon the new reference level and the rate
specified in these parameters. Failure to observe this precaution could
result in bodily injury.

Using the Keypad/Display to Program, Monitor, and Control the Drive 3-1
3-2 Carrier VFD Quick Reference
 CHAPTER 4
Identifying Parameter Defaults
For Carrier Drives
Use the following table to identify and set the parameter defaults for Carrier drives.

Important: Setting P.050 (Restore Defaults) to ON will restore the drive to Reliance defaults,
not Carrier defaults. If this has been done, set the following parameters to restore
Carrier defaults.

Parameter No. Parameter Name Setting

P.000 Control Source rE
P.001 Accel Time 1 8
P.002 Decel Time 1 20
P.003 Minimum Speed 0.5
P.004 Maximum Speed Job-specific (50 or 60)
P.005 Current Limit 110
P.0091 Terminal Strip Analog Input Offset -10
P.0101 Terminal Strip Analog Input Gain 0.99 (50LR4060, 64LR4060)
1.030 (41LR4060)
P.011 Terminal Strip Analog Input Configure 4
P.013 Output Relay Configuration 2
P.027 Forward/Reverse Configuration 1
P.028 Speed Display Scaling Job-specific
P.043 Fault Auto Reset Attempts 10
P.044 Fault Auto Reset Time 30
P.052 AUTO/MAN Key Disable ON
H.000 Motor Nameplate Volts Job-specific
H.001 Motor Nameplate Base Frequency Job-specific
H.002 Motor Nameplate Amps Job-specific
H.021 AC Line Volts Job-specific
H.022 Overfrequency Limit Job-specific (57 or 69)
r.001 Analog Output 1 Source 4
r.0021 Analog Output 1 Offset 60 (50LR4060, 64LR4060)
135 (41LR4060)
r.0031 Analog Output 1 Gain 0.505 (50LR4060, 64LR4060)
0.503 (41LR4060)
r.035 Relay Output 1 (NO) Configuration 5
r.036 Relay Output 2 (NO/NC) Configuration 2
r.037 Relay Output 3 (NO/NC) Configuration 1
r.046 Relay Output 3 Delay Time -999
r.050 Speed Detection Level 1 35
1
These parameters must be tuned or calibrated per the VFD Control Verification procedures (running and
non-running) found in the Carrier 19XR/XRV Start-Up, Operation, and Maintenance Instructions on pages
59-60.

For job-specific parameters, refer to the 19XR, XRV Start-Up, Operation, and Maintenance
Instructions manual (531-982) for further instructions. For descriptions of all parameters, refer to
the LiquiFlo Software Start-Up and Reference manual (D2-3410).

Identifying Parameter Defaults For Carrier Drives 4-1

4-2 Carrier VFD Quick Reference
 CHAPTER 5
Verifying the Installation

Record the following job information:

1. Job Name:
2. Job Number:
3. City:
4. State:
5. Zip Code:

Record the following nameplate information:

1. Chiller Serial Number:

2. VFD Part Number:
3. VFD Serial Number:
4. Motor Rated Load Amps:
5. Incoming Voltage:
6. Incoming Frequency:
7. Carrier Part Number
and Revision:
8. ICVC Software Number:

Verifying the Installation 5-1

5-2 Carrier VFD Quick Reference
 CHAPTER 6
Troubleshooting the Drive

This chapter describes how to troubleshoot the drive and the equipment that is
needed to do so.

6.1 Test Equipment Needed To Troubleshoot

An isolated multimeter will be needed to measure DC bus voltage and to make
resistance checks. Note that dedicated troubleshooting test points are not provided.

6.2 Verifying That DC Bus Capacitors Are Discharged

ATTENTION: DC bus capacitors retain hazardous voltages after input

power has been disconnected. After disconnecting input power, wait five
! (5) minutes for the DC bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of life.

The drive’s DC bus capacitors retain hazardous voltages after input power has been
disconnected. Perform the following steps before touching any internal components:

Step 1. Turn off and lock out input power. Wait five minutes.

Step 2. Verify that there is no voltage at the drive’s input power terminals.
Step 3. Measure the DC bus potential with a voltmeter while standing on a
non-conductive surface and wearing insulated gloves (1000 V).

Measure the DC bus potential at the test points on the Power Module
Interface board. See figure 6.1 for 414 amp drives; see figure 6.2 for 500
amp and 643 amp drives.
Step 4. Once the drive has been serviced, reapply input power.

Troubleshooting the Drive 6-1

 Initial DC Bus
Measurement
Points

POS NEG
(+) (-)

TP1 TP2

Figure 6.1 – DC Bus Voltage Terminals (414 Amp Drives)

6-2 Carrier VFD Quick Reference

 Initial DC Bus
Measurement
Points

Figure 6.2 – DC Bus Voltage Terminals (500 Amp and 643 Amp Drives)

Troubleshooting the Drive 6-3

 6.3 Checking the Power Modules and Motor with Input
Power Off
Use the following procedure to check the drive’s Power Module circuitry with power off:

ATTENTION: DC bus capacitors retain hazardous voltages after input

power has been disconnected. After disconnecting input power, wait five
! (5) minutes for the DC bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of life.

Step 1. Turn off and lock out input power. Wait five minutes.
Step 2. Verify that there is no voltage at the drive’s input power terminals.
Step 3. Check the DC bus potential with a voltmeter as described in section 6.2 to
ensure that the DC bus capacitors are discharged.
Step 4. Disconnect the motor from the drive.
Step 5. Check all AC line and DC bus fuses.
Step 6. If a fuse is open, use a multimeter to check the input diodes and output
IGBTs. See table 6.1.
Step 7. Check motor impedance.
Step 8. Reconnect the motor to the drive.
Step 9. Reapply input power.

6-4 Carrier VFD Quick Reference

 Table 6.1 – Resistance Checks

Input Meter
Diode Connection Component is OK if
No. (+) (-) resistance (R) is: Component is defective if:

1 * SCR1 10 < R < 1 megohm Continuity (short circuit) or

open when the meter is
2 * SCR2 connected with reversed
3 * SCR3 polarity.

4 * SCR4

5 * SCR5

6 * SCR6

7 SCR1 **

8 SCR2 **

9 SCR3 **
10 SCR4 **

11 SCR5 **

12 SCR6 **
* (+) DC Bus Volts power terminal
** (-) DC Bus Volts power terminal

Table 6.1 - Resistance Checks (Continued)

Meter
IGBT Connection Component is OK if
No. (+) (-) resistance (R) is: Component is defective if:

1 * W/T3 10 < R < 1 megohm Continuity (short circuit) or

open when the meter is
2 * V/T2 connected with reversed
3 * U/T1 polarity.

4 W/T3 **

5 V/T2 **

6 U/T1 **
* (+) DC Bus Volts power terminal
** (-) DC Bus Volts power terminal

Troubleshooting the Drive 6-5

 6.4 Troubleshooting the Drive Using Error Codes
The drive can display two kinds of error codes, called alarm and fault codes, to signal
a problem detected during self tuning or drive operation. Fault and alarm codes are
shown in tables 6.2 and 6.3. A special type of fault code, which occurs rarely, is the
fatal fault code. If the code you see is not in tables 6.2 or 6.3, refer to section 6.5 .

Alarm Codes

An alarm condition is signified by a two- or three-letter code flashing on the display.

The drive will continue to operate during the alarm condition. You should investigate
the cause of the alarm to ensure that it does not lead to a fault condition. The alarm
code remains on the display as long as the alarm condition exists. The drive
automatically clears the alarm code when the condition causing it is removed.

Fault Codes

A fault condition is also signified by a two- or three-letter code flashing on the display.
If a fault occurs, the drive coasts to stop and the RUNNING LED turns off. The first
fault detected is maintained flashing on the display, regardless of whether other faults
occur after it. The fault code remains on the display until it is cleared by the operator
using the STOP/RESET key or using the fault reset input from the selected control
source (P.000).

Error Log

The drive automatically stores all fault codes for faults that have occurred in the
system error log. The error log is accessible through the keypad, the optional OIM, or
the optional CS3000 software.There is no visual indication that there are faults in the
log. You must access the error log to view the faults.

The error log holds the 10 most recent faults that have occurred. The last fault to occur
is the first one to appear on the display when you access the error log. The faults in
the log are numbered sequentially. The most recent fault is identified with the highest
number (up to 9). Once the log is full, older faults are discarded from the log as new
faults occur.

For each entry in the error log, the system also displays the day and time that the fault
occurred. The day data is based on a relative 247-day counter (rolls over after
247.55). The time is based on a 24-hour clock. The first digits of the clock data
represent hours. The last two digits represent minutes. The clock can be reset using
P.030 (Elapsed Time Meter Reset).

All entries in the error log and the day and time data are retained if power is lost. Refer
to section 6.4.3 for the procedure for accessing and clearing the error log using the
keypad.

6-6 Carrier VFD Quick Reference

 6.4.1 Identifying Alarm Codes and Recovering

Drive alarm codes are shown in table 6.2. Note that the alarm code will only be
displayed for as long as the problem exists. Once the problem has been corrected, the
alarm code will disappear from the display.
Table 6.2 – List of Alarm Codes

Alarm
Code Description Alarm Cause Corrective Action
HIdc High DC bus The DC bus is charged above the Increase the deceleration time in
voltage trip threshold. (If U.018 > 415, P.002, P.018.
DC bus is above 741 VDC. If U.018
≤ 415, DC bus is above 669 VDC.) Install optional snubber resistor
braking kit.

Verify that the AC input is within

specification. Install an isolation
transformer if required.

Check the actual line voltage against

U.018.
I-Ac V/Hz identification V/Hz identification procedure is Allow identification procedure to
procedure active enabled and in progress. finish.

Press keypad STOP/RESET to

cancel identification procedure if
desired.
I-En V/Hz identification H.020 = On; V/Hz identification Proceed with V/Hz identification
procedure procedure has been enabled but not procedure, start drive and allow
enabled started. procedure to begin. Display will
change to I-Ac when drive is started.

Change H.020 to OFF to cancel

identification and clear I-En if
desired.
LIL Low AC input line AC input line is low. Adjust line voltage parameter (H.021
For SVC, indicates DC bus is being or U.018) to match actual AC line
regulated. No corrective action is voltage.
required.
S-Ac Vector self-tuning Vector self-tuning is enabled and in Allow vector self-tuning procedure to
active progress. finish.

Press keypad STOP/RESET to

cancel vector self-tuning procedure
if desired.
S-En Vector self-tuning U.008 = On; vector self-tuning has Proceed with vector self-tuning, start
enabled been enabled but not started. drive and allow self-tuning
procedure to begin. Display will
change to S-Ac when drive is
started.

Change U.008 to OFF to cancel

self-tuning and clear S-En if desired.

Troubleshooting the Drive 6-7

 6.4.2 Identifying Fault Codes and Recovering

ATTENTION: DC bus capacitors retain hazardous voltages after input

power has been disconnected. After disconnecting input power, wait five
! minutes for the DC bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of life.

Drive fault codes are shown in table 6.3. To clear a single fault that has occurred so
that the drive can be started again, correct any problems indicated by the fault code
and press the STOP/RESET key on the keypad, or assert the fault reset from the
selected control source (P.000). Because multiple faults can occur and only the first
will be displayed, you must access the error log in order to view all of the faults that
have occurred. See section 6.4.3 for instructions on how to view the error log.

Table 6.3 – List of Fault Codes

Fault
Code Description Fault Cause Corrective Action
AIn Analog input signal P.011 = 4 or 5 and 4 to 20 mA analog Verify that P.011 is set correctly.
loss input is below 1 mA. Check that the analog input source
supply ≥1 mA.
bYC Incorrect precharge Precharge initiated and incorrect Check operation of the precharge.
status precharge status is returned.
CHS Default parameter During drive operation: Contact Reliance or replace Regulator
restore (checksum Regulator board failure. board.
error) After Regulator board replacement: Contact Reliance.
EC Earth current failure Unintentional grounding of the input. Check isolation between ground and
(ground fault) output terminals. Possible leakage,
current sensor defects; replace
sensor.
EEr Non-volatile Failure on write to non-volatile Connect CS3000 software to upload
memory write memory. parameters or record by hand. Then
failure replace Regulator board. Parameter
values will be lost when power is
cycled.
EL Encoder loss Drive is not detecting feedback from Check the connection between the
the encoder. encoder and the drive. Check the
encoder/motor coupling.

For SVC operation, conditions exist for For SVC operation, check motor data
more than 5 seconds that may result in parameters. Check U.006. Incorrect
an inability to complete a ramp-to-rest magnetizing current may be generated
stop. by performing self-tuning with a load
connected to the motor.
FL Function loss Function loss input on control terminal Check external interlocks at terminals
is opened. 16, 20.
HId High time Identification process for V/Hz has See H.019 for identification result.
identification been aborted.
aborted
HIL High line voltage Input voltage more than 15% above Check actual line voltage against
nominal. U.018 or H.021.

6-8 Carrier VFD Quick Reference

 Table 6.3 – List of Fault Codes (Continued)

Fault
Code Description Fault Cause Corrective Action
HU High DC bus DC bus voltage too high (capacitor Check input line voltage; if necessary,
voltage protection). add transformer.
Deceleration time too short. Increase deceleration time
P.002/P.018/P.023 versus Maximum
Speed/Hz (P.004). Install DB option
with resistors.
IPL Input phase loss Voltage ripple on DC bus due to Verify that proper voltage is being
missing input phase or an imbalance applied to the drive. Check all phases.
between phases.
LU Low DC bus DC bus voltage too low. Line dip too Check input voltage, line fuses. If
voltage long (P.042). necessary, add transformer. Check
value of Ride Through Time (P.042),
Line Voltage (H.021, U.018).
Input rectifier diodes defective. Check DC bus voltage. If incorrect,
replace diode set.
nCL Network comm loss Communications with the Check network cabling from network
AutoMax network have been lost. master to network option board. Check
that network master is operating
properly.
nId Identification Drive started but Identification Reset fault. Perform Identification
Request not yet Result = Zero. Request. Restart drive.
performed (V/Hz
only)
OC Overcurrent Output phase-to-phase short. Check isolation between each output
(steady state). line.
Trips between 185 Bus voltage line-to-line. Check transistor modules for correct
to 200% load output. If incorrect, possible board
(based on inverter defect; replace. Possible Hall effect
type current) check current sensor defective; replace.
Power Module Ground fault. Check isolation between ground and
rating. output terminals. Possible leakage
current sensor defect; replace sensor.
Momentary overload. Check for motor overload; reduce load
on motor.
Bad motor. Check motor for correct operation.
Torque boost / V/Hz too high (V/Hz). Check parameters H.001, H.002,
and/or H.003. Enable Identification
Request (H.020)
Motor unknown to regulator (V/Hz). Check that regulator was updated with
actual motor characteristics via
Identification Request (H.020).
Parameter settings (vector). Check Encoder PPR (U.001), Motor
Poles (U.002), Base Frequency
(U.003), Motor Nameplate Amps
(U.004), Magnetizing Current (U.006),
Speed Regulator Prop. Gain (U.012).
Encoder wired incorrectly, wrong PPR. Check encoder wiring. Perform vector
self-tuning.
OCA Overcurrent (at Overcurrent condition occurred while See OC fault corrective actions.
acceleration) accelerating. Increase acceleration time (P.001,
Acceleration time too short. P.017, P.021).

Troubleshooting the Drive 6-9

 Table 6.3 – List of Fault Codes (Continued)

Fault
Code Description Fault Cause Corrective Action
OCb Overcurrent DC voltage too high. Check parameters H.006, H.007.
(at DC braking)
OCd Overcurrent (at Overcurrent condition occurred while See OC fault corrective actions.
deceleration) decelerating. Increase deceleration time (P.002,
Deceleration time too short. P.018, P.022).
OF Overfrequency Drive has exceeded maximum Vector: Check parameters Encoder
allowable output frequency. PPR (U.001), Motor Poles (U.002),
Regenerating energy is too high. Base Frequency (U.003).
Stability or slip compensation circuit
V/Hz: Check DC bus voltage; increase
adds frequency reference. decelerating time. Check values Max
If H.016 ON, searching current is tooSpeed (P.004) / Overfreq. (H.022).
high. Motor is too small. Check slip compensation (H.004).
If H.016 ON, check motor size versus
Power Module size, recheck setting of
P.005 (too high).
OH Drive Cooling fan failure. Check ambient temperature, cooling
overtemperature fan, minimum clearances around drive.
OL Motor overload Excess motor current. Vector: Check actual/Motor Rated
V/Hz: Torque boost too high, therm. Nameplate Amps (U.004)
overload level too low. V/Hz: Check actual current/Torque
Boost (H.003).
Check that Power Module is sized
correctly.
Reduce load on motor (for example, at
low frequency).
Excess load on motor, for example, at Check that Power Module is sized
too low speeds. correctly. Reduce load on motor (e.g.,
at low frequency).
Loss of phase connection. Check output lines to the motor.
OPL Motor output phase Phase lost between drive and motor. Check connections and cable of all 3
loss phases and motor windings. Replace
any damaged cable.
OSP Overspeed RPM above 130% Maximum Speed Check Encoder PPR (U.001), Motor
(Vector only) (P.004), speed regulator response not Poles (U.002), Base Frequency
optimized. (U.003), Motor Nameplate RPM
Speed (U.005). Check Reg.
Proportional (U.012) Integral Gain
(U.013)
PUc Missing Power Bad or disconnected cable between Check cables between Regulator
Module ID Regulator and Power Module. board and Power Module.
connector
PUn Power Module not Drive parameters have been restored Power Module must be configured by
identified to power-up defaults. Regulator has Reliance service personnel.
not been configured to match Power
Module.
PUo Drive power Power Module overloaded. Check load to Power Module.
electronic Too high DC Braking Current Check Power Module sizing versus
overload (H.007) or Torque Boost (H.003). application. Check DC Braking Current
value (H.007). Check Torque Boost
(H.003).
SF Self-tuning status See parameter U.009
(Vector only)

6-10 Carrier VFD Quick Reference

 Table 6.3 – List of Fault Codes (Continued)

Fault
Code Description Fault Cause Corrective Action
SrL Communication Serial port communication cable, PC Check connection cable and
loss between or OIM communication port setup. communication port setup.
Regulator/PC/OIM
UAr Spurious host PC Regulator board failure. Replace Regulator board.
comm interrupt
UbS Asymmetrical bus One of 3 differnet faults has occurred;
fault. Look at the 3 1. Input Ground Fault - Excessive 1. Check the connection from the
LEDs on the Power current flowing bwtween any of the current transformer to the Bus Control
Module Interface three input phases and earth ground. board.
board. They 2 . Asymmetrical Bus - When 2. Replace shorted capacitor, fix loose
indicate which fault measuring between the cap bank connection, or replace discharge
has occurred by midpoint and the +DC bus and -DC resistor.
flashing in unison. bus, there is a 200 V or greater
mismatch.
1 = Input Ground 3. Slow Ramp Rate of DC Bus - DC 3. Turn on drive. If UbS is displayed,
Fault; bus did not change to the ful value turn drive off and then on again very
2 = Asymmetrical given time allowed. Can occur only at quickly. If the UbS fault goes away and
Bus; power-up. the DC bus charges, replace the Bus
3 = Slow Ramp Control board.
Rate of DC Bus

6.4.3 Accessing, Reading, and Clearing the Faults in the Error Log
The following procedure shows how to access and clear the error log. Note that you
cannot clear a single entry from the error log. The entire log, including all the fault
codes and the day and time stamp of each fault, will be cleared simultaneously using
this procedure.

Step 1. Press the PROGRAM key.

The First Menu General parameters are

displayed. The PROGRAM LED will turn on.

Troubleshooting the Drive 6-11

 Step 2. Press the ▼ key until Err is displayed.

Step 3. Press the ENTER key.

If no faults have occured, Err will be

displayed again. If only one fault has
occurred, the fault code will be displayed as
the first entry in the log. If more than one
fault has ocurred, the first entry is the latest
fault that occurred.

Step 4. Press the ▲ or the ▼ key. The display steps through the error log entries,
which are numbered 0 through 9 (maximum).

Step 5. Press the ENTER key.

The display shows the day stamp, which can

range from 0 to 248 days.

6-12 Carrier VFD Quick Reference

 Step 6. Press the ▼ key.

The display shows the time stamp, which is

based on a 24-hour clock. Use the arrow
keys to move between the day and time
data.

Step 7. Press the PROGRAM key, which displays the error log entries again.The
display shows the error log entry viewed prior to or associated with the time
stamp.

Step 8. Repeat steps 4 though 7 for each additional error log entry to view the time
and date for each error log entry.

Step 9. When you have viewed all the entries, you should clear the error log. Press
the ▼ key while you are viewing any entry in the log until the display shows
CLr. Press ENTER to clear the error log. All entries will be cleared.

Step 10. Err will be displayed again to indicate that the log is empty.

Step 11. Press the PROGRAM key to access monitor mode.

Troubleshooting the Drive 6-13

 6.5 Identifying Fatal Fault Codes and Recovering
Fatal fault codes are distinguished by the letter F preceding the code. They normally
indicate a malfunction of the microprocessor on the Regulator board. In some cases,
fatal fault codes can be reset and the drive can be re-started. Table 6.4 lists the fatal
fault codes which can be reset. If any other fault code appears on the display, you will
need to replace the Regulator board.

If the fault code FUE appears in error log entry 0, it indicates a fatal fault occurred as
power was lost. Contact Reliance Electric or observe the drive for subsequent fatal
errors before turning off power. Fatal fault codes are lost after power loss.

Table 6.4 – Fatal Fault Codes That Can Be Reset

Code Fault Description Fault Cause Corrective Action

F3 Encoder power-up Encoder voltage is less than Turn off power to the drive. Disconnect
diagnostic error. 10 V. the encoder wiring from the terminal strip.
Turn power to the drive back on.
If the F3 error does not occur again, the
problem is in the wiring between the drive
and the encoder.
If the F3 error does occur again, the
problem is in the Regulator board, which
should be replaced.
F 60 Option port identification The option board could not Check the ribbon cable between the
error. be identified by the regulator. Regulator board and the option board.
Check the option board’s jumper settings.
Refer to the appropriate option board
instruction manual for more information
about the option board.
F 61 Option board power-up Option board has failed one Check the ribbon cable between the
diagnostic failure. or more power-up Regulator board and the network option
diagnostics. board. Replace the option board if
necessary.
Refer to the appropriate option board
instruction manual for more information
about the option board.
F 62 Option board runtime During operation, the option If intermittent, check for causes of noise,
or error. board watchdog failed or for proper grounding, and that outputs
F 26 handshaking with the drive are not exceeding rated current
failed. capacities.
Replace the option board if necessary.
Refer to the appropriate option board
instruction manual for more information
about the option board.

6-14 Carrier VFD Quick Reference

 6.6 Indentifying PMC Board Fault Codes and Recovering
ATTENTION: Viewing the PMC board LEDs requires electrical circuits
to be exposed. Stay clear if unit must be running. Disconnect and lock
! out or tag power source if contact must be made. Failure to observe this
precaution could result in severe bodily injury or loss of life.

Table 6.5 lists PMC board fault codes. These faults can be identified using the three
LEDs located on the Regulator board.

Table 6.5 – PMC Board Fault Codes

Status of LEDs 1-3 Fault Description Corrective Action

LEDs 1-3 all on. Normal operation None required.

(60 Hz, 50% duty);
no fault.

LEDs 1-3 all off. VAC_LINE = ‘lo’ None required. The board will
recover when the line
becomes present.
LEDs 1-3 flash in a VDC_CHG = ‘lo’ Reset board.
3-flash sequence.

LEDs 1-3 flash in a ASYM_FAULT = ‘lo’ Reset board.

2-flash sequence.

LEDs 1-3 flash in a ACGNDFLT = ‘lo’ Reset board. (This circuit was
1-flash sequence. removed on the 350 HP
assembly.)

6.7 Resetting a Checksum (CHS) Fault

Perform the following procedure when a new Regulator board is installed or if a CHS
fault repeats.

Step 1. Press and hold STOPIRESET, PROGRAM, and DOWN ARROW for 5 to 10
seconds. A PUn error should appear.
Step 2. Press PROGRAM. P.--- is displayed.
Step 3. Press ENTER. P.000 is displayed.

Perform steps 4 through 7 if access to the second menu has not already been
enabled.

Step 4. Press UP ARROW until P.006 is displayed.

Step 5. Press ENTER.
Step 6. Press UP ARROW until 107 is displayed.
Step 7. Press ENTER.

Perform steps 8 through 11 if changing modes of operation (V/Hz or Vec). Otherwise,

skip to step 12.

Troubleshooting the Drive 6-15

 Step 8. Press UP ARROW until P.048 is displayed.
Step 9. Press ENTER.
Step 10. Press UP or DOWN ARROW to select UEC or U-H mode.
Step 11. Press ENTER. Observe SELF is displayed briefly.
Step 12. Press UP or DOWN ARROW until P.006 is displayed.
Step 13. Press ENTER.
Step 14. Press UP ARROW until 75 is displayed.
Step 15. Press ENTER.
Step 16. Press UP ARROW until R998 is displayed.
Step 17. Press ENTER.
Step 18. Press UP ARROW until ON is displayed.
Step 19. Press ENTER.
Step 20. Press UP ARROW until P.999 is displayed. Depending on software version,
the display may show PUGH or P.999.

If PUCH is displayed, wait for 0 to display. The procedure is complete.

If P.999 is displayed, continue with step 21.

Step 21. Press ENTER.
Step 22. Press UP ARROW until the correct power unit current and voltage rating
code appears. The codes are as follows:
Model Amps Code
Number
41LR4060 414 41.4
50LR4060 500 50.4
64LR4060 643 64.4

Step 23. Press ENTER. PUCH should appear briefly.

The drive is ready to operate. If in vector mode, enter the correct values for
U parameters and perform SELF TUNING.

6-16 Carrier VFD Quick Reference

Publication D2-3466-1 - June 2002 Copyright  2002 Rockwell Automation. All rights reserved. Printed in USA.