Carrier Computer Drive D2 3466 2 User Manual

Carrier VFD Quick Reference  
Instruction Manual D2-3466-2  
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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  
Electricisnotresponsibleforunauthorizedaccessviolationswithin the user’sorganization. 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.  
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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.  
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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.  
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CONTENTS  
Chapter 1  
Chapter 2  
Using This Manual  
1.1 Required Publications...................................................................................... 1-1  
1.2 Getting Assistance from Reliance Electric....................................................... 1-1  
Identifying Drive Components Using Reference Drawings and Parts Lists  
2.1 VFD Chiller Installation Drawing (500A and 643A VFD) ................................. 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 (19XV04003001 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  
Chapter 4  
Chapter 5  
Chapter 6  
Using the Keypad/Display to Program, Monitor, and Control the Drive..............3-1  
Identifying Parameter Defaults For Carrier Drives...............................................4-1  
Verifying the Installation......................................... ...............................................5-1  
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
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II  
Carrier VFD Quick Reference  
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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:  
LiquiFlo AC General Purpose (Volts/Hertz) and Vector Duty Drive  
D2-3410  
Software Start-Up and Reference Manual  
LiquiFlo AC Power Modules Hardware Reference, Installation, and  
D2-3411  
Troubleshooting  
Super Remote Meter Interface (RMI) Board for GV3000 and  
D2-3341  
LiquiFlo AC Drives  
Control and Configuration Software  
D2-3448  
19XR, XRV Start-Up, Operation, and Maintenance Instructions  
531-982  
(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  
1-864-284-5444.  
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  
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1-2  
Carrier VFD Quick Reference  
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CHAPTER 2  
Identifying Drive Components Using  
Reference Drawings and Parts Lists  
Replace with 2.fm (11 X 17 Z-fold)  
Identifying Drive Components Using Reference Drawings and Parts Lists  
2-1  
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2-2  
Carrier VFD Quick Reference  
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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).  
Drive Status  
LEDs  
Keypad  
Display  
P.- - -  
AUTO  
MAN  
Forward  
Reverse  
RUNNING  
REMOTE  
JOG  
SPEED  
VOLTS  
Monitor Mode  
LEDs  
AMPS  
RUN  
JOG  
Hz  
AUTO  
PROGRAM  
Kw  
FORWARD  
TORQUE  
Password  
REVERSE  
PROGRAM  
Password LED  
ENTER  
STOP  
RESET  
START  
RELIANCE  
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  
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3-2  
Carrier VFD Quick Reference  
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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.  
P.000  
Parameter Name  
Control Source  
Setting  
rE  
P.001  
Accel Time 1  
8
P.002  
Decel Time 1  
20  
P.003  
Minimum Speed  
Maximum Speed  
Current Limit  
0.5  
P.004  
Job-specific (50 or 60)  
P.005  
110  
-10  
1
Terminal Strip Analog Input Offset  
P. 0 0 9  
Terminal Strip Analog Input Gain  
0.99 (50LR4060, 64LR4060)  
1.030 (41LR4060)  
P. 0 1 0  
P.011  
P.013  
P.027  
P.028  
P.043  
P.044  
P.052  
H.000  
H.001  
H.002  
H.021  
H.022  
r.001  
Terminal Strip Analog Input Configure  
Output Relay Configuration  
Forward/Reverse Configuration  
Speed Display Scaling  
4
2
1
Job-specific  
Fault Auto Reset Attempts  
Fault Auto Reset Time  
10  
30  
ON  
AUTO/MAN Key Disable  
Motor Nameplate Volts  
Job-specific  
Motor Nameplate Base Frequency  
Motor Nameplate Amps  
AC Line Volts  
Job-specific  
1.03 x Motor Nameplate Amps  
Job-specific  
Overfrequency Limit  
Job-specific (57 or 69)  
4
Analog Output 1 Source  
Analog Output 1 Offset  
60 (50LR4060, 64LR4060)  
135 (41LR4060)  
r.002  
Analog Output 1 Gain  
0.505 (50LR4060, 64LR4060)  
0.503 (41LR4060)  
r.003  
r.035  
r.036  
r.037  
r.046  
r.050  
Relay Output 1 (NO) Configuration  
Relay Output 2 (NO/NC) Configuration  
Relay Output 3 (NO/NC) Configuration  
Relay Output 3 Delay Time  
5
2
1
-999  
35  
Speed Detection Level 1  
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  
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4-2  
Carrier VFD Quick Reference  
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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  
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5-2  
Carrier VFD Quick Reference  
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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  
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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  
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Initial DC Bus  
Measurement  
Points  
Figure 6.2 – DC Bus Voltage Terminals (500 Amp and 643 Amp Drives)  
Troubleshooting the Drive  
6-3  
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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  
Step 7. Check motor impedance.  
Step 8. Reconnect the motor to the drive.  
Step 9. Reapply input power.  
6-4  
Carrier VFD Quick Reference  
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Table 6.1 – Resistance Checks  
Input  
Meter  
Diode Connection  
Component is OK if  
resistance (R) is:  
No.  
1
(+)  
*
(-)  
Component is defective if:  
SCR1  
SCR2  
SCR3  
SCR4  
SCR5  
SCR6  
10 < R < 1 megohm  
Continuity (short circuit) or  
open when the meter is  
connected with reversed  
polarity.  
2
*
3
*
4
*
5
*
6
*
7
SCR1 **  
SCR2 **  
SCR3 **  
SCR4 **  
SCR5 **  
SCR6 **  
8
9
10  
11  
12  
* (+) DC Bus Volts power terminal  
** (-) DC Bus Volts power terminal  
Table 6.1 - Resistance Checks (Continued)  
Meter  
IGBT  
No.  
Connection  
Component is OK if  
resistance (R) is:  
(+)  
(-)  
W/T3  
V/T2  
U/T1  
Component is defective if:  
1
2
3
4
5
6
*
*
*
10 < R < 1 megohm  
Continuity (short circuit) or  
open when the meter is  
connected with reversed  
polarity.  
W/T3 **  
V/T2 **  
U/T1 **  
* (+) DC Bus Volts power terminal  
** (-) DC Bus Volts power terminal  
Troubleshooting the Drive  
6-5  
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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  
6-6  
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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  
HIdc  
Description  
High DC bus  
voltage  
Alarm Cause  
The DC bus is charged above the  
trip threshold. (If U.018 > 415,  
Corrective Action  
Increase the deceleration time in  
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  
I-En  
V/Hz identification V/Hz identification procedure is  
procedure active enabled and in progress.  
Allow identification procedure to  
finish.  
Press keypad STOP/RESET to  
cancel identification procedure if  
desired.  
V/Hz identification H.020 = On; V/Hz identification  
Proceed with V/Hz identification  
procedure  
enabled  
procedure has been enabled but not procedure, start drive and allow  
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.  
For SVC, indicates DC bus is being or U.018) to match actual AC line  
regulated. No corrective action is  
required.  
Adjust line voltage parameter (H.021  
voltage.  
S-Ac  
Vector self-tuning  
active  
Vector self-tuning is enabled and in Allow vector self-tuning procedure to  
progress.  
finish.  
Press keypad STOP/RESET to  
cancel vector self-tuning procedure  
if desired.  
S-En  
Vector self-tuning  
enabled  
U.008 = On; vector self-tuning has  
been enabled but not started.  
Proceed with vector self-tuning, start  
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  
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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  
Description  
Analog input signal P.011 = 4 or 5 and 4 to 20 mA analog Verify that P.011 is set correctly.  
Code  
AIn  
Fault Cause  
Corrective Action  
loss  
input is below 1 mA.  
Check that the analog input source  
supply 1 mA.  
bYC  
CHS  
Incorrect precharge Precharge initiated and incorrect  
status precharge status is returned.  
Default parameter During drive operation:  
restore (checksum Regulator board failure.  
Check operation of the precharge.  
Contact Reliance or replace Regulator  
board.  
Contact Reliance.  
error)  
After Regulator board replacement:  
EC  
Earth current failure Unintentional grounding of the input.  
(ground fault)  
Check isolation between ground and  
output terminals. Possible leakage,  
current sensor defects; replace  
sensor.  
EEr  
Non-volatile  
memory write  
failure  
Failure on write to non-volatile  
memory.  
Connect CS3000 software to upload  
parameters or record by hand. Then  
replace Regulator board. Parameter  
values will be lost when power is  
cycled.  
EL  
Encoder loss  
Drive is not detecting feedback from  
the encoder.  
Check the connection between the  
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  
aborted  
Identification process for V/Hz has  
been aborted.  
See H.019 for identification result.  
HIL  
6-8  
High line voltage  
Input voltage more than 15% above  
nominal.  
Check actual line voltage against  
U.018 or H.021.  
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Table 6.3 – List of Fault Codes (Continued)  
Fault  
Code  
HU  
Description  
High DC bus  
voltage  
Fault Cause  
DC bus voltage too high (capacitor  
protection).  
Corrective Action  
Check input line voltage; if necessary,  
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  
LU  
Input phase loss  
Voltage ripple on DC bus due to  
missing input phase or an imbalance applied to the drive. Check all phases.  
between phases.  
DC bus voltage too low. Line dip too  
long (P.042).  
Verify that proper voltage is being  
Low DC bus  
voltage  
Check input voltage, line fuses. If  
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  
nId  
Network comm loss Communications with the  
AutoMax network have been lost.  
Check network cabling from network  
master to network option board. Check  
that network master is operating  
properly.  
Reset fault. Perform Identification  
Request. Restart drive.  
Identification  
Request not yet  
performed (V/Hz  
only)  
Drive started but Identification  
Result = Zero.  
OC  
Overcurrent  
Output phase-to-phase short.  
Bus voltage line-to-line.  
Check isolation between each output  
line.  
Check transistor modules for correct  
output. If incorrect, possible board  
defect; replace. Possible Hall effect  
current sensor defective; replace.  
Check isolation between ground and  
output terminals. Possible leakage  
current sensor defect; replace sensor.  
(steady state).  
Trips between 185  
to 200% load  
(based on inverter  
type current) check  
Power Module  
rating.  
Ground fault.  
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).  
Parameter settings (vector).  
Check that regulator was updated with  
actual motor characteristics via  
Identification Request (H.020).  
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  
acceleration)  
Overcurrent condition occurred while See OC fault corrective actions.  
accelerating.  
Increase acceleration time (P.001,  
P.017, P.021).  
Acceleration time too short.  
Troubleshooting the Drive  
6-9  
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Table 6.3 – List of Fault Codes (Continued)  
Fault  
Code  
Description  
Fault Cause  
Corrective Action  
OCb  
Overcurrent  
(at DC braking)  
DC voltage too high.  
Check parameters H.006, H.007.  
OCd  
OF  
Overcurrent (at  
deceleration)  
Overcurrent condition occurred while See OC fault corrective actions.  
decelerating.  
Increase deceleration time (P.002,  
P.018, P.022).  
Deceleration time too short.  
Overfrequency  
Drive has exceeded maximum  
allowable output frequency.  
Regenerating energy is too high.  
Stability or slip compensation circuit  
adds frequency reference.  
If H.016 ON, searching current is too  
high. Motor is too small.  
Vector: Check parameters Encoder  
PPR (U.001), Motor Poles (U.002),  
Base Frequency (U.003).  
V/Hz: Check DC bus voltage; increase  
decelerating time. Check values Max  
Speed (P.004) / Overfreq. (H.022).  
Check slip compensation (H.004).  
If H.016 ON, check motor size versus  
Power Module size, recheck setting of  
P.005 (too high).  
OH  
OL  
Drive  
Cooling fan failure.  
Check ambient temperature, cooling  
fan, minimum clearances around drive.  
Vector: Check actual/Motor Rated  
Nameplate Amps (U.004)  
V/Hz: Check actual current/Torque  
Boost (H.003).  
overtemperature  
Motor overload  
Excess motor current.  
V/Hz: Torque boost too high, therm.  
overload level too low.  
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  
OSP  
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.  
Overspeed  
(Vector only)  
RPM above 130% Maximum Speed  
(P.004), speed regulator response not Poles (U.002), Base Frequency  
Check Encoder PPR (U.001), Motor  
optimized.  
(U.003), Motor Nameplate RPM  
Speed (U.005). Check Reg.  
Proportional (U.012) Integral Gain  
(U.013)  
PUc  
PUn  
Missing Power  
Module ID  
Bad or disconnected cable between  
Regulator and Power Module.  
Check cables between Regulator  
board and Power Module.  
connector  
Power Module not Drive parameters have been restored Power Module must be configured by  
identified  
to power-up defaults. Regulator has  
not been configured to match Power  
Module.  
Reliance service personnel.  
PUo  
Drive power  
electronic  
overload  
Power Module overloaded.  
Too high DC Braking Current  
(H.007) or Torque Boost (H.003).  
Check load to Power Module.  
Check Power Module sizing versus  
application. Check DC Braking Current  
value (H.007). Check Torque Boost  
(H.003).  
SF  
Self-tuning status  
(Vector only)  
See parameter U.009  
6-10  
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Table 6.3 – List of Fault Codes (Continued)  
Fault  
Code  
SrL  
Description  
Communication  
loss between  
Regulator/PC/OIM  
Spurious host PC  
comm interrupt  
Fault Cause  
Corrective Action  
Serial port communication cable, PC Check connection cable and  
or OIM communication port setup.  
Regulator board failure.  
communication port setup.  
Replace Regulator board.  
UAr  
UbS  
Asymmetrical bus One of 3 differnet faults has occurred;  
fault. Look at the 3 1. Input Ground Fault - Excessive  
LEDs on the Power current flowing bwtween any of the  
1. Check the connection from the  
current transformer to the Bus Control  
three input phases and earth ground. board.  
Module Interface  
board. They  
2 . Asymmetrical Bus - When  
2. Replace shorted capacitor, fix loose  
connection, or replace discharge  
resistor.  
indicate which fault measuring between the cap bank  
has occurred by midpoint and the +DC bus and -DC  
flashing in unison. bus, there is a 200 V or greater  
mismatch.  
1 = Input Ground  
Fault;  
2 = Asymmetrical  
Bus;  
3 = Slow Ramp  
Rate of DC Bus  
3. Slow Ramp Rate of DC Bus - DC 3. Turn on drive. If UbS is displayed,  
bus did not change to the ful value turn drive off and then on again very  
given time allowed. Can occur only at quickly. If the UbS fault goes away and  
power-up.  
the DC bus charges, replace the Bus  
Control board.  
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.  
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6-11  
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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  
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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  
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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  
F 3  
Fault Description  
Encoder power-up  
diagnostic error.  
Fault Cause  
Corrective Action  
Encoder voltage is less than Turn off power to the drive. Disconnect  
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  
F 61  
Option port identification  
error.  
The option board could not Check the ribbon cable between the  
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.  
Option board power-up  
diagnostic failure.  
Option board has failed one Check the ribbon cable between the  
or more power-up  
diagnostics.  
Regulator board and the network option  
board. Replace the option board if  
necessary.  
Refer to the appropriate option board  
instruction manual for more information  
about the option board.  
F 62  
or  
F 26  
Option board runtime  
error.  
During operation, the option If intermittent, check for causes of noise,  
board watchdog failed or  
handshaking with the drive  
failed.  
for proper grounding, and that outputs  
are not exceeding rated current  
capacities.  
Replace the option board if necessary.  
Refer to the appropriate option board  
instruction manual for more information  
about the option board.  
6-14  
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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  
None required.  
LEDs 1-3 all on.  
Normal operation  
(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  
3-flash sequence.  
VDC_CHG = ‘lo’  
ASYM_FAULT = lo’  
ACGNDFLT = lo’  
Reset board.  
LEDs 1-3 flash in a  
2-flash sequence.  
Reset board.  
LEDs 1-3 flash in a  
1-flash sequence.  
Reset board. (This circuit was  
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  
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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  
50LR4060  
64LR4060  
414  
500  
643  
41.4  
50.4  
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  
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error that you have found. For convenience, you may attach copies of the pages with  
your comments. After you have completed this form, please return it to:  
Rockwell Automation / Reliance Electric Drives  
Technical Documentation  
6040 Ponders Court  
Greenville, SC 29607  
Fax: 864-284-5483  
Publication Name: LiquiFlo 1.5 AC Drive, Hardware Reference Version 1.2  
Publication Number: D2-3466-2  
Publication Date: May 2005  
Comments:  
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Address:  
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Phone: (  
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Copyright ©2005 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.  
Publication D2-3466-2 - May 2005 -- Supercedes D2-3466-1 - June 2002  
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