Installation, Operation and Maintenance Manual

IOMM Starter-3 Group: Chiller Part Number: 331375501 Effective: Dec. 2010 Supercedes: March. 2010

Starters for Centrifugal Chillers

Low Voltage, Solid State and Wye-Delta Medium Voltage, Solid State and Across-the-Line

Table of Contents
General ................................................................................................................... 3
Variable Frequency Drives............................................................................................................ 4 Basic Electrical Terms .................................................................................................................. 4 Model Identification ..................................................................................................................... 5

Starter Field Installation....................................................................................... 5

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

Dimensions & Terminal Sizes ............................................................................... 8

Low Voltage, Solid State (RVSS and RVST) ................................................................................ 8 Low Voltage, Wye-Delta (D3DW & D3dt)................................................................................ 15 Medium Voltage, Solid State (MVSS & HVSS) ......................................................................... 22 Medium Voltage, Across-The-Line (MVAT & HVAT)................................................................ 24

Field Power Wiring.............................................................................................. 26 Field Control Wiring ........................................................................................... 28

Low Voltage Starters .................................................................................................................. 29 Medium/high Voltage Starters..................................................................................................... 30

Startup .................................................................................................................. 33
Low Voltage Solid State (RVSS) ................................................................................................ 33 Low Voltage Wye-Delta (D3YD ................................................................................................. 36 Medium Voltage, Solid State (MVSS, HVSS) ............................................................................ 39

Operation, Low Voltage Starters, 200 600 Volts ............................................ 42

Introduction ................................................................................................................................ 42 Viewing Data .............................................................................................................................. 42 Changing Parameters .................................................................................................................. 47 Fault Code Troubleshooting Chart.............................................................................................. 55 General Troubleshooting Chart................................................................................................... 63

Operation, Medium/High Voltage Starters, 2300V 7.2KV............................ 67

Introduction ................................................................................................................................ 67 Viewing Data .............................................................................................................................. 67 Changing Parameters .................................................................................................................. 68 Quick Start .................................................................................................................................. 71 Troubleshooting .......................................................................................................................... 73 Fault/Log Codes.......................................................................................................................... 75 LED Diagnostics......................................................................................................................... 78

Maintenance......................................................................................................... 79 Index of Figures & Tables................................................................................... 80

"McQuay" is a registered trademark of McQuay International2010 "Illustrations and data cover McQuay International products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice".

IOMM Starter-3

General
These starters are completely automatic and require no operator intervention (other than clearing and resetting faults) to perform their function of providing a controlled connection of the compressor motor to the power supply. The Wye-Delta and solid-state starters have similar software characteristics and are discussed together in their operating section. However, some parameters and data are different. Where this occurs, separate tables and figures are provided. The low voltage (200-600 volts) starters are characterized by their control software, known as D3 Control. Certain electrical operating data for these low voltage starters is transmitted to the chiller and can be viewed on the operator touch screen if the Full Metering Option has been ordered. See page 42 for details. Medium voltage (2300-72,000 volts) starters share common software known as MX3 control. Figure 1, Wye-Delta Starter

Incoming Lugs Terminal Strip Surge Capacitor

LED Display D3 Controller

Control Transformer and Fuses Contactors Transition Resistors

IOMM Starter-3

Figure 2, Solid State Starter, Remote Mounted

Terminal Strip

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

Variable Frequency Drives

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

Basic Electrical Terms

Bypass contactor: Contactors that bypass auto-transformers, reactors, or SCRs, and allow full power to reach the motor directly. Closed transition: A reduced voltage starter characteristic when the motor is NOT temporarily disconnected from the line during the transition from starting mode to operating mode. The electrical load is transferred to resistors during the transition phase and the second inrush spike is suppressed Full load amps (FLA): The maximum amps the motor is designed for. Inrush current: The amount of current that a specific motor and starter combination will draw during start-up. Normal inrush current will be substantially less than LRA for all starter types, except for across-the-line starters. Interrupting capacity: The maximum fault current that a circuit breaker or fused disconnect can successfully interrupt. As the rating increases, the construction becomes heavier duty. For disconnect switches with fuses, the rating is based on 0 to 600 volts. For circuit breakers, the voltage and amperage relationship is considered with interrupting capacity decreasing as voltage increases.
4 IOMM Starter-3

Locked rotor amps (LRA): The amount of current that a specific motor will draw at startup, when full voltage is applied across the line. The LRA may be 6 to 8 times FLA, or possibly higher in some cases. Low Voltage: Voltages up to 600 volts Medium Voltage: Voltages from 1000 volts to 69,000 (1kV to 69kV) Open transition: A reduced voltage starter characteristic occurring when the motor is temporarily disconnected from power at the time the starter changes from the starting mode to the final running mode. A second smaller inrush spike will occur. McQuay does not recommend use of this type of starter. Phase amps: The current draw inside the delta connection of a wye-delta motor winding. It is equal to 0.577 x RLA of the motor for a specific load. Rated load amps (RLA): Actual amperage that the motor draws for a specific application. Centrifugal compressor motors operate at a RLA significantly below their maximum full load amps. RLA is used to determine electrical component sizing such as wire size and disconnect switches. Starting torque: Minimum torque required to begin the motors rotation. Withstand rating: There is a period of time that the short circuit current passes to the shorted circuit before the protection device can open. This time can be as long as 0.020 seconds (one cycle). The withstand rating of a starter is the maximum short circuit current that it can pass safely without emitting sparks or debris.

Model Identification
Full model numbers are as shown below followed by two digits representing the units Rated Load Amps (RLA), such as RRSS14 RVSS: low voltage, solid state, free standing RVST: low voltage, solid state, terminal (unit) mounted MVSS: medium voltage, solid state, free standing only D3WD: low voltage, wye-delta, free standing D3WT: low voltage, wye-delta, terminal (unit) mounted MVAT: medium voltage, across-the-line, free standing only MVSS medium voltage solid state, free standing only

Starter Field Installation

Mounting Arrangements
Low voltage starters can be factory-mounted with power and control wiring factoryinstalled or they can be free-standing, requiring field mounting remote from the unit and field-wiring of power and control wiring. Because of dimension restrictions for shipping, some factory-mounted starters for large chillers are shipped separate from the unit. Mounting supports are on the unit and preassembled cable kits are provided. Mounting and wiring on site are the customers responsibility and can be subcontracted to McQuay Factory Service if desired.

IOMM Starter-3

Medium voltage starters and some size low voltage starters on WSC 100 through 126 are only available for free-standing applications. Low voltage starters can be supplied in several different mounting arrangements depending on the chiller size and starter type. See Table 1 for available arrangements. Factory-Mounted (optional): The starter is mounted on the chiller unit with the back of the starter against the motor terminal box and wired directly to the motor. This arrangement is only available on WSC/WDC 063, 079, or 087 units (cover photograph). Free-standing (standard): Floor-mounted, separate from the chiller unit, and field wired to the compressor motor. This is available on all units and is the only starter arrangement available for WDC/WCC 100 and 126 dual compressor units.

Brackets and cable (optional): Starters for WSC/WCC 100 and 126 single compressor units may be shipped separately from the chiller unit and furnished with mounting brackets and interconnecting cables for field mounting and connection by others. This option must be clearly specified when chillers are ordered since brackets are welded onto the evaporator during its construction. Table 1, Starter/VFD Mounting Arrangements
Size WSC/WDC 050 WSC/WDC 063 WSC/WDC 079 WSC/WDC 087 WSC 100 - 126 WDC 100 - 126 WCC 100 - 126 FactoryMounted X X X X FreeStanding X X X X X X X Brackets & Cables

NOTE: WSC are single compressor chillers, WDC and WCC are dual compressor chillers

Receiving and Setting

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

Location and Mounting

Clearance
The starter must be mounted on a level concrete or steel base and must be located to provide adequate service. Local codes or the National Electric Code (NEC) can require more clearance in and around electrical components and must be checked.

Mounting
Make sure that the floor or structural support is adequate to support the full weight of the unit.
6 IOMM Starter-3

Standard NEMA 1 and NEMA 12 starters must be installed indoors in an area that is not exposed to direct water spray. Do not install in areas where the ambient temperature falls below 32F (0C) or exceeds 104F (40C) enclosed, or 122F (50C) open unless this was noted at the time of order placement and special precautions were taken to protect against these abnormal temperatures. Heatsink temperatures can run as high as 158F (70C) during normal operation. Do not mount the starter in contact with any material that cannot accept this heat. The starter must be mounted with the heat sink fins oriented vertically in an area that will not experience excessive shock or vibration.

Environmental Requirements
Provisions should be provided in the starter enclosure to ensure that the temperature inside the enclosure never rises above 122F (50C) or the starter could be damaged or the life of the starter could be reduced. Storage temperature limits are -4F to 155F (-20C to 70C).

Safety Precautions
!

WARNING

An incoming disconnect must be locked open before wiring or servicing the starter, motor, or other related equipment. Shock hazard exists. Pressing the Stop push-button on the chiller control panel does not remove AC mains potential. The equipment must only be serviced by qualified personnel fully familiar with the equipment.

WARNING

For safety of maintenance personal as well as others who might be exposed to electrical hazards associated with maintenance activities, the safety related work practices of NFPA 70, Part II, should always be followed when working on electrical equipment.

The opening of the branch circuit protective device may be an indication that a fault current has been interrupted. To reduce the risk of electrical shock, current carrying parts and other components of the starter should be inspected and replaced if damaged.

Power Factor Capacitors, Surge Capacitors and Lightning Arrestors

These devices MUST NOT be used with solid state starters. The SCRs in the starter will be damaged by the di/dt levels created. On wye-delta starters, they are connected between the starter and the motor.

IOMM Starter-3

Dimensions & Terminal Sizes

Low Voltage, Solid State (RVSS and RVST)
Figure 3, Solid-state Starter with Circuit Breaker/ Disconnect Models RVSS47 RVSS82, RVST47 RVST82
Removable Cable Entrance Panel Terminal Strip Grounding Lug

Line Side Lugs Access for factory wiring to motor Disconnect Switch Motor Lugs Remote Switch Operator (to Door) SCRs

(3) Current Transformers

Bypass Contactor Primary Transformer Fuses

Motor Control Relays (MCR)

Secondary Transformer Fuses

Control Transformer

NOTES: 1. 2. Free-standing Models RVST47 to RSVT 82 have 6-inch high feet not shown in photograph. Free-standing Models RVST14 to RSVT 41 are similar in appearance but in a shorter enclosure. They have 18-inch high feet not shown in photograph.

IOMM Starter-3

Figure 4, Solid-state, Free-standing Models RVSS14 to RVSS41

NOTE: For starters equipped with optional power factor correction capacitors and/or fused disconnect switches, use Drawing RVSS 14 82, which is 78 inches high rather than this 66-inch high unit.
38.0 (965.2) CUTOUT: 4" x 10 15/16" THROUGH TOP WITH COVER (CUSTOMER MOTOR LEADS) 18.1 (458.5) 9.4 (240.5) CUTOUT: 8" x 16" THROUGH TOP (CUSTOMER SUPPLIED "VAC")

Starter Model No.

Incoming Lug Size to Standard Power Block

1.5 (38.1) 16.0 (406.4)

Outgoing Connectio n Size

TOP VIEW

16.0 (406.4)

38.0 (965.2)

McQuay

RVSS14 (2) #6 - 300 0.5 RVSS17 (2) #6 - 300 0.5 RVSS20 (2) #6 - 300 0.5 RVSS27 (2) #6 - 300 0.5 RVSS34 (2) #6 - 300 0.5 RVSS41 (2) #6 - 300 0.5 NOTES: 1. Outgoing lugs are NEMA 2 hole pattern.

48.0 (1219.2)

Optional
58.0 (1473.2) 66.0 (1676.4)

Starter Model Size RVSS14 RVSS17 RVSS20 RVSS27 RVSS34 RVSS41

Breaker Size (Amps) 250 250 300 400 500 600

Incoming Lug Size Circuit Breaker #6-350 #6-350 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500

Incoming Lug Size Disconnect Switch #6-350 #6-350 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500

L.SIDE VIEW
18.0 (406.4)

FRONT VIEW
(W/ OPTIONAL MOUNTING LEGS)

NOTES: 1. All dimensions are in inches (mm). 2. The location of factory-mounted starters is shown on the chiller unit dimension drawing. 3. Free-standing Models RSVT have optional 18-inch legs as shown in front view. 4. Power factor correction capacitors cannot be mounted in this size enclosure. 5. Weight of free-standing model is 450 lbs (204 kg). 6. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure. 7. For free-standing starters, the outgoing connections can be made through the top of the enclosure or through the upper-left rear area. 8. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

IOMM Starter-3

Figure 5, Free-Standing, Solid-state Starter Models RVSS14 to RVSS82

NOTE: For RVSS 14 41 starters without p.f. correction or fused disconnects, use CD RVSS 14 41.
00.0 (00.0) 00.0 (00.0) 4.0 (101.6) 18.0 (457.2) 34.0 38.0 (863.6) (965.2) CUTOUT: 8.0 (203.2) x 16.0 (406.4) THROUGH TOP

12.0 (304.8) 16.0 (406.4) 7.5 (190.5) 17.4 (441.9)

TOP VIEW

00.0 (00.0) 78.0 (1981.2)

TURN LATCHES (SLOT HEAD) TYP. 3 PLACES

ALTERNATE CABLE EXIT PANEL

Notes: 1. All dimensions in inches (mm). 2. Enclosure is NEMA 1. 3. Cable entrance and exit through 8.0 (203.2) x 18.0 (457.2) cutout on top. 4. Shown with optional mounting legs. 5. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

54.0 (1371.6)

R. SIDE VIEW
6.0 (152.4) 0.00 (00.0)

FRONT VIEW
0.00 (00.0) 38.0 (965.2) 16.0 (406.4) 00.0 (00.0)

Starter Model RVSS14 RVSS17 RVSS20 RVSS27 RVSS34 RVSS41 RVSS47 RVSS57 RVSS67 RVSS82

(All) Outgoing

Incoming to

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

(2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 300
(2) #6-350 (4) 1/0 750 (4) 1/0-750 (4) 1/0-750

Starter Model RVSS1

Incoming to

Incoming to

NOTE: Outgoing connection is NEMA 2-hole pattern 10

4 RVSS1 7 RVSS2 0 RVSS2 7 RVSS3 4 RVSS4 1 RVSS4 7 RVSS5 7 RVSS6 7 RVSS8 2

#6-350 #6-350 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 (3) #1/0-500 (3) #1/O-500 (4) #250-500 (4) #250-500

#6-350 #6-350 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 (2) #1/0-500 (2) #1/0-500 (4) #250-500 (4) #250-500

IOMM Starter-3

Figure 6, Free-Standing, Solid-state Starter Models RVSS47 to RVSS82

00.0 (00.0) 00.0 (00.0) 4.0 (101.6)

18.0 (457.2)

38.0 34.0 (863.6) (965.2) CABLE ACCESS: 8.0 (203.2) x 16.0 (406.4) THROUGH TOP

Starter Model No. RVSS47 RVSS57 RVSS67 RVSS82

12.0 (304.8) 16.0 (406.4) 16.7 (425.4) 7.5 (190.5) 17.4 (441.9)

TOP VIEW

Incoming Lug Size, to Standard Power Block (2) #6 - 350 (4) 1/0-750 (4) 1/0-750 (4) 1/0-750

Outgoing Connection Size 0.66 0.5 0.66 0.66

00.0 (00.0) 78.0 (1981.2)

TURN LATCHES (SLOT HEAD) TYP. 3 PLACES

ALTERNATE CABLE EXIT PANEL

Starter Model Size RVSS47 RVSS57 RVSS67 RVSS82

Breaker Size (Amps) 800 800 1200 1200

54.0 (1371.6)

Optional Incoming Incoming Lug Size Lug Size Circuit Disconnect Breaker Switch (3) #1/0-500 (2) #1/0-500 (3) #1/O-500 (2) #1/0-500 (4) #250-500 (4) #250-500 (4) #250-500 (4) #250-500

R. SIDE VIEW
6.0 (152.4) 0.00 (00.0)

FRONT VIEW
0.00 (00.0) 38.0 (965.2) 16.0 (406.4) 18.5 (469.9) 00.0 (00.0)

NOTES: 1. All dimensions are in inches (mm). 2. The location of factory-mounted starters is shown on the chiller unit dimension drawing. 3. The optional 6-inch feet are for free-standing starters only. 4. Weight of free-standing models is 600 lbs (272 kg) 5. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure. 6. For free-standing starters, the outgoing connections can be made through the top of the enclosure or through the upper-left rear area. 7. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

IOMM Starter-3

11

Figure 7, Free-Standing, Solid-state Starter Models RVSS96 to RVSS4K

TOP VIEW
72.0 (1828.8)

(2) REMOVABLE LIFTING EYES 25.3 (642.6) 25.3 (642.6) 24.0 (609.6)

FRONT VIEW

1.0 (25)

RIGHT SIDE VIEW

NOTES: 1. All dimensions are in inches (mm). 2. Cable entry and exit through the enclosure top. 3. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

Standard Starter Model No. Breaker Size (Amps) 1600 2000 2000 Incoming Lug Size, to Power Block #2 - 600 #2 - 600 #2 - 600 Incoming Lug Size Disconnect Switch (5) #300-600 (5) #300-600 (5) #300-600

Optional Incoming Lug Size Circuit Breaker (5) #300-600 (5) #300-600 (5) #300-600 Outgoing Connection Size 0.5 CSO CSO

RVSS96 RVSS2K RVSS4K

NOTE

12

90.0 (2286.0)

IOMM Starter-3

Figure 8, Unit-Mounted, Solid-state Starter Models RVST14 to RVST41

38.0 (965.2) CUTOUT: 4" x 10 15/16" THROUGH TOP WITH COVER (CUSTOMER MOTOR LEADS) 18.1 (458.5) 9.4 (240.5)

CUTOUT: 8" x 16" THROUGH TOP (CUSTOMER SUPPLIED "VAC")

1.5 (38.1) 16.0 (406.4)

Starter Model RVST14 RVST17 RVST20 RVST27 RVST34 RVST41

NOTES:

TOP VIEW

16.0 (406.4)

38.0 (965.2)

Incoming to Standard Power Block (2) #6-300 (2) #6-300 (2) #6-300 (2) #6-300 (2) #6-300 (2) #6-300

1. Outgoing lugs are factory-connected to the motor on

McQuay

unit-mounted starters.

48.0 (1219.2)

Optional Starter Model Size RVST14 RVST17 RVST20 RVST27 RVST34 RVST41 Breaker Size (Amps) 250 250 300 400 500 600 Incoming Lug Size Circuit Breaker #6-350 #6-350 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 Incoming Lug Size Disconnect Switch #6-350 #6-350 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500 (2) #3/0-500

L.SIDE VIEW FRONT VIEW

NOTES: 1. All dimensions are in inches (mm). 2. The location of factory-mounted starters is shown on the chiller unit dimension drawing. 3. Power factor correction capacitors cannot be mounted in this size enclosure. 4. Weight of free-standing model is 450 lbs (204 kg). 5. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure. 6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

IOMM Starter-3

40.0 (1016.0) 48.0 (1219.2)

13

Figure 9, Unit-Mounted, Solid-state Starter Models RVST47 to RVST82

Starter Model No. RVST47 RVST57 RVST67 RVST82

Incoming Lug Size, to Std. Power Block (2) #6 - 350 (4) 1/0-750 (4) 1/0-750 (4) 1/0-750

Outgoing Connection Size 0.66 0.5 0.66 0.66

Starter Model Size RVST47 RVST57 RVST67 RVST82

Breaker Size (Amps) 800 800 1200 1200

Optional Incoming Incoming Lug Size Lug Size Circuit Disconnect Breaker Switch (3) #1-500 (2) #1-500 (3) #1-500 (2) #1-500 (4) #250-500 (4) #250-500 (4) #250-500 (4) #250-500

NOTES: 1. All dimensions are in inches (mm). 2. The location of factory-mounted starters is shown on the chiller unit dimension drawing. 3. Weight of free-standing models is 600 lbs (272 kg) 4. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure. 5. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code

14

IOMM Starter-3

Low Voltage, Wye-Delta (D3DW & D3dt)

Figure 10, Models D3WD62 D3WD65, D3WT62 D3WT65 Wye-Delta, Closed Transition, Low Voltage Starter
Grounding Lug TB4 Terminal Board

Incoming Power Connection Opening to Motor Terminal Box for Factory-Mounted and Wired Starters Disconnect Switch

(6) Motor Leads

(3) Current Transformers (CTs) Disconnect Handle

Start & Run Contactors

Primary Control Power Fuses

Control Module with Digital Readout (Front) Y-Connection Starting Contactor Resistor Contactor for Closed Transition Transition Resistors Control Transformer Motor Control Relays (Behind)

NOTE: Models D3WD11 D3WD43 and D3WT11 D3WT43 are similar in appearance, but in a shorter cabinet.

IOMM Starter-3

15

Figure 11, Wye-Delta Starter, Free-Standing Models D3WD11 to D3WD43

NOTE: For starters equipped with optional power factor correction capacitors and/or fused disconnect switches, use Drawing D3WD11-65, which is 78 inches high rather than this 66-inch high unit.
38.0 (965.2) CUTOUT: 4" x 10 15/16" THROUGH TOP WITH COVER (CUSTOMER MOTOR LEADS) 18.1 (458.5) 9.4 (240.5) CUTOUT: 8" x 16" THROUGH TOP (CUSTOMER SUPPLIED "VAC")

Starter Model No. D3WD11 D3WD12 D3WD14 D3WD15 D3WD25 D3WD31 D3WD34 D3WD43

TOP VIEW

16.0 (406.4)

38.0 (965.2)

Incoming Lug Size, Std. Power Block (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 350

1.5 (38.1) 16.0 (406.4)

Outgoing Conn. Hole Size 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45

McQuay

48.0 (1219.2)

L.SIDE VIEW
18.0 (406.4)

Optional Breaker Incoming Incoming Starter Size Lug Size Lug Size Size (Amps) Circuit Disconnect Breaker Switch D3DW11 200 #6-350 #6-350 D3DW12 250 #6-350 #6-350 D3DW14 250 #6-350 #6-350 (2) #3/0D3DW15 300 #6-350 (2) #3/0(2)500 #3/0D3DW25 400 (2)500 #3/0(2)500 #3/0D3DW31 400 500 (2)500 #3/0(2) #3/0D3DW34 500 (2)500 #3/0(2)500 #3/0D3DW43 600 500 500

FRONT VIEW
(W/ OPTIONAL MOUNTING LEGS)

NOTES: 1. 2. 3. 4. 5. All dimensions are in inches (mm). Free-standing Models RSVT have optional 18-inch legs as shown in front view. Power factor correction capacitors cannot be mounted in this size enclosure. Weight of free-standing model is 450 lbs (204 kg). The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

16

58.0 (1473.2) 66.0 (1676.4)

IOMM Starter-3

Figure 12, Wye-Delta Starter, Free-Standing Models D3WD11 to D3WD65,

NOTE: For D3WD11-43 without p.f. correction or fused disconnects, use drawing D3DW11-43.

00.0 (00.0) 00.0 (00.0) 4.0 (101.6)

18.0 (457.2)

38.0 34.0 (863.6) (965.2) CABLE ACCESS: 8.0 (203.2) x 16.0 (406.4) THROUGH TOP

Starter Model No. D3WD11 D3WD12 D3WD14 D3WD15 D3WD25 D3WD31 D3WD34 D3WD43 D3WT62 D3WT65

12.0 (304.8) 16.0 (406.4) 16.7 (425.4) 7.5 (190.5) 17.4 (441.9)

TOP VIEW

00.0 (00.0) 78.0 (1981.2)

TURN LATCHES (SLOT HEAD) TYP. 3 PLACES

ALTERNATE CABLE EXIT PANEL

Incoming Lug Size, Std. Power Block (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 300 (2) #6 - 350 (2) #6 - 300 (2) #6 - 300 (2) #6 - 350 (4) #1/0(4)750 #1/0750

Outgoing Connection Hole Size 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45 0.45

54.0 (1371.6)

Starter Size D3DW11 D3DW12 D3DW14 D3DW15 D3DW25 D3DW31 D3DW34 D3DW43 D3DW62 D3DW65

R. SIDE VIEW
6.0 (152.4) 0.00 (00.0)

Optional Breaker Incoming Incoming Size Lug Size Lug Size (Amps) Circuit Disconnect Breaker Switch 200 #6-350 #6-350 250 #6-350 #6-350 250 #6-350 #6-350 (2) #3/0300 #6-350 (2)500 #3/0(2) #3/0400 (2)500 #3/0(2)500 #3/0400 (2)500 #3/0(2)500 #3/0500 (2)500 #3/0(2)500 #3/0600 500 500 800 (2) #1-500 (2) #1-500 1000 (2) #1-500 (2) #1-500

FRONT VIEW
0.00 (00.0) 38.0 (965.2) 16.0 (406.4) 18.5 (469.9) 00.0 (00.0)

NOTES: 1. Optional 6-inch feet can be ordered for free-standing starters. 2. Weight of free-standing unit is 600 lbs (272 kg). 3. Power factor correction capacitors up to 50 KVAR can be mounted internally. 4. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure. 5. The outgoing connections can be made through the top of the enclosure or the upper-left rear area. 6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

IOMM Starter-3

17

Figure 13, Wye-Delta Starter, Free-Standing Models D3WD62 to D3WD65

00.0 (00.0) 00.0 (00.0) 4.0 (101.6) 18.0 (457.2) 38.0 34.0 (863.6) (965.2) CABLE ACCESS: 8.0 (203.2) x 16.0 (406.4) THROUGH TOP

12.0 (304.8) 16.0 (406.4) 16.7 (425.4) 7.5 (190.5) 17.4 (441.9)

TOP VIEW

Starter Model No. D3WD62 D3WD65

00.0 (00.0) 78.0 (1981.2)

Incoming Lug Size, Std. Power Block (4) #1/0-750 (4) #1/0-750

Outgoing Conn. Hole Size 0.45 0.45

TURN LATCHES (SLOT HEAD) TYP. 3 PLACES

ALTERNATE CABLE EXIT PANEL

Starter Size

Optional Breaker Incoming Incoming Size Lug Size Lug Size (Amps) Disconnect Circuit Switch Breaker 800 1000 (2) #1-500 (2) #1-500 (2) #1-500 (2) #1-500

54.0 (1371.6)

D3DW62 D3DW65

R. SIDE VIEW
6.0 (152.4) 0.00 (00.0)

FRONT VIEW
0.00 (00.0) 38.0 (965.2) 16.0 (406.4) 18.5 (469.9) 00.0 (00.0)

NOTES: 1. Optional 6-inch feet can be ordered for free-standing starters. 2. Weight of free-standing unit is 600 lbs (272 kg). 3. Power factor correction capacitors up to 50 KVAR can be mounted internally. 4. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure. 5. The outgoing connections can be made through the top of the enclosure or through the upper-left rear area. 6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

18

IOMM Starter-3

Figure 14, Wye-Delta Starter, Free-Standing, Models D3WD86 to D3WD2K

TOP VIEW
72.0 (1828.8) (2) REMOVABLE LIFTING EYES

27.1 (687.1) 25.3 (642.6) 24.0 (609.6)

Incoming Outgoing Starter Lug Size, Conn. Model No. Std. Power Size Block D3WD86 #2 - 600 0.66 D3WD1K #2 - 600 0.66 D3WD2K #2 - 600 0.66

FRONT VIEW
6.0 (152)

65.9 (1673.9)

RIGHT SIDE VIEW

NOTES: 1. 2. 3. All dimensions in inches (mm) Cable entry and exit through the enclosure top. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

IOMM Starter-3

90.0 (2286.0)

HANDLE 3-PT LATCHING (PADLOCKABLE) MULTI-DOOR INTERLOCK

Standard Breaker Incoming Incoming Starter Size Lug Size Lug Size Size (Amps) Circuit Disconnect Breaker Switch (4) #250(4) #250D3DW86 1200 500 500 (5) #300(5) #300D3DW1K 1600 600 600 (5) #300(5) #300D3DW2K 2000 600 600

19

Figure 15, Wye-Delta Starter, Unit Mounted, Models D3WT11 to D3WT43

Starter Model No. D3WT11 D3WT12 D3WT14 D3WT15 D3WT25 D3WT31 D3WT34 D3WT43

Incoming Lug Size,Std. Power Block (2) #6 - 350 (2) #6 - 350 (2) #6 - 350 (2) #6 - 350 (2) #6 - 350 (2) #6 - 350 (2) #6 - 350 (2) #6 - 350

Standard Breaker Incoming Incoming Starter Size Lug Size Lug Size Size (Amps) Circuit Disconnect Switch Breaker D3DT11 200 #6-350 #6-350 D3DT12 250 #6-350 #6-350 D3DT14 250 #6-350 #6-350 (2) #3/0D3DT15 300 #6-350 500 (2) #3/0(2) #3/0D3DT25 400 500 500 (2) #3/0(2) #3/0D3DT31 400 500 500 (2) #3/0(2) #3/0D3DT34 500 500 500 (2) #3/0(2) #3/0-

NOTES: 1. All dimensions are in inches (mm). 2. Power factor correction capacitors cannot be mounted in this size enclosure. 3. Incoming power connection is through the 8 x 16 plate at the right rear corner. Remove plate prior to drilling any holes. 4. The starter location is shown on the chiller unit dimension drawing. 5. Outgoing lugs are factory-connected to the motor on unit-mounted starters. 6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

20

IOMM Starter-3

Figure 16, Wye-Delta Starter, Unit Mounted, Models D3WT62 to D3WT65

Starter Model No. D3WT62 D3WT65

Incoming Lug Size, Standard Power Block (4) #1/0-750 (4) #1/0-750

Optional Breaker Incoming Incoming Starter Size Lug Size Lug Size Size (Amps) Circuit Disconnect Switch Breaker D3DT62 800 (2) #1-500 (2) #1-500 D3DT65 1000 (2) #1-500 (2) #1-500

NOTES: 1. All dimensions are in inches (mm). 2. Power factor correction capacitors cannot be mounted in this size enclosure. 3. Incoming power connection is through the 8 x 16 plate at the right rear corner. Remove plate prior to drilling any holes. 4. The starter location is shown on the chiller unit dimension drawing. 5. Outgoing lugs are factory-connected to the motor on factory-mounted starters. 6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the units Technical Data Sheet to size any upstream protection devices required by local code.

IOMM Starter-3

21

Medium Voltage, Solid State (MVSS & HVSS)

Figure 17, Solid-state, Free-Standing Only, Medium Voltage, All Models MVSS 2300V to 4160V
3.0 (76.2)

24.0 (609.6)

30.0 (762.0) 2

21.0 (533.4)

8.0 (203.2)

VIEW FROM TOP

1

DISCONNECT SHIELD 400A DISCONNECT

FU2

FU3

R RATED FUSES

FU1

INLINE BYPASS CONTACTOR CONTACTOR

92.5 (2349.5)

2640:1 CT1,2,3

LANDING PAD ASSEMBLY

36.0 (914.4)

FRONT INTERIOR VIEW

NOTES: 1 2 3. 4. REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED. CABLE ENTRY/EXIT AREA. NO CUTOUT SUPPLIED. CUSTOMER TO CUT AS REQUIRED. ENCLOSURE COLOR: ANSI 61 GREY TIGHTEN BOLTS PER CHART BELOW STEEL BOLT TORQUE IN FOOT-POUNDS 1/4-20 5/16-18 3/8-16 1/2-13 5/8-11 5 5. 12 20 50 95

STARTER WEIGHT: APPOXIMATELY 1800LBS

6. Dimensions shown are for standard starters without options that can affect unit dimensions and weight. Consult the local McQuay sales office for information.

22

IOMM Starter-3

Figure 18, Solid-state, Free-Standing Only, Medium Voltage, All Models HVSS
3.0 (76.2) TYP.

5100V to 7200V

30.0 36.0 (914.4) (762.0) TYP.

2.0 (50.8) TYP.

8.0 (203.2) TYP.

VIEW FROM TOP

1 1

7.12KV 400A DISCONNECT DISCONNECT BARRIER

FU1

FU2

R RATED FUSING

92.5 (2349.5)

INLINE CONTACTOR

FU3

STACK ASSEMBLY SHIPPING SUPPORTS SEE CAUTION! NOTE

BYPASS CONTACTOR

LANDING PAD ASSEMBLY (T1, T2, T3) CUSTOMER LOAD SIDE CONNECTION CT'S 1-3, 2640:1

T1 XFMR

30.0 (762.0)

45.0 (1143.0)

FRONT INTERIOR VIEW

NOTES:

1 2 3. 4. 5. 6.

REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED. CABLE EXIT AREA. NO CUTOUT SUPPLIED. CUSTOMER TO CUT AS REQUIRED. ENCLOSURE COLOR: ANSI 61 GREY. TOTAL WEIGHT IS APPROXIMATELY 2400LBS. TYPICAL LAYOUT FOR EACH STARTER. TIGHTEN BOLTS PER CHART AT RIGHT. STEEL BOLT TORQUE IN FOOT-POUNDS 1/4-20 5/16-18 3/8-16 1/2-13 5/8-11 5 12 20 50 95

7. Dimensions shown are for standard starters without options that can affect unit dimensions and weight. Consult the local McQuay sales office for information.

IOMM Starter-3

23

Medium Voltage, Across-The-Line (MVAT & HVAT)

Figure 19, Across-the-Line, Medium Voltage Free-Standing Only Models MVAT12-24, MVAT 16-25, MVAT13-26 Model MVAT 36

NOTES: 1. 1, Removable lifting eyebolts. Plug holes if removed 2. 2, Cable entry/exit area. 3. 3, Alternate cable entry/exit, cut as required. 4. Color is ANSI 61 grey 5. Approximate weight is 1200 lbs.

24

IOMM Starter-3

Figure 20 Across-the-Line, Medium Voltage, Free-Standing Only Model HVAT27, 5100V to 7200V
2.00 3.00 8.00

24.00

LOW VOLTAGE DOOR IDENTIFICATION: 1.) RUN PILOT LIGHT (RED) 2.) FAULT PILOT LIGHT (AMBER) 3.) OFF PILOT LIGHT (GREEN) 4.) RUN BUTTON (RED) 5.) STOP BUTTON (GREEN)

VIEW FROM TOP

20.00 1 1 SIDE ACCESS AREA WITH COVER PLATE TYPICAL BOTH SIDES CUSTOMER LINE SIDE CONNECTIONS 4.50 1.00

8.00

VIEWING WINDOW

WARNING

ON

SWITCH MAY BE ENERGIZED BY BACKFEED

DISCONNECT
OFF LOCKOUT

2300 VAC

DISCONNECT SHIELD

MEDIUM VOLTAGE BARRIER

FU1

FU2

4 92.50

5 LOW VOLTAGE SECTION

FU3

1 2

"R" RATED FUSES

LOW VOLTAGE SECTION

M CONATACTOR 400A MEDIUM VOLTAGE SECTION

DANGER
HAZARDOUS VOLTAGE INSIDE

CT1, CT2, CT3 500:5 CTS

CT1, CT2, CT3 500:5 CTS CUSTOMER LOAD SIDE LANDING PADS SEE DETAIL "A T1 T3

2300 VAC

CUSTOMER LOAD SIDE LANDING PADS SEE DETAIL "A T1 XFMR

T2

T1 XFMR

24.00

30.00 3

FRONT VIEW
3.50 3.00

FRONT INTERIOR VIEW

32.00

RIGHT SIDE INTERIOR VIEW

.25

NOTES:

1 2

REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED. CABLE ENTRY/EXIT AREA. NO CUTOUT SUPPLIED. CUSTOMER TO CUT AS REQUIRED. MODEL BSR MVAT36 IS 36 INCHES WIDE. ENCLOSURE COLOR: ANSI 61 GREY APPROXIMATE WEIGHT: 1200 LBS

1.50

3.00 3

1.75 .63

3.00

4. 5.

0.50 THRU, (2 PLACES) FOR CUSTOMER CONNECTIONS

LANDING PAD DETAIL "A

MATERIAL: .25" THICK TIN PLATED COPPER

IOMM Starter-3

25

Field Power Wiring

Power wiring between the starter and the compressor motor terminals must be field supplied and installed on units with remote-mounted, free-standing starters. See the field wiring diagram on page 31. Wiring, fuse and wire size must be in accordance with the National Electric Code (NEC). Standard NEMA motor starters require modification to meet McQuay specifications. Refer to McQuay Specification 735999901 (latest revision).
!

CAUTION

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

Refer to Figure 23 on page 31 for power wiring connections. Power wiring to compressors must be in proper phase sequence. Motor rotation is set up for clockwise rotation facing the lead end with phase sequence of 1-2-3. Care must be taken that the proper phase sequence is carried through the starter to compressor. With the phase sequence of 1-2-3 and L1 connected to T1 and T6, L2 connected to T2 and T4, and L3 connected to T3 and T5, rotation is proper. See diagram in terminal box cover. The McQuay start-up technician will check the phase sequence. Note: Do not make final connections to motor terminals until wiring has been checked and approved by a McQuay technician.
!

CAUTION

Connections to terminals must be made with copper lugs and copper wire to avoid possible equipment damage. Under no circumstances should a compressor be brought up to speed until proper sequence and rotation have been established. Serious damage can result if the compressor starts in the wrong direction. Such damage is not covered by product warranty

General Wiring Practice

Wire groups

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

26

IOMM Starter-3

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

BEFORE APPLYING MAIN POWER

The starter has been fully tested before leaving the factory to help a rapid and problemfree start-up. Before applying power to the starter, consult the start-up checklist below. 1. Inspect starter and remove any foreign matter. 2. Inspect the starter for any shipping damage. 3. Ensure that all electrical connections are as per the system schematics supplied with the starter and/or connection diagrams. 4. Ensure that all connections are properly tightened. 5. Test L to T resistance of each phase and ensure that it is greater than 50 kohms. Reverse leads and test again. 6. Check that the gate to cathode resistance of each SCR is between 8 and 50 ohms. 7. Check the resistance of all power and motor leads to ground to ensure that there is no foreign matter present or damage to the insulation which can short one or more of the phases to ground. 8. Apply 120 Vac control voltage to the starter.

Medium Voltage, Solid State, Across-the-Line

Incoming and outgoing connections are NEMA 2-hole pattern, -inch, 1 -inch apart, as defined by NEMA Standard CC!-2 Bus Tabs per phase.

Compressor Motor Connections

Power wiring connections at the motor are spark plug type terminals with threaded copper bar, sized per the following table.
Type/Size Low Voltage to 750 A, to 575V Med. Voltage to 275 A, to 4160 V Hi Voltage to 275 A, to 7200 V Comp. Size CE 063-126 CE 063-126 CE 063-126 Terminal Size 0.635-11 UNC-2A, 1.88 in. long 0.375-16 UNC-2A, 0.97 in. long 0.375-16 UNC-2A, 1.00 in. long

IOMM Starter-3

27

Field Control Wiring

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

General Practice
Signal wiring refers to wires connected to the control terminals that are low voltage, below 15V. Shielded wire is required to prevent electrical noise interference from causing improper operation or nuisance trips. Signal wire should be rated for at least 300V. Keep signal wire as far away as possible from control and power wiring.

Control wiring refers to wires connected to the control terminal strip that carry 24V to 220V. Use only UL or CSA recognized wire. Use copper wire rated for 60/75C.

Control Power Wiring

Control power wiring for starters covered in this manual is shown on Figure 23 on page 31. Low voltage starters may have additional control wiring as shown on Figure 22 if the optional full metering package is ordered with the unit. The control circuit on the McQuay centrifugal packaged chiller is designed for 115-volts. Control power can be supplied from three different sources: If the unit is supplied with a factory-mounted starter, the control circuit power supply is factory-wired from a transformer located in the starter. A free-standing starter furnished by McQuay, or by the customer to McQuay specifications, will have a control transformer in it and requires field wiring to terminals in the compressor terminal box. Power can be supplied from a separate circuit and fused at 20 amps inductive load. The control circuit disconnect switch must be tagged to prevent current interruption. Other than for service work, the switch is to remain on at all times in order to keep oil heaters operative and prevent refrigerant from diluting the oil.
!

DANGER

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

28

IOMM Starter-3

Separate Power Source

Chiller control power usually comes from a control transformer located in the starter and factory or field wired to the chiller control panel. In the event a separate transformer supplies control voltage, it must be rated at 3 KVA, with an inrush rating of 12 KVA minimum at 80% power factor and 95% secondary voltage. For control wire sizing, refer to NEC. Articles 215 and 310. In the absence of complete information to permit calculations, the voltage drop should be physically measured. Table 2, Control Power Line Sizing
Maximum Length, ft (m) Wire Size (AWG) Maximum Length, ft (m) Wire Size (AWG) 6 4 3 0 (0) to 50 (15.2) 12 120 (36.6) to 200 (61.0) 50 (15.2) to 75 (22.9) 10 200 (61.0) to 275 (83.8) 75 (22.9) to 120 (36.6) 8 275 (83.8) to 350 (106.7) Notes: 1. Maximum length is the distance a conductor will traverse between the control power source and the unit control panel. 2. Panel terminal connectors will accommodate up to number 10 AWG wire. Larger conductors will require an intermediate junction box.

The Unit On/Off switch located in the Unit Control Panel should be turned to the "Off" position any time compressor operation is not desired.

Low Voltage Starters

Control wiring for low voltage starters is per the wiring diagram on page 31. If the optional Full Metering Display has been ordered, the following section will apply. Wiring for Optional Remote D3 Display Figure 21, Starter Panel Remote mounted low voltage wye-delta and solid state starters require field wiring to activate the optional full metering display on the chillers operator interface panel. The wiring is from the D3 board in the starter to the compressor controller and to the bias block; both located in the compressor control panel. See Figure 22, Field Wiring for Optional D3 . The location of the connections in the starter are shown to the right.

Wiring Connection on Starter for Optional Display

IOMM Starter-3

29

Figure 22, Field Wiring for Optional D3 Communication

NOTES. 1. See Figure 3 for Starter connection location. 2. The compressor controller serial card location is in the lower-center of the compressor controller, under the operating buttons. 3. The bias block is located on the rail, just to the left of the compressor controller. 4. Note that the connections are (-) to (-), (+) to (+), and SCOM to GND, with a shield connection on the starter terminal board.

Medium/high Voltage Starters

Control wiring for medium and high voltage solid state and across-the-line starters is per the wiring diagram on page 31.

30

IOMM Starter-3

Figure 23, Control and Power Field Wiring

MICROTECH CONTROL BOX TERMINALS
(115V) PE 85
POWER

(24V)

GND

54

* NOTE 7
NEUTRAL

86 80 74 86 86 70 55
H O

* NOTE 10 * COOLING TOWER FOURTH STAGE STARTER

H O

C4
A

EP2

* NOTE 10
H

79 73
O

* COOLING TOWER THIRD STAGE STARTER

O A

C3

78 77

EP1

* NOTE 10
H

* COOLING TOWER SECONDH STAGE STARTER

76
O

C2

75

H O

* NOTE 10
H

CP2 T3-S EF CF

* COOLING TOWER FIRST STAGE STARTER

O A

C1

COMMON

81 82(NO) 83(NC) A

ALARM RELAY (NOTE 4)

POWER

84

52

H O

COOLING TOWER BYPASS VALVE COOLING TOWER VFD

1-10 VDC 1-10 VDC

71 71 53

CP1

L1

L2

L3

MICROTECH COMPRESSOR CONTROL BOX TERMINALS CTB1

NOTE 2 GND
CP1 CP2 23(5A)

STARTER LOAD SIDE TERMINBALS VFD

U V W

- FOR DC VOLTAGE AND 4-20 MA CONNECTIONS (SEE NOTE 3) - FOR DETAILS OF CONTROL REFER TO UNIT CONTROL SCHEMATIC 330342101 - COMPRESSOR CONTROL SCHEMATIC 330342201 - LEGEND: 330343001

115 VAC
T1 PE L1 L2 23 24 25 T1 T2 T3 T4 T5 T6 T6 T2 T4 T3 T5

COMPRESSOR TERMINALS STARTER LOAD SIDE TERMINBALS WYE-DELTA

T1 T2 T3 T4 T5 T6

COMPRESSOR MOTOR STARTER

(NOTE 1)

24(5) 25

COMPRESSOR TERMINALS
1 2 3 4 6 11 12 22 1 2 3 4 11 11 12 22 T1 T6 T2 T4 T3 T5

* FIELD SUPPLIED ITEM

NOTE 12

STARTER LOAD SIDE TERMINBALS SOLID STATE

T1 T2 T3

COMPRESSOR TERMINALS STARTER LOAD SIDE TERMINBALS MEDIUM AND HIGH VOLTAGE
T1 T2 T3

-LOAD-

NOTE 2

LESS THAN 30V OR 24VAC

T1

T2

T3

COMPRESSOR TERMINALS

330387901-0A

See notes on the following page.

IOMM Starter-3

31

NOTES for Wiring Diagram

1. Compressor motor starters are either factory-mounted and wired, or shipped separate for fieldmounting and wiring. If provided by others, starters must comply with McQuay specification 7359999 Rev 29 (2007). All line and load side power conductors must be copper. If starters are freestanding, then field control wiring between the starter and the control panel is required. Minimum wire size for 115 Vac is 12 GA for a maximum length of 50 feet. If greater than 50 feet, refer to McQuay for recommended wire size minimum. Wire size for 24 Vac is 18 GA. All wiring to be installed as NEC Class 1 wiring system and must be made with copper wire and copper lugs only. All 24 Vac wiring must be run in separate conduit from 115 Vac wiring. Main power wiring between starter and motor terminal is factory-installed when chillers are supplied with unit-mounted starters. For wye-delta, and solid state starters connected to six (6) terminal motors (low voltage), the conductors between the starter and motor carry phase current and wire size selection is based on 58 percent of the motor rated load amperes (RLA). Wiring of free-standing starters must be in accordance with the NEC and connection to the compressor motor terminals shall be made with copper wire and copper lugs only. Main power wiring between the starter and motor terminals is factory-installed when chillers are supplied with unit-mounted starters. The Full Metering option will require some field wiring when free-standing starters are used, as shown in Figure 22 on page 30.

2.

3.

4.

5.

6. Customer furnished 24 or 120 Vac power for alarm relay coil can be connected between UTB1 terminals 84 power and 51 neutral of the control panel. For normally open contacts, wire between 82 & 81. For normally closed contacts, wire between 83 & 81. The alarm is operator programmable. The maximum rating of the alarm relay coil is 25 VA. 7. Remote on/off control of unit can be accomplished by installing a set of dry contacts between terminals 70 and 54. 8. Evaporator and condenser flow switches are required and must be wired as shown. If field supplied pressure differential switches are used then these must be installed across the vessel and not the pump. 9. Customer supplied 115 Vac, 20 amp power for optional evaporator and condenser water pump control power and tower fans is supplied to unit control terminals (UTBI) 85 power / 86 neutral, PE equipment ground. 10. Optional customer supplied 115 Vac, 25 VA maximum coil rated chilled water pump relay (EP 1 & 2) can be wired as shown. This option will cycle the chilled water pump in response to building load. 11. The condenser water pump must cycle with the unit. A customer supplied 115 Vac 25 VA maximum coil rated condenser water pump relay (CP1 & 2) is to be wired as shown. 12. Optional customer supplied 115 Vac, 25 VA maximum coil rated cooling tower fan relays (CL C4) can be wired as shown. This option will cycle the cooling tower fans in order to maintain unit head pressure. 13. Auxiliary 24 Vac rated contacts in both the chilled water and condenser water pump starters must be wired as shown. 14. For VFD, Wye-Delta, and solid state starters connected to six (6) terminal motors, the conductors between the starter and motor carry phase current and their ampacity must be based on 58 percent of the motor rated load amperes (RLA) times 1.25. Wiring of free-standing starter must be in accordance with the NEC and connection to the compressor motor terminals shall be made with copper wire and copper lugs only. Main power wiring between the starter and motor terminals is factory-installed when chillers are supplied with unit-mounted starters.

32

IOMM Starter-3

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

Low Voltage Solid State (RVSS)

LED Display
Located on the starter control board View parameters, messages and faults. Shows software revision on power up.

Programming
Press PARAM to enter the menu and then UP or DOWN to reach the desired parameter. Press ENTER to show the present value of the parameter. Press UP or DOWN to change the parameter value. Press ENTER to store the new value or PARAM to abandon the change.

Quick Meters
Press DOWN to display the motor thermal overload content. Press UP to display the incoming line phase order. Press ENTER to display the status meter.

Fault Log
Select P32 and press ENTER. The most recent fault will be displayed as xFyy where x will be 1 to indicate the most recent fault is being displayed and yy is the fault code. Press DOWN to view older faults. Up to 9 faults may be stored in the log.

Resetting a Fault
Press RESET to reset from a fault.Resetting Parameters Press and hold PARAM and ENTER on power up to reset parameters to default values.

IOMM Starter-3

33

Emergency Thermal Reset

Press RESET and DOWN to perform an emergency thermal reset.

Messages (RVSS)
No Line Ready Accelerating Up to Speed Run Done with ramp but not yet Up to Speed. Decelerating Overload Alarm The motor overload level is between 90% and 100%. Overload Fault The motor overload level has reached 100%. Overload Lockout A start is not allowed until the motor overload level cools below 60%. Control Power Lockout A start is not allowed because the control power is too low. xxx xxx = overload content. Press DOWN to toggle. xx xx = Alarm code. If the condition persists, a fault will occur. xx xx = Fault code. Press RESET to clear. Instantaneous Overcurrent Press RESET to clear. Default Flashes when parameter defaults are loaded.

Default Meter Display (P13) (RVSS)

0: 1: 2: 3: 4: 5: 6: 0: 1: 2: 3: 4: 5: Status Ave RMS Current L1 RMS Current L2 RMS Current L3 RMS Current Current Imbalance % Ground Fault Current OFF (no output) Ave Current (0 200% RLA) Ave Current (0 800% RLA) Ave Voltage (0 750VAC) Thermal Overload% KW (0 - 10KW) 7: 8: 9: 10: 11: 12: 13: 6: 7: 8: 9: 10: 11: Ave L-L Voltage RMS L1-L2 Voltage RMS L2-L3 Voltage RMS L3-L1 Voltage RMS Overload % PF KW KW (0 100KW) KW (0 1MW) KW (0 10MW) Analog Input Output Voltage (% of FV) Calibrate (full 100% output) 14: 15: 16: 17: 18: 19: KVA KWh MWh Phase Rotation Line Frequency Analog Input

Analog Output Function (P28) (RVSS)

CT Burden Switch Settings (P1 and P23) (RVSS)

864:1 CTs 24 to 42 42 to 50 50 to 108 108 to 190 FLA in Amps 2640:1 CTs 5760:1 CTs 73 to128 160 to 280 128 to 151 280 to 330 151 to 330 330 to 720 330 to 590 720 to 1280 8000:1 CTs 223 to 390 390 to 465 465 to 1000 1000 to 1800 Setting SW1 SW2 Off Off Off On On Off On On

Parameters (RVSS)
DESCRIPTION P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 Motor FLA Motor RLA Motor Service Factor Motor Overload Class Initial Motor Current Maximum Motor Current Ramp Time UTS Time Stop Mode Decel Begin Level Values 1 to 9999 Amps 1 to 9999 Amps 1.00 to 1.99 OFF, 1 to 40 50 to 400 %FLA 100 to 800 %FLA 0 to 300 seconds 1 to 900 seconds CoS: Coast dcL: Voltage Decel 100 to 0 %Volts DEFAULT 10 10 1.08 10 250 300 10 15 CoS 40 SET TO:

Continued on next page.

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IOMM Starter-3

DESCRIPTION P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24 P25 P26 P27 P28 P29 P30 P31 P32 Decel End Level Decel Time Default Meter Display Overcurrent Trip Level Overcurrent Trip Delay Time Rated RMS Voltage Over Voltage Trip Level Under Voltage Trip Level Over/Under Voltage Delay Time Current Imbalance Trip Level Controlled Fault Stop Auto Fault Reset Time CT Ratio Control Source Modbus Address Modbus Baud Rate Modbus Timeout Analog Output Function Analog Output Span Analog Output Offset Passcode Fault Log

Values 50 to 0 %Volts 1 to 180 seconds 0 to 19 OFF, 50 to 800 %RLA 0.1 to 90.0 seconds 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 575, 600, 660, 1000 Volts OFF, 1 to 40 % rated Volts OFF, 1 to 40 % rated Volts 0.1 to 90.0 seconds 5 to 40 % OFF, On OFF, 1 to 120 seconds 72, 96, 144, 288, 864, 2640, 2880, 5760, 8000 TEr: Terminal NEt: Network 1 to 247 1.2, 2.4, 4.8, 9.6, 19.2 Kbps OFF, 1 to 120 seconds 0 to 11 1 to 125 % 0 to 99 % 0 to 9999 xFyy

DEFAULT 20 15 1 OFF 2.0 480 10 10 1.0 10 OFF 60 2640 tEr 1 19.2 3 1 100 0

SET TO:

Fault/Alarm Codes (RVSS)

Description 00 01 02 10 12 13 15 21 22 23 24 25 26 27 28 30 31 37 38 39 40 41 47 48 50 51 52 No fault UTS Time Limit Expired Motor Thermal Overload Trip Phase Rotation Error, not ABC Low Line Frequency High Line Frequency Input power not three phase Low Line L1-L2 Voltage Low Line L2-L3 Voltage Low Line L3-L1 Voltage High Line L1-L2 Voltage High Line L2-L3 Voltage High Line L3-L1 Voltage Phase Loss No Line Voltage I.O.C. (Instantaneous Overcurrent) Overcurrent Current Imbalance Ground Fault No Current at Run Shorted / Open SCR Current While Stopped Stack Protection Fault Bypass Contactor Fault (on STOP input) Control Power Low Current Sensor Offset Error Burden Switch Error Controlled Stop Y Y N N N N Y Y Y Y Y Y N N N Y Y Y N N N N Y N N Auto Reset Y N Y Y Y Y Y Y Y Y Y Y Y Y N N Y N Y N N Y N Y N N

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Description 60 61 71 82 94 95 96 97 98 99 Thermistor Trip (on DIN#1) Stack OT Switch Trip (on DIN#2) Analog Input Trip Modbus Timeout CPU Error Software Fault CPU Error Parameter Storage Fault CPU Error Illegal Instruction Trap CPU Error Software Watchdog Fault CPU Error Spurious Interrupt CPU Error Program Storage Fault

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

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

If a fault occurs that has a Y in the Controlled Stop column, and P21 (Controlled Fault Stop) is set to On, and P9 (Stop Mode) is set to dcL, then the starter will perform a voltage decel to stop. Otherwise it will coast to stop. If a fault occurs that has a Y in the Auto Reset column, and P22 (Auto Fault Reset Time) is set to some value other than OFF, then the fault will automatically be cleared after the time specified by P22.

Low Voltage Wye-Delta (D3YD

Operation

LED Display View parameters, messages and faults. Shows software revision on power up. Press PARAM to enter the menu and then UP or DOWN to reach the desired parameter. Press ENTER to show the present value of the parameter. Press UP or DOWN to change the parameter value. Press ENTER to store the new value or PARAM to abandon the change. Press DOWN to display the motor thermal overload content. Press UP to display the incoming line phase order. Press ENTER to display the status meter. Select P24 and press ENTER. The most recent fault will be displayed as xFyy where x will be 1 to indicate the most recent fault is being displayed and yy is the fault code. Press DOWN to view older faults. Up to 9 faults may be stored in the log. Press RESET to reset from a fault.

Programming

Quick Meters

Fault Log

Resetting a Fault

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Resetting Parameters

Press and hold PARAM and ENTER on power up to reset parameters to default values. Press RESET and DOWN to perform an emergency thermal reset.
No Line Ready Running in wye mode. Running in delta mode. Overload Alarm The motor overload level is between 90% and 100%. Overload Fault The motor overload level has reached 100%. Overload Lockout A start is not allowed until the motor overload level cools below 60%. Control Power Lockout A start is not allowed because the control power is too low. xxx xxx = overload content. Press DOWN to toggle. xx xx = Alarm code. If the condition persists, a fault will occur. xx xx = Fault code. Press RESET to clear. Instantaneous Overcurrent Press RESET to clear. Default Flashes when parameter defaults are loaded.

Emergency Thermal Reset

Messages (D3YD)

Default Meter Display (P5) (D3YD)

0: 1: 2: 3: 4: 5: 6: Status Ave RMS Current L1 RMS Current L2 RMS Current L3 RMS Current Current Imbalance % Ground Fault Current 7: 8: 9: 10: 11: 12: 13: Ave L-L Voltage RMS L1-L2 Voltage RMS L2-L3 Voltage RMS L3-L1 Voltage RMS Overload % PF KW 14: 15: 16: 17: 18: 19: KVA KWh MWh Phase Rotation Line Frequency Analog Input

Analog Output Function (P20) (D3YD)

0: 1: 2: 3: 4: 5: OFF (no output) Ave Current (0 200% RLA) Ave Current (0 800% RLA) Ave Voltage (0 750VAC) Thermal Overload% KW (0 - 10KW) 6: 7: 8: 9: 10: 11: KW (0 100KW) KW (0 1MW) KW (0 10MW) Analog Input Reserved Calibrate (full 100% output)

CT Burden Switch Settings (P1 and P15) (D3YD)

864:1 CTs 24 to 42 42 to 50 50 to 108 108 to 190 RLA in Amps 2640:1 CTs 5760:1 CTs 73 to 128 160 to 280 128 to 151 280 to 330 151 to 330 330 to 720 330 to 590 720 to 1280 8000:1 CTs 223 to 390 390 to 465 465 to 1000 1000 to 1800 Setting SW1 SW2 Off Off Off On On Off On On

Parameters (D3YD)
P1 P2 P3 P4 P5 DESCRIPTION Motor RLA Motor Service Factor Motor Overload Class Transition Time Default Meter Display Values 1 to 9999 Amps 1.00 to 1.99 OFF, 1 to 40 1 to 30 seconds 0 to 19 DEFAULT 1 1.08 10 10 0

Continued on next page.

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P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24

DESCRIPTION Sequence Complete Delay Time Overcurrent Trip Level Overcurrent Trip Delay Time Rated RMS Voltage Over Voltage Trip Level Under Voltage Trip Level Over/Under Voltage Delay Time Current Imbalance Trip Level Auto Fault Reset Time CT Ratio Control Source Modbus Address Modbus Baud Rate Modbus Timeout Analog Output Function Analog Output Span Analog Output Offset Passcode Fault Log

Values 0.1 to 5.0 seconds OFF, 50 to 800 %RLA 0.1 to 90.0 seconds 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 575, 600, 660, 1000 Volts OFF, 1 to 40 % rated Volts OFF, 1 to 40 % rated Volts 0.1 to 90.0 seconds 5 to 40 % OFF, 1 to 120 seconds 72, 96, 144, 288, 864, 2640, 2880, 5760, 8000 TEr: Terminal NEt: Network 1 to 247 1.2, 2.4, 4.8, 9.6, 19.2 Kbps OFF, 1 to 120 seconds 0 to 11 1 to 125 % 0 to 99 % 0 to 9999 xFyy

DEFAULT 2.0 OFF 2.0 480 10 15 1.0 20 60 2640 tEr 2 19.2 3 1 100 0

Fault/Alarm Codes (D3YD)

Description 00 02 10 12 13 15 21 22 23 24 25 26 27 28 30 31 37 38 39 40 41 48 50 51 No fault Motor Thermal Overload Trip Phase Rotation Error, not ABC Low Line Frequency High Line Frequency Input power not three phase Low Line L1-L2 Voltage Low Line L2-L3 Voltage Low Line L3-L1 Voltage High Line L1-L2 Voltage High Line L2-L3 Voltage High Line L3-L1 Voltage Phase Loss No Line Voltage I.O.C. (Instantaneous Overcurrent) Overcurrent Current Imbalance Ground Fault No Current at Run Open Line or Motor Lead Current While Stopped 2M Feedback Fault (on DIN#2) Control Power Low Current Sensor Offset Error Auto Reset N Y Y Y Y Y Y Y Y Y Y Y Y N N Y N Y N N N Y N

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Description 52 60 71 82 94 95 96 97 98 99 Burden Switch Error Thermistor Trip (on DIN#1) Analog Input Trip Modbus Timeout CPU Error Software Fault CPU Error Parameter Storage Fault CPU Error Illegal Instruction Trap CPU Error Software Watchdog Fault CPU Error Spurious Interrupt CPU Error Program Storage Fault

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

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

Medium Voltage, Solid State (MVSS, HVSS)

Quick Start Motor FLA
Parameter Description

The motor FLA parameter must be set to the full load amps of the motor connected to the starter for the starter to function correctly. NOTE: The starter uses the entered motor FLA for every current based calculation. If the motor FLA is not entered correctly, the current ramp profile and many of the starters advanced protection features will not function properly.
Parameter Values

The motor FLA parameter is adjustable from 1 to 1200 amps in 1-amp increments.
Parameter Default

The default value for the motor FLA is 1 amp.

Serv. Fact (Service Factor)

Description

The service factor parameter should be set to the service factor of the motor. The service factor is used for the overload calculations. The service factor is factory set, will be checked by the start-up technician and should not require further adjustment. If the service factor of the motor is not known, then the service factor should be set to 1.08.
Values

The service factor can be set from 1.00 to 1.99, in 0.01 increments. NOTE: The NEC (National Electrical Code) does not allow the service factor to be set above 1.40. Check with other local electrical codes for their requirements.
Default

The default value for the service factor is 1.08.

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Start Mode
Description

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

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

Default

The default value for the Start Mode is Curr.

Stop Mode
Description

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

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

Default

The default value for the Stop Mode is Coas.

Int. Curr. (initial current)

Description

The initial current parameter is set as a percentage of the motor FLA parameter setting. The initial current parameter sets the current that will initially reach the motor when a start is commanded. If the motor does not rotate within a few seconds after a start command, the initial current should be increased. If the motor takes off too quickly after a start command, the initial current should be decreased. The initial current must be set to a value that is lower than the maximum current parameter setting. A typical setting for the initial current parameter is from 50% to 175%.
Values

The initial current is adjustable from 50% to 400% in 1% intervals.

Default

The default value for the initial current is 100%.

Max. Curr. (maximum current)

Description

The maximum current parameter is set as a percentage of the motor FLA parameter setting. The maximum current parameter performs two functions. It sets the current for the end of the ramp profile and sets the maximum current that is allowed to reach the motor while the motor is being started. If the ramp time expires before the motor has reached full speed, the starter will hold the current at the maximum current level until the stall time expires, the motor reaches full speed, or the overload trips. Typically, the maximum current is set to 600% unless the power system or load dictates the setting of a lower maximum current.
Values

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

40 IOMM Starter-3

Default

The default value for the maximum current is 600%.

Ramp Time
Description

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

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

Default

The default value for the ramp time is 15 seconds.

Overload
Default

The default value for the overload parameter is 10.

Phase Order
Description

The line phasing parameter sets the phase sensitivity of the starter. This can be used to protect the motor from a possible change in the incoming phase sequence. If the incoming phase sequence does not match the set phase rotation, the starter will display phs err while stopped and will fault if a start is attempted.
Values

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

The default value for the phase sensitivity parameter is ABC.

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Operation, Low Voltage Starters, 200 600 Volts

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

Viewing Data
The information in this section applies to low voltage, solid start and wye-delta starters, with the exceptions noted at the end of the section beginning on page 51. Starter information is available on the starter-mounted LED as explained beginning on page 45. If the optional Full Meter Display (available only on low voltage starters) is ordered with the unit, power information will also be available on the chillers operator interface touchscreen, as explained below. Figure 24, Optional Starter View Screen

The ability to view the starters power characteristics and to set starter setpoints on the operator interface screen is an optional extra available at the time of purchase. If the optional Full Meter Display is supplied on the unit, the POWER button (or STARTER in some software versions) will be visible on the upper left side of the VIEW screen as shown above. Pressing this button will open the screen shown in Figure 25 in the blank area to the right of the screen shown above.

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Figure 25, Expanded Starter View Screen The screen shown to the right will be superimposed on the right side of the VIEW screen shown in Figure 24 when the optional Full Meter Display is included with the unit. If the Full Meter Display package is not ordered, only the Percent Unit RLA amps will appear on the Home screen. This Starter/Power screen will remain visible until another display button; such as STATE, I/O, etc, is selected.

The option will also provide a starter setpoint screen as in Figure 26. Without this option, the setpoints are made on the starter keypad.

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Figure 26, Optional Starter Setpoint Screen

Table 3, Starter Setpoints

Description Ground Fault Current Trip Ground Fault Enable Maximum Current Unbalance Starter Ramp Time Maximum Starter Current Initial Starter Current Rated load Amps Full Load Amps 1. 2. 3. No. 8 7 6 5 4 3 2 1 Default 1% OFF 10% 15 sec. 600% 100% 1A 1A Range 1 to 100% RLA On or OFF 5% to 40% 0 to 30 seconds 100% to 800% of FLA (SP1) 50% to 400% of FLA (SP1) Factory set at design conditions Factory set to motor max current rating Password M M T T T T T T Comments Sets the value for ground current above which the compressor will be shut down Turns the ground fault option on or off Sets the value for current unbalance above which the compressor will be shut down Sets the time the starter ramps up the motor current Sets the maximum current when the compressor starts Sets the initial current when the compressor starts Value that gives the 100% RLA value and used for motor protection Value used to compute SP3 and SP4

The setpoints shown above are for solid state starters. Other types of starters will have slightly different setpoints. Units without the starter display option have the setpoints set in the starter itself. Do not change these setpoints after McQuay startup. Do not remove the D3 control wiring. If accidentally disconnected, contact McQuay service.

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Standard Starter Keypad and Display

When the optional full metering display is not ordered, the LED display located in the starter provides information on starter operation and programming. The 4-digit, 7-segment display shows starter meter outputs and programming data. Special symbols provide further information about the starter operation (see the following section). Figure 27, Starter-mounted LED
Reset Key
RESET

LED Display

PARA M

DOW N

UP

ENTER

Operating Keys

The LED display and keypad is used to: 1. 2. 3. 4. Perform operations View and set parameters (setpoints) View operating messages View faults and alarms

Special Messages Displayed

The keypads display may show the following special information under certain conditions. Table 4, LED Special Characters Displayed
No Line Ready Accelerating or Kicking Up to Speed Run Done with Accel ramp but not yet Up to Speed. Decelerating Motor Overload Alarm The motor overload level is between 90% and 100%. Overload Fault The motor overload level has reached 100%. Overload Lockout A start is not allowed until the motor overload level cools below 60%. Control Power Lockout A start is not allowed because the control power is too low. Lock out State xx xxx xx xx Phase order meter showing ABC Phase order meter showing CBA Phase order meter showing Single Phase xxx = overload content. xx = Parameter code. xx = Alarm code. If the condition persists, a fault will occur. xx = Fault code. Instantaneous Overcurrent Default Flashes when parameter defaults are loaded. Energy Saver In reflash mode In reflash mode, programming In reflash mode, verifying In reflash mode, complete

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Display Operation
LED Display
View parameters, messages and faults. Shows software revision on power up.

Fault Log
Press PARAM, Select P24 and press ENTER. The most recent fault will be displayed as xFyy where x will be 1 to indicate the most recent fault is being displayed and yy is the fault code. Press DOWN to view older faults. Up to 9 faults may be stored in the log.

Programming
Press PARAM to enter the menu and then UP or DOWN to reach the desired parameter. Press ENTER to show the present value of the parameter. Press UP or DOWN to change the parameter value. Press ENTER to store the new value or PARAM to abandon the change.

Resetting a Fault
First correct the cause of the fault. Then press RESET to reset from a fault. Press and hold PARAM and ENTER on power up to reset parameters to default values. Press RESET and DOWN to perform an emergency thermal reset.

Quick Meters
Press DOWN to display the motor thermal overload content. Press UP to display the incoming line phase order. Press ENTER to display the status meter.

Resetting Parameters

Emergency Thermal Reset

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

Changing Parameter Values

Parameter change mode can be entered by: At the default meter display, press the PARAM key to enter parameter mode. Use the UP and DOWN keys to scroll through the available parameters. The value of the parameter can be viewed by pressing the ENTER key. When viewing the parameter value, the parameter can be changed by using the UP and DOWN keys. 5. To store the new value, press the ENTER key. When the ENTER key is pressed the value will be saved and the display will go back to parameter # P_. To exit parameter change mode without saving the new parameter value either: 1. 2. 3. 4. 1. Press the PARAM key to return to the parameter number display. 2. Wait 60 seconds and the display will return to the default meter display. The starter setpoint parameters are factory set and subsequently reviewed during commissioning by the McQuay startup technician. They should not be changed unless authorized by McQuay. The programming procedure is explained above and the following table shows the range of values and defaults. Table 5, Setpoints, Wye-Delta Starter
P1 P2 P3 P4 P5 P6 P7 Description Motor RLA Motor Service Factor Motor Overload Class Transition Time Default Meter Display Sequence Complete Delay Time Overcurrent Trip Level Continued on next page. Values 1 to 9999 Amps 1.00 to 1.99 OFF, 1 to 40 1 to 30 seconds 0 to 19 0.1 to 5.0 seconds OFF, 50 to 800 %RLA Default 1 1.08 10 10 0 2.0 OFF

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P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24

Description Overcurrent Trip Delay Time Rated RMS Voltage Over Voltage Trip Level Under Voltage Trip Level Over/Under Voltage Delay Time Current Imbalance Trip Level Auto Fault Reset Time CT Ratio Control Source Modbus Address Modbus Baud Rate Modbus Timeout Analog Output Function Analog Output Span Analog Output Offset Passcode (See Note) Fault Log

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

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

Table 6, Setpoints, Solid State Starter

P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P23 P24 P25 Description Motor FLA Motor RLA Motor Service Factor Motor Overload Class Initial Motor Current Maximum Motor Current Ramp Time UTS Time (Up To Speed) Stop Mode Decel Begin Level Decel End Level Decel Time Default Meter Display Overcurrent Trip Level Overcurrent Trip Delay Time Rated RMS Voltage Over Voltage Trip Level Under Voltage Trip Level Over/Under Voltage Delay Time Current Imbalance Trip Level Controlled Fault Stop Auto Fault Reset Time CT Ratio Control Source Modbus Address Continued on next page. Values 1 to 9999 Amps 1 to 9999 Amps 1.00 to 1.99 OFF, 1 to 40 50 to 400 %FLA 100 to 800 %FLA 0 to 300 seconds 1 to 900 seconds CoS: Coast dcL: Voltage Decel 100 to 0 %Volts 50 to 0 %Volts 1 to 180 seconds 0 to 19 OFF, 50 to 800 %RLA 0.1 to 90.0 seconds 208, 220, 230, 240, 380, 415, 440, 460, 480, 575 Volts OFF, 1 to 40 % rated Volts OFF, 1 to 40 % rated Volts 0.1 to 90.0 seconds 5 to 40 % OFF, On OFF, 1 to 120 seconds 72, 96, 144, 288, 864, 2640, 2880, 5760, 8000 Ter: Terminal, Net: Network 1 to 247 Default 10 10 1.08 10 100 600 15 30 CoS 40 20 15 0 OFF 2.0 480 10 15 1.0 35 OFF 60 2640 tEr 2

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P26 P27 P28 P29 P30 P31 P32

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

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

Default 19.2 3 1 100 0 Disabled

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

Messages
Setpoint P5 for Wye-Delta or P13 for solid state can be set to establish what message is shown on the LED. Selecting meter display 0 (which is the default) will display the active status message as shown in Table 7 or Table 8, except if there is a fault (requiring a message) or some other information has been requested. Alternatively, parameter P5 or P13 can be set to select a message (1 to 19 as shown in Table 9). Table 7, Status Messages, Wye-Delta Starter
No Line Ready Running in wye mode. Running in delta mode. Overload Alarm The motor overload level is between 90% and 100%. Overload Fault The motor overload level has reached 100%. Overload Lockout A start is not allowed until the motor overload level cools below 100%. Control Power Lockout A start is not allowed because the control power is too low. xxx xxx = overload content. Press DOWN to toggle. xx xx = Alarm code. If the condition persists, a fault will occur. xx xx = Fault code. Press RESET to clear. Instantaneous Overcurrent Press RESET to clear. Default Flashes when parameter defaults are loaded.

Table 8, Status Messages, Solid State Starter

No Line Ready Accelerating Up to Speed Run Done with ramp but not yet Up to Speed. Decelerating Overload Alarm The motor overload level is between 90% and 100%. Overload Fault The motor overload level has reached 100%. Overload Lockout A start is not allowed until the motor overload level cools below 100%. Control Power Lockout A start is not allowed because the control power is too low. xxx xxx = overload content. Press DOWN to toggle. xx xx = Alarm code. If the condition persists, a fault will occur. xx xx = Fault code. Press RESET to clear. Instantaneous Overcurrent Press RESET to clear. Default Flashes when parameter defaults are loaded.

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Table 9, Default Meter Display

0: 1: 2: 3: 4: 5: 6: Status Message Ave RMS Current L1 RMS Current L2 RMS Current L3 RMS Current Current Imbalance % Ground Fault Current 7: Ave L-L Voltage RMS 8: L1-L2 Voltage RMS 9: L2-L3 Voltage RMS 10: L3-L1 Voltage RMS 11: Overload % 12: Power Factor 13: KW 14: KVA 15: KWh 16: MWh 17: Phase Rotation 18: Line Frequency 19: Analog Input

Display Output for the Standard Keypad

The display will output different information depending on the operation of the starter. See Table 4, LED Special Characters Displayed.

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

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

Running
When running, the display will show the user selected meter function. The following meters can be selected using the Meter display parameter P13.
Status Avg. RMS current Phase 1 RMS current Phase 2 RMS current Phase 3 RMS current Current Imbalance % GF Current (% FLA) Avg. Voltage (RMS) L1-L2 Voltage (RMS) L2-L3 Voltage (RMS) L3-L1 Voltage (RMS) Overload % Power Factor KW KVA KWh MWh Phase Rotation Line Frequency

Alarm Condition
When an alarm condition exists, the display alternates between displaying the selected meter and the alarm code. The alarm code is displayed as A XX, where XX is the alarm code. When a thermal overload alarm condition exists, A OL will be displayed. When a no line alarm condition exists, noL will be displayed. When the starter is stopped, the selected meter is not displayed.

Lockout Condition
When a lockout condition exists, the display shows the lockout code. The lockout code is displayed as L XX: where XX is the lockout code. Following are the defined lockout conditions and their codes: When a motor thermal overload lockout condition exists, L OL will be displayed. When a power stack thermal overload lockout condition exists, L Ot will be displayed. When a low control power lockout condition exists, L CP will be displayed. When there are multiple lockout codes, each will be displayed at 2 second intervals.

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

Quick Meters
Although any meter may be viewed by changing the meter parameter, there are 3 Quick Meters that are always available with a single key press. When the starter is in the normal display mode, the display may be toggled between the information currently displayed and the following quick meters.
Status Meter Overload Meter Toggle between the programmed meter display and the starter operational status display (rdY, run, utS, dcL, etc) by pressing the ENTER key. Toggle between the programmed meter display and the overload content by pressing the DOWN key. The overload will be displayed as oXXX where XXX is the overload content. For example if the overload content is 76 percent, it will be displayed as o 76. Toggle between the programmed meter display and the phase order by pressing the UP key. The phase order will be displayed as AbC or CbA. The phase order must be AbC to operate.

Phase Order Meter

Restoring Factory Parameter Settings

To restore ALL parameters to the factory default settings, press and hold the PARAM and ENTER pushbutton switch on power up. The display will blink dFLt. Parameters unique to the motor starter applications will need to be set again to appropriate values before motor operation

Resetting a Fault
To reset from a fault condition, press RESET.

Emergency Thermal Reset

To perform an emergency thermal reset, press RESET and DOWN. This will set the motor thermal overload content to 0.

Wye Delta
When the D3 control is provided for Wye-Delta there is Wye-Delta specific software and the D3 control is configured to operate an electromechanical closed transition Wye-Delta (Star-Delta) starter. When equipped with Wye-Delta software, all D3 motor and starter protective functions, except bad SCR detection and power stack overload, are available to provide full motor and starter protection. There is an additional specific parameter for Transition Time. This sets the time when the Wye to Delta transition occurs during starting. A closed transition starter uses resistors that are inserted during the transition so that the motor is never completely disconnected from the input line. The presence of these resistors in a closed transition starter smoothes the transition from Wye to Delta operation mode. A typical closed transition Wye-Delta starter schematic is shown in Figure 28, Wye Delta Motor Connection to the D3 Control.

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Figure 28, Wye Delta Motor Connection to the D3 Control

L1 L2 L3 T o T B 3, C1+ (W hite W ire) T o T B 3, C 1- (B lack W ire) T o T B3, C 2+ (W hite W ire ) T o T B 3, C 2- (B lack W ire) T o T B3, C 3+ (W hite W ire ) T o T B 3, C 3- (B lack W ire) To TB6 (SCR 2) K2 To TB4 (SCR 1) K1 To TB8 (SCR 3) K3 C urrent F eedbacks to M X

1M R esistor

2S

2M

Line Voltage & Frequenc y to MX

R esistor R esistor

T3

T6

1S

T2

T5

T1

T4

C ontrol P ow er

2M C onfirm Input C om m on 2M MX 2S UTS MX R un MX 1S 2M 1M 1S 2M 2S 1M M echanical Interlock 1S

The closed transition resistors generally are sized to be in the circuit for a short period of time. To protect the resistors from over heating, one input should be programmed as a Bypass/2M contact feedback input and the Bypass/2M confirm parameter must be set. For the Wye-Delta starter mode to operate properly, one output relay needs to be programmed to the RUN output function and another output relay needs to be programmed to the UTS output function. (Refer to parameters I/0 04-06, P42-44 for more information).
Wye-Delta Operation

When the D3 control Starter Type parameter (FUN 07, P64) is set to Wye-Delta, the D3 control is configured to operate an electromechanical Wye-Delta (Star-Delta) starter. When in Wye-Delta mode, all D3 motor and starter protective functions except bad SCR detection and power stack overload, are available to provide full motor and starter protection. The D3 control utilizes an intelligent Wye to Delta transition algorithm. If during starting the measured motor current drops below 85% of FLA and more than 25% of the UTS / Transition Time (QST 09, P9) has elapsed then a Wye to Delta transition will occur. The intelligent transition algorithm prevents unnecessarily prolonged motor starts thereby

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reducing motor heating. If a Wye to Delta transition has not already occurred, a transition will always occur when the complete UTS / Transition Time (QST 09, P9) expires. The D3 control can operate two configurations of Wye-Delta starters, open transition and closed transition. An open transition starter momentarily disconnects the motor from the input line during the transition from Wye to Delta operating mode. A closed transition starter uses resistors that are inserted during the transition so that the motor is never completely disconnected from the input line. The presence of these resistors in a closed transition starter smoothes the transition from Wye to Delta operating mode. A typical closed transition WyeDelta starter schematic is shown in Figure 28. For the Wye-Delta starter mode to operate properly, one output relay needs to be programmed to the RUN output function and another output relay needs to be programmed to the UTS output function. (Refer to parameters I/0 04-06, P42-44 for more information.) Based on the typical closed transition schematic shown in Figure 28, Wye Delta Motor Connection to the D3 Control, when a start command is given the starter will enter the Wye starting mode by energizing the relay programmed as RUN. The transition to Wye (Starting) mode occurs as follows: 1. Start command is given to the starter. 2. The RUN relay is energized which energizes the 1S contactor. 3. When the 1S contactor pulls in, the 1M contactor is energized. The D3 starter will remain in the Wye mode until either: 1. The start command is removed. 2. The Transition Time (QST 09, P9) expires or The measured motor current is less than 85% of FLA and at least 25% of the Transition Time (QST 09, P9) has elapsed. 3. A fault occurs. When the Transition Time (QST 09, P9) expires, the starter will change from Wye starting mode to the Delta or normal running mode by energizing the relay programmed as UTS. In Delta mode, the RUN and UTS relays are both energized and the motor is connected in the normal running Delta configuration. The transition to Delta (Run) mode occurs as follows: 1. The Transition Time (QST 09, P9) expires or The measured motor current is less than 85% of FLA and at least 25% of the Transition Time (QST 09, P9) has elapsed. 2. The UTS relay is energized which energizes the 2S contactor. 3. When the 2S contactor pulls in, resistors are inserted in the circuit and the 1S contactor is DE-energized. 4. When the 1S contactor drops out the 2M contactor is energized. 5. When the 2M contactor is pulled in, feedback can be sent to the D3 control board to confirm that the transition sequence to Delta is complete.

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The starter will remain in the Delta or running mode until the start command is removed or a fault occurs. Usually the D3 intelligent Wye to Delta transition algorithm provides an optimal transition point that minimizes the transient current and torque surges that can occur. However sometimes, based on the motor and loading, the Wye to Delta transition will occur only after the Transition Time has expired. In order to reduce the current surge that can take place during the transition from Wye to Delta mode, the Transition Time parameter (QST 09, P9) should be adjusted so that the transition occurs as close to full speed as possible within the constraints of the load. If the transition time is set too short, a large current and torque surge may occur during the transition. If the transition time is set too long, the motor may not have sufficient torque to continue accelerating when in Wye mode and may stop accelerating at a low speed until the transition to Delta mode occurs. If this occurs, the start is unnecessarily prolonged and motor heating is increased. A typical closed transition Wye-Delta starting current profile is shown in Figure 29. Figure 29, Wye Delta Profile
Wye-Delta Closed Transition Current Profile
600%

500%

% Full Load Motor Current

400%

300%

200%

100%

0%

% speed

100%

Transition from Wye to Delta mode

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

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Fault Code Troubleshooting Chart

The following is a list of possible fault messages that can be generated by the D3 starter control.
Code Description Detailed Description of Fault / Possible Solutions Motor did not achieve full speed before the UTS timer (QST 09, P9) expired. Check motor for jammed or overloaded condition. UTS Time F01 Limit Expired Verify that the combined kick time (CFN11, P14) and acceleration ramp time (QST 08, P8) is shorter than the UTS timer setting. Evaluate acceleration ramp settings. The acceleration ramp settings may be too low to permit the motor to start and achieve full speed. If so, revise acceleration ramp settings to provide more motor torque during starting. Evaluate UTS timer setting and, if acceptable, increase UTS timer setting (QST 09, P9). The D3 motor thermal overload protection has tripped. Check motor for mechanical failure, jammed, or overloaded condition. Verify the motor thermal overload parameter settings (QST 03, P3 and PFN 12-16, P3538) and motor service factor setting (QST 02, P2). Motor F02 (F OL) Thermal Overload Trip If motor OL trip occurs during starting, review acceleration ramp profile settings. Verify that there is not an input line power quality problem or excessive line distortion present. Verify that PF caps, if installed, are ahead of CTs. Reset overload when content falls below 15%. Phase F10 Rotation Error, not ABC Input phase rotation is not ABC and Input Phase Sensitivity parameter (FUN 04, P67) is set to ABC only. Verify correct phase rotation of input power. Correct wiring if necessary. Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67). Input phase rotation is not CBA and Input Phase Sensitivity parameter (FUN 04, P67) is set to CBA only. Verify correct phase rotation of input power. Correct wiring if necessary. Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67). Line frequency below 23 Hz was detected. Verify input line frequency. F12 Low Line Frequency If operating on a generator, check generator speed governor for malfunctions. Check input supply for open fuses or open connections Line power quality problem / excessive line distortion. Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch settings are correct.

Phase F11 Rotation Error, not CBA

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Code

Description

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

F13

High Line Frequency

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

Input power F14 not single phase

Verify that input power is single phase. Verify that single-phase power is connected to the L1 and L2 inputs. Correct wiring if necessary. Verify that the SCR gate wires are properly connected to the D3 control board. Single-phase power has been detected when the starter is expecting three-phase power.

Input power F15 not three phase

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

F21

Low Line L1L2

Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly. Check input supply for open fuses or open connections. On medium voltage systems, verify wiring of the voltage measurement circuit. Low voltage below the Undervoltage Trip Level parameter setting (PFN 08, P31) was detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).

F22

Low Line L2L3

Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly. Check input supply for open fuses or open connections. On medium voltage systems, verify wiring of the voltage feedback measurement circuit. Low voltage below the Undervoltage Trip Level parameter setting (PFN 08, P31) was detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).

F23

Low Line L3L1

Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly. Check input supply for open fuses or open connections. On medium voltage systems, verify wiring of the voltage feedback measurement circuit.

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Code

Description

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

F24

High Line L1-L2

detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32). Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly. Line power quality problems/ excessive line distortions. High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was

F25

High Line L2-L3

detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32). Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly. Line power quality problems/ excessive line distortions. High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was

F26

High Line L3-L1

detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32). Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly. Line power quality problems/ excessive line distortions. The D3 control has detected the loss of one or more input or output phases when the starter was running. Can also be caused by line power dropouts. Check input supply for open fuses.

F27

Phase Loss

Check power supply wiring for open or intermittent connections. Check motor wiring for open or intermittent connections. On medium voltage systems, verify wiring of the voltage feedback measurement circuit. Check Gate and Cathode connections to D3 board No input voltage was detected for longer than the Inline Configuration time delay parameter setting (I/O 15, P53) when a start command was given to the starter. If an inline contactor is being used, verify that the setting of the Inline Configuration time delay parameter (I/O 15, P53) allows enough time for the inline contactor to completely close before the No Line fault occurs. Check input supply for open disconnects, open fuses, open circuit breakers, or disconnected wiring. Verify that the SCR gate wires are properly connected to the D3 control board. On medium voltage systems, verify wiring of the voltage feedback measurement circuit.

F28

No Line

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Fault Code

Description

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

I.O.C. F30 (Instantaneous Overcurrent Current)

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

F31

Overcurrent

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

F34

Undercurrent

longer than the Under Current Trip Delay time setting (PFN 04, P27). Check system for cause of under current condition. A current imbalance larger than the Current Imbalance Trip Level parameter setting (PFN 05, P28) was present for longer than ten (10) seconds.

F37

Current Imbalance

Check motor wiring for cause of imbalance. (Verify dual voltage and 6 lead motors for correct wiring configuration). Check for large input voltage imbalances that can result in large current imbalances. Check motor for internal problems. Ground current above the Ground Fault Trip level setting (PFN 06, P29) has been detected for longer than 3 seconds. Check motor wiring for ground faults. Check motor for ground faults.

F38

Ground Fault

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

F39

No Current at Run

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

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Fault Code

Description

Detailed Description of Fault / Possible Solutions

Check if load is still connected to starter Check if motor may have been driven by the load (a regeneration condition) Check Gate and Cathode connections to D3 for loose connections. Check for inline contactor or disconnect. A shorted or open SCR condition has been detected. Verify that all SCR gate leads wires are properly connected at the SCR devices and the D3 control board. F40 Shorted / Open SCR Verify that the Input Phase Sensitivity parameter setting (FUN 04, P67) is correct. Verify that the Starter Type parameter setting (FUN 07, P64) is correct. Verify the motor wiring. (Verify dual voltage motors for correct wiring configuration). Motor current was detected while the starter was not running. Examine starter for shorted SCRs. F41 Current at Stop Examine bypass contactor (if present) to verify that it is open when starter is stopped. Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch settings are correct. The D3 electronic power stack OL protection has detected an overload condition. Stack Protection F47 Fault (stack thermal overload) Check motor for jammed or overloaded condition. Verify Starter Model Number parameter setting (FUN 13, P70) is correct (if available). Verify that the CT ratio (FUN 03, P68) and burden switch settings are correct. Motor load exceeds power stack rating. Consult factory A digital input has been programmed as a Bypass/2M Contactor Feedback input and an incorrect bypass feedback has been detected for longer than the Bypass Confirm time parameter setting (I/O 16, P54). Verify that the bypass/2M contactor coil and feedback wiring is correct. Bypass /2M F48 Contactor Fault Verify that the bypass/2M contactor power supply is present. Verify that the appropriate Digital Input Configuration parameter has been programmed correctly. Verify that the bypass contactor(s) are actually not damaged or faulty. Verify that the relay output that is connected to the bypass/2M contactor(s) is programmed to the UTS function. Check all SCRs with ohmmeter for shorts.

F39

No Current at Run (Contd)

Continued on next page.

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Fault Code

Description

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

F50

Control Power Low

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

Current F51 Sensor Offset Error

Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch settings are correct. Verify that no actual current is flowing through any of the starters CTs when the starter is not running. Consult factory if fault persists.

F52

Burden Switch Error

The burden switch settings were changed when starter was running. Only change burden switches when starter is not running. DI#1 has been programmed as a fault type digital input and the input indicates a fault

External F60 Fault on DI#1 Input

condition is present. Verify that the appropriate Digital Input Configuration parameter has been programmed correctly. Verify wiring and level of input. DI#2 has been programmed as a fault type digital input and input indicates a fault condition

External F61 Fault on DI#2 Input

is present. Verify that the appropriate Digital Input Configuration parameter has been programmed correctly. Verify wiring and level of input. DI#3 input has been programmed as a fault type digital input and input indicates a fault

External F62 Fault on DI#3 input

condition is present. Verify that the appropriate Digital Input Configuration parameter has been programmed correctly. Verify wiring and level of input.

Continued on next page.

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Fault Code

Description

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

F71

Analog Input Level Fault Trip.

Verify settings of all Analog Input parameters (I/O 07-11, P45-49). Verify correct positioning of input jumper JP3 (Voltage or Current) on the D3 control card. Verify correct grounding of analog input connection to prevent noise or ground loops from affecting input. Indicates that communication has been lost with a remote device such as a remote keypad. (This fault will normally occur if the remote keypad is disconnected while the D3 control board is powered up. Only connect and disconnect a remote keypad when the control power is off.) Verify that the remote keypad cable has not been damaged and that its connectors are firmly seated at both the keypad and the D3 Control board. Verify that the display interface board (when present) is firmly attached to D3 control card. Route keypad cables away from high power and/or high noise areas to reduce possible electrical noise pickup. Indicates that the starter has lost serial communications. Fault occurs when the starter has not received a valid serial communications within the Communication Timeout parameter (FUN 12, P59) defined time.

SPI F81 Communication Fault

F82

Modbus Timeout Fault Verify communication parameter settings (FUN 10-12, P59-P61). Check wiring between the remote network and the D3 control card. Examine remote system for cause of communication loss. Typically occurs when attempting to run a version of control software that is incompatible with the D3 control board hardware being used. Verify that the software is a correct version for the D3 control board being used. Consult factory for more details. Fault can also occur if the D3 control has detected an internal software problem. Consult factory.

F94

CPU Error SW fault

F95

CPU Error Parameter EEPROM Checksum Fault

The non-volatile user parameter values have been found to be corrupted. Typically occurs when the D3 control is re-flashed with new software. Perform a Factory Parameter reset and then properly set all user parameters before resuming normal operation.

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Fault Code

Description

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

F96

CPU Error CPU Error

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

F97

SW Watchdog Fault

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

F98

CPU Error CPU Error

The D3 control has detected an internal CPU problem. Consult factory. The non-volatile program memory has been corrupted. Consult factory. Control software will need to be reloaded in to the D3 control card before normal operation can resume.

F99

Program EPROM Checksum Fault

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General Troubleshooting Chart

The following troubleshooting charts can be used to help solve many of the more common problems that may occur. Motor does not start, no output to motor
Condition Display Blank, CPU Heartbeat LED on D3 board not blinking. Fault Displayed. Cause Control voltage absent. D3 control board problem. Fault Occurred. Start/Stop control input problems. Control Source parameters ( P4-5) not set correctly. Solution Check for proper control voltage input. Verify fuses and wiring. Consult factory. See fault code troubleshooting table for more details. Verify that the start/stop wiring and start input voltage levels are correct. Verify that the parameters are set correctly. Check input supply for inline contactor, open disconnects, open fuses, open circuit breakers, or disconnected wiring. Verify that the SCR gate wires are NOL or No Line is displayed and a sratr command is given, it will fault in F28. No line voltage has been detected by the D3 st is given rterarter. properly connected to the D3 control board. On medium voltage systems, verify wiring of the voltage feedback measurement circuit. See fault code troubleshooting table for more details.

Start command given but nothing happens.

During starting, motor rotates but does not reach full speed
Condition Fault Displayed. Cause Fault Occurred. Maximum Motor Current setting ( P7) set too low. Motor loading too high and/or current not dropping below 175% FLA indicating that the motor has Display shows Accel or Run. not come up to speed. Motor FLA ( P1) or CT ratio ( P1 & P15) parameter set incorrectly. Abnormally low line voltage. A mechanical or supplemental brake is still engaged. Motor Hums before turning Initial current to low FLA or CT incorrect Verify that Motor FLA and CT ratio parameters are set correctly. Fix cause of low line voltage. Verify that any external brakes are disengaged. Increase initial current Verify FLA or CTs Reduce load on motor during starting. more details. Review acceleration ramp settings. Solution See fault code troubleshooting table for

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Acceleration not operating as desired

Condition Cause Ramp time ( P8) too short. Initial current ( P6) set too high. Maximum current ( P7) set too high. Kick start current ( P13) too high. Motor accelerates too quickly. Kick start time ( P14) too long. Motor RLA ( P1) or CT ratio ( P15) parameter set incorrectly. Starter Type parameter ( P64) set incorrectly. Maximum Motor Current setting ( P7) set too low. Motor loading too high. Motor accelerates too slowly Motor RLA ( P1) or CT ratio ( P15) parameter set incorrectly. Abnormally low line voltage. Ramp time to long Solution Increase ramp time. Decrease Initial current. Decrease Maximum current. Decrease or turn off Kick current. Decrease Kick time. Verify that Motor FLA and CT ratio parameters are set correctly. Verify that Starter Type parameter is set correctly. Review acceleration ramp settings. Reduce load on motor during starting. Verify that Motor FLA and CT ratio parameters are set correctly. Fix cause of low line voltage. Decrease ramp time

Motor stops unexpectedly while running

Condition Fault Displayed. Fault Occurred. Cause Solution See fault code troubleshooting table for more details. Verify start command input signal is present or serial communications Ready Displayed. Start command lost. start command is present. Check any permissives that may be wired into the run command (Start/Stop) Display Blank, Heartbeat LED on D3 board not blinking. Control voltage absent. D3 control board problem. Check for proper control voltage input. Verify wiring and fuses. Consult factory.

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Metering incorrect
Condition Cause Solution Verify correct CT wiring and verify CTs installed or wired incorrectly. Power Metering not reading correctly. CT ratio parameter (FUN 03, P68) set incorrectly. Burden switches set incorrectly. that the CTs are installed with all the White dots towards the input line side. Verify that the CT ratio parameter is set correctly. Verify that the burden switches are set correctly. Verify correct CT wiring and verify PF Meter not reading correctly. CTs installed or wired incorrectly. that the CTs are installed with all the White dots towards the input line side. Energy Saver active. Loose connections. Turn off Energy Saver if not desired. Shut off all power and check all connections. Verify that the SCRs gate leads are SCR fault. Motor Current or Voltage meters fluctuating with steady load. Load actually not steady. Other equipment on same power feed causing power fluctuations and/or distortion. Voltage Metering not reading correctly. In medium voltage systems, Rated Voltage parameter (FUN 05, P66) set incorrectly. CT ratio parameter (FUN 03, P68) set incorrectly. Current Metering not reading correctly. CTs installed or wired incorrectly. Burden switches set incorrectly. connected properly and the SCRs are ok. Verify that the load is actually steady and that there are not mechanical issues. Fix cause of power fluctuations and/or distortion. Verify that Rated Voltage parameter is set correctly. Verify that the CT ratio parameter is set correctly. Verify that the burden switches are set correctly. Verify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side. CT ratio parameter (FUN 03, P68) set incorrectly. Ground Fault Current Metering not reading correctly. CTs installed or wired incorrectly. Burden switches set incorrectly. Verify that the CT ratio parameter is set correctly. Verify that the burden switches are set correctly. Verify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side.

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Other Situations
Condition Cause Solution If input phasing correct, exchange Motor Rotates in Wrong Direction Phasing incorrect any two output wires. If input phasing incorrect, exchange any two input wires. Erratic Operation Loose connections Motor overloaded Too many starts per hour Shut off all power and check all connections. Reduce motor load. Allow for adequate motor cooling between starts. Set Hot/Cold ratio higher or lengthen cooling time. Reduce ambient temperature or High ambient temperature Motor Overheats Acceleration time too long Incorrect motor OL settings Motor cooling obstructed/damaged Starter cooling fans do not operate (When Present) Fan power supply lost Fan wiring problem Fan failure Voltage/Current output jumper (JP1) not set correctly. Wiring problem Analog Output Function parameter (I/O 12, P50) set incorrectly. Analog Output Offset and/or Span parameters (I/O 13-14, P51-52) set Analog Output not functioning properly Load on analog output too high. incorrectly. provide for better cooling. Set OL class lower to compensate for ambient temperature. Reduce starting load and/or review acceleration ramp settings. Review and correct if necessary motor OL settings. Remove cooling air obstructions. Check motor cooling fan. Verify fan power supply, check fuses. Check fan wiring. Replace fan Set jumper to give correct output. Verify output wiring. Verify that the Analog Output Function parameter is set correctly. Verify that the Analog Output Span and Offset parameters are set correctly. Verify that load on analog output meets D3 control analog output specifications. Verify correct grounding of analog Ground loop or noise problems. output connection to prevent noise or ground loops from affecting output.

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Operation, Medium/High Voltage Starters, 2300V 7.2KV

Introduction
This section contains information on medium voltage, across-the-line and solid state starters as manufactured by Benshaw Inc. for McQuay centrifugal Chillers. Medium voltage starters have similar software (Micro II Control) and are grouped together in this manual. Model numbers are as follows: Model Number Description MVSS36 to MVSS30 Solid State, 2300V, Free-standing MVSS50 to MVSS21 Solid State, 3300V, Free-standing MVSS40 to MVSS20 Solid State, 4160V, Free-standing HVSS42 to HVSS05 Solid State, 5.1KV to 7.2KV, Free-standing MVAT12 to MVAT36 Across-the-Line, 2300V, Free-standing MVAT16 to MVAT25 Across-the-Line, 3300V, Free-standing MVAT13 to MVAT26 Across-the-Line, 4160V, Free-standing HVAT27 Across-the-Line, 6600V, Free-standing Figure 30, LED Display/Keypad

Viewing Data
Description of the LEDs on the Keypad
The keypad provides three LED indicators in addition to the 2x16 character display. The LEDs provide starter status information.

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Follow these steps to access a specific parameter in the Micro II controller menu structure Press the Menu button to enter the menu system. Press the Up or Down buttons to get the desired menu on the display. Press the Enter button to go into the menu. Press the Up or Down button to get to the desired sub-menu, if necessary. Press the Enter button to go into the sub-menu, if necessary. Press the Up or Down arrow buttons until the parameter is displayed.

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

Menu Buttons
General:

The Micro II starter controller has a display/keypad (see Figure 30) that allows the user to set the starter parameters using a plain English interface. The functions of the display buttons are as follows.

MENU

Press to enter the menu system. Press to abandon changes made to a parameter (before pressing the Enter key). Press to exit a sub-menu. Press to exit the menu system. Press to enter a menu. Press to enter a sub-menu. Press to change the parameter displayed. Press to store the new value entered. Select the menu to enter. Select the sub-menu to enter. Scroll between parameters when in a specific menu or sub-menu. Increase a parameter value. Press to view the meters when the main display is shown. Select the menu to enter. Select the sub-menu to enter. Scroll between parameters when in a specific menu or sub-menu. Decrease a parameter value. Press to view the meters when the main display is shown. Press to start the motor when the starter is connected for local display control. Press to activate the BIST (Built-In Self test) If 2-wire control is used or the Start button is disabled, this button is inoperative. Press to stop the motor when the starter is connected for local display control.

ENTER

START

STOP
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If 2-wire control is used or the Stop button is disabled, this button is inoperative.

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Menu Structure
The Micro II control has a 2 level menu structure. There are eight main menus that contain parameters related to the different functions of the starter and five of the main menus contain additional sub-menus that divide the parameters into functional groups. The following shows the structure of the menu structure. Table 10, Main Menu
Quick Start Motor Nameplate Starter Setup Starter Modes Forward1 Profile Forward2 Profile Tachometer Setup Decel Setup Port Ctl Setup True Torque Ramp Motor Protection Overload Class Line Current Line Voltage Line Frequency Ground Fault Shorted Scr Over Curr. Trip Under Curr. Trip Start Lockouts Starting Timers Permissive Input Misc. Fault Classes Meters & Relays Meters Setup Standard Relays Extended Relays

Continued Event Recorder Control Config System Clock System Password Comm. Settings Options List Software Part# Factory Setup Hardware Setup Bist Setup/Run Factory Control RTD Setup Rtd Module Setup Rtd Setpnts 1-8 RTD Setpnts 9-16

Changing a Parameter
To change a parameter, follow these steps: View the desired parameter by following the Viewing a Parameter instructions. Press the Enter button to switch to the change parameter screen. Press the Up or Down buttons to get the desired value on the screen. Press the Enter button to store the new value.

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

Quick Start
Motor FLA
Parameter Description

The motor FLA parameter must be set to the full load amps of the motor connected to the starter for the starter to function correctly. NOTE: The starter uses the entered motor FLA for every current based calculation. If the motor FLA is not entered correctly, the current ramp profile and many of the starters advanced protection features will not function properly.
Parameter Values

The motor FLA parameter is adjustable from 1 to 1200 amps in 1-amp increments.
Parameter Default

The default value for the motor FLA is 1 amp.

Serv. Fact (Service Factor)

Description

The service factor parameter should be set to the service factor of the motor. The service factor is used for the overload calculations. The service factor is factory set, will be checked by the start-up technician and should not require further adjustment. If the service factor of the motor is not known, then the service factor should be set to 1.00.
Values

The service factor can be set from 1.00 to 1.99, in 0.01 increments. NOTE: The NEC (National Electrical Code) does not allow the service factor to be set above 1.40. Check with other local electrical codes for their requirements.
Default

The default value for the service factor is 1.15.

Start Mode
Description

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

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

Default

The default value for the Start Mode is Curr.

Stop Mode
Description

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

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

Default

The default value for the Stop Mode is Coas.

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Int. Curr. (initial current)

Description

The initial current parameter is set as a percentage of the motor FLA parameter setting. The initial current parameter sets the current that will initially reach the motor when a start is commanded. If the motor does not rotate within a few seconds after a start command, the initial current should be increased. If the motor takes off too quickly after a start command, the initial current should be decreased. The initial current must be set to a value that is lower than the maximum current parameter setting. A typical setting for the initial current parameter is from 50% to 175%.
Values

The initial current is adjustable from 50% to 400% in 1% intervals.

Default

The default value for the initial current is 100%.

Max. Curr. (maximum current)

Description

The maximum current parameter is set as a percentage of the motor FLA parameter setting. The maximum current parameter performs two functions. It sets the current for the end of the ramp profile and sets the maximum current that is allowed to reach the motor while the motor is being started. If the ramp time expires before the motor has reached full speed, the starter will hold the current at the maximum current level until the stall time expires, the motor reaches full speed, or the overload trips. Typically, the maximum current is set to 600% unless the power system or load dictates the setting of a lower maximum current.
Values

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

Default

The default value for the maximum current is 600%.

Ramp Time
Description

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

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

Default

The default value for the ramp time is 15 seconds.

Overload
Description

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

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Default

The default value for the overload parameter is 10.

Phase Order
Description

The line phasing parameter sets the phase sensitivity of the starter. This can be used to protect the motor from a possible change in the incoming phase sequence. If the incoming phase sequence does not match the set phase rotation, the starter will display phs err while stopped and will fault if a start is attempted.
Values

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

The default value for the phase sensitivity parameter is INS.

Troubleshooting
The following troubleshooting charts can be used to help solve some of the more common problems that occur. Table 11, Motor will not start, no output to motor.
Display Fault Displayed. Watchdog LED on. Display is blank. Stopped No line Cause Solution Shown on display. See fault code table. CPU card problem. Consult McQuay Factory Service. Control voltage is absent. Check for proper control voltage. FU1 on power card. Replace FU1. Ribbon Cables. Check ribbon cables. Control Devices Check control devices Display buttons disabled. Enable display buttons. Missing at least one phase of main power Check power system.

Table 12, Motor rotates but does not reach full speed.
Display Fault displayed. Accel or Running Cause Shown on display Mechanical problems. Abnormally low line voltage. Solution See fault code table. Check for load binding. Check motor. Fix line voltage problem

Table 13, Deceleration profile not operating correctly.

Display Motor stops too quickly. Time seems correct but motor surges at start of decel. Time seems correct but motor stops before cycle complete. Time seems correct but water hammer occurs at end of cycle. Cause Time setting. or improper level setting. Decel level 1 Decel level 2. TruTorque DCL End Torque Decel level 2. TruTorque DCL End Torque Solution Contact McQuay Factory Service Contact McQuay Factory Service Contact McQuay Factory Service Contact McQuay Factory Service

Table 14, Motor stops while running.

Display Fault displayed. Display is blank. Stopped Cause Shown on display. Control voltage is absent. FU1 on power card Control devices. Solution See fault code table. Check control wiring and voltage. Replace fuse. Check control system.

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Table 15, Other situations.

Display Power Metering not working. TruTorque Ramp not working. Cause CT installed wrong. CT installed wrong. Motor Motor current or voltage fluctuates with steady Energy saver load. Power connection. Erratic operation. Loose connections. Ramp time. Initial current. Maximum current setting. Accelerates too quickly. Kick Start. Improper FLA setting. Initial torque. Maximum torque. Ramp time. Initial current. Maximum current setting. Accelerates too slowly Kick Start. Improper FLA setting. Initial torque. Maximum torque. Duty cycle. High ambient. Too long acceleration time. Motor overheats. Wrong overload setting. Too long jog cycle. Solution Fix CT installation. White dot to line side. Fix CT installation. White dot to line side Verify motor is operating correctly. Set energy saver to off. Shut off power and check connections Shut off all power and check connections.

Contact McQuay Factory Service

Contact McQuay Factory Service

Motor short circuit.

Fans do not operate Display buttons dont work.

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

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Fault/Log Codes
The following is a list of the possible fault and log codes that can be generated depending on the type of starter. The fault class lists the default setting for each fault; either critical or non-critical. NonC = Non-critical Crit = Critical Table 16, Fault/Log Codes
Fault/ Log No. 1 2
3 4

Fault Class NonC NonC

NonC NonC

Fault/Event Recorder Text Sequence Not CBA Sequence Not ABC

No Phase Order High Freq. Trip

Description/Possible Solutions
Incoming phase sequence is actually ABC but starter is set to CBA Incoming phase Sequence is actually CBA but starter is set to ABC No phase order detected. Line frequency went above the high freq. trip setting Line power quality problem. Low control power problem. Generator governor is malfunctioning

NonC

Low Freq. Trip

NonC

Jog Not Allowed

NonC

100% Not Allowed

9 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

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

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

30 31 46 49

Crit NonC NonC NonC

Def Param Loaded REV Not Allowed BIST Canceled Tach Loss

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

Continued on next page.

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Fault/ Log No.

50 51 52

Fault Class
Crit Crit Crit

Fault/Event Recorder Text

Key Pad Failure TT Overcurrent Limit Curr. At Stop

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

53 56 64 65 66 67 68 69 70 71 72

NonC NonC Dis NonC NonC NonC NonC NonC NonC NonC Crit

No Curr. At Run Phase Detection Bad RTD Detected RTD Alarm Limit RTD Comm Loss PWR DIP data Lost Jog Timer Limit Zero Speed Timer Low Control PWR Ground Fault DIP SW set Wrong

73 74 75 76 77 78 79 80 81

NonC NonC NonC Crit NonC NonC NonC NonC NonC

Bypass Fault UTS Timer Limit External Trip Disconnect Open In-line Fault Over Curr Trip Under Curr Trip High Field Curr. Field Loss

The current went below the under-current trip setting

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

82 83 84 87 90

NonC NonC NonC NonC Crit

Loss of SYNC High PF Trip Low PF Trip Incomplete Seq. OL Lock

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

Continued on next page.

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Fault/ Log No.

91

Fault Class
Crit

Fault/Event Recorder Text

Unauthorized RUN

Description/Possible Solutions
The start/stop circuitry has failed. A fast start/stop sequence was performed. Check wire connected to terminal JC13-3. A shorted SCR on line 1 was detected Check all 3 SCRs for shorts A shorted SCR on line 2 was detected. Check all 3 SCRs for shorts A shorted SCR on line 3 was detected Check all 3 SCRs with ohmmeter for shorts. Shorted SCRs on line 2 and 3 were detected Check all 3 SCRs with ohmmeter for shorts. Shorted SCRs on line 1 and 3 were detected Check all 3 SCRs with ohmmeter for shorts. Shorted SCRs on line 1 and 2 were detected Check all 3 SCRs with ohmmeter for shorts. A start was commanded while no line power was detected.

92 93 94 95 96 97 98 99 101 102 103 104 105 106 107 147 148 154 155

Crit Crit Crit Crit Crit Crit NonC Crit

Shorted SCR Shorted SCR Shorted SCR Shorted SCR Shorted SCR Shorted SCR No Mains Power I. O. C. Blank Log Log:Disconnect O Log:DIR Change Start Commanded Stop Commanded Stop Complete Log: System UTS Log:BIST Entered Log:BIST Passed Log:Password CLR Log:Events CLR

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

156
157 158

Log:System Reset Log:Time Changed

PWR Ret BYP IN PWR Ret BYP OUT PWR Loss Voltage PWR Loss Current PORT BYP Open Log:System Reset RTD Warn Limit Log:Loss of SYNC Log:If Ctrl Mode Log:By-Pass Drop Log:OL Warn Log:OL Lock

Log:System Reset. Log:Time changed.

Line power returned while the bypass contactor was in. Line power returned after the bypass contactor was dropped out. PORT mode was entered due to low line voltage. PORT mode was entered due to loss of current. Bypass contactor was dropped out while in PORT mode. The unit was reset. One of the RTD warning set points was exceeded. Log:Loss of SYNC. Log:If Ctrl Mode. The integral bypass contactors dropped out and were re-energized. Possible short term drop in line voltage. The thermal overload went above 90% thermal content. The thermal overload tripped. Check motor and load for cause of overload.

Log:Hardware PWR UP Log:Hardware PWR UP. Log:Emerg Reset Log:Emergency reset.

159
160 161 162 163 164 165 169 185 186 188 189 190

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LED Diagnostics
There are several LEDs located on the Micro II circuit cards. These LEDs can be used to help troubleshoot problems with the starter. Refer to the circuit card layouts for LED locations. Table 17, LED Diagnostics
CARD LED #
LEDC1 LEDC2 Computer NS MS DE Local I/O Controller Card TXD RXD LED1 LED2

NAME
Watch Dog/Power Fail/Reset Control power DeviceNet Network Status DeviceNet Module Status Data Enable Transmit Data Receive Data Operation Communication

INDICATION
On when reset/CPU failure/control voltage failure. On if control voltage is present. See DeviceNet manual. See DeviceNet manual. On when card is transmitting data. On when card is transmitting data. On when card is receiving data. Flashes when card is operating. On when valid data is received over the master link. Indicates forward SCR condition; Stop - LEDs must be on or the SCR is shorted

LEDP1 Power LEDP2 LEDP3 SCR Status

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

Condition of SCRs L1 and L2 - SCRs A and B L1 - L6 Pulse Generator L3 and L4 - SCRs C and D L5 and L6 - SCRs E and F A-F SCR gate voltage

Indicates SCR condition; Stop - LEDs will be off when stopped. Start - LEDs will be bright when the in-line is energized. LEDs will go progressively dimmer as motor accelerates. Run - LEDs will be off when motor reaches full voltage. These LEDs will be on, while ramping, to indicate that gate power is reaching the SCRs.

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Maintenance
Preventive Maintenance
During Commissioning

Torque all power connections during commissioning, including prewired equipment. Check all control wiring for loose connections. If fans are installed, check for proper operation. Re-torque all power connections, including pre-wired equipment. If fans are installed, check for proper operation. Re-torque all power connections, including pre-wired equipment annually. Clean accumulated dust with clean compressed air. Inspect cooling fans, if present, every three months. Clean or replace air vent filters every three months.

One Month After Commissioning

After First Month of Operation

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Index of Figures & Tables

FIGURES
Figure 1, Wye-Delta Starter...................................................................................3 Figure 2, Solid State Starter, Wall Mounted..........................................................4 Figure 3, Solid-state Starter with Circuit Breaker/ Disconnect .............................8 Figure 4, Solid-state, Free-standing Models RVSS14 to RVSS41 ........................9 Figure 5, Free-Standing, Solid-state Starter Models RVSS14 to RVSS82 ..........10 Figure 6, Free-Standing, Solid-state Starter Models RVSS47 to RVSS82 .......... 11 Figure 7, Free-Standing, Solid-state Starter Models RVSS96 to RVSS4K .........12 Figure 8, Unit-Mounted, Solid-state Starter Models RVST14 to RVST41 .........13 Figure 9, Unit-Mounted, Solid-state Starter Models RVST47 to RVST82 .........14 Figure 10, Models D3WD62 D3WD65, D3WT62 D3WT65 .......................15 Figure 11, Wye-Delta Starter, Free-Standing Models D3WD11 to D3WD43.....16 Figure 12, Wye-Delta Starter, Free-Standing Models D3WD11 to D3WD65,....17 Figure 13, Wye-Delta Starter, Free-Standing Models D3WD62 to D3WD65 ....18 Figure 14, Wye-Delta Starter, Free-Standing, Models D3WD86 to D3WD2K...19 Figure 15, Wye-Delta Starter, Unit Mounted, Models D3WT11 to D3WT43 ....20 Figure 16, Wye-Delta Starter, Unit Mounted, Models D3WT62 to D3WT65 ....21 Figure 17, Solid-state, Free-Standing Only, Medium Voltage, ............................22 Figure 18, Solid-state, Free-Standing Only, Medium Voltage, ............................23 Figure 19, Across-the-Line, Medium Voltage Free-Standing Only .....................24 Figure 20 Across-the-Line, Medium Voltage, Free-Standing Only ,...............25 Figure 21, Starter Panel.......................................................................................29 Figure 22, Field Wiring for Optional D3 Communication ..................................30 Figure 23, Control and Power Field Wiring ........................................................31 Figure 24, Optional Starter View Screen.............................................................42 Figure 25, Expanded Starter View Screen...........................................................43 Figure 26, Optional Starter Setpoint Screen........................................................44 Figure 27, Starter-mounted LED .........................................................................45 Figure 28, Wye Delta Motor Connection to the D3 Control ...............................52 Figure 29, Wye Delta Profile...............................................................................54 Figure 30, LED Display/Keypad.........................................................................67

TABLES
Table 1, Starter/VFD Mounting Arrangements......................................................6 Table 2, Control Power Line Sizing ....................................................................29 Table 3, Starter Setpoints ....................................................................................44 Table 4, LED Special Characters Displayed .......................................................45 Table 5, Setpoints, Wye-Delta Starter .................................................................47 Table 6, Setpoints, Solid State Starter .................................................................48 Table 7, Status Messages, Wye-Delta Starter ......................................................49 Table 8, Status Messages, Solid State Starter ......................................................49 Table 9, Default Meter Display ...........................................................................50 Table 10, Main Menu ..........................................................................................70 Table 11, Motor will not start, no output to motor...............................................73 Table 12, Motor rotates but does not reach full speed.........................................73 Table 13, Deceleration profile not operating correctly. .......................................73 Table 14, Motor stops while running...................................................................73 Table 15, Other situations. ..................................................................................74 Table 16, Fault/Log Codes ..................................................................................75 Table 17, LED Diagnostics .................................................................................78

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All McQuay equipment is sold pursuant to McQuays Standard Terms and Conditions of Sale and Limited Product Warranty. Consult your local McQuay Representative for warranty details. Refer to form 933-430285Y-00-A (09/08). To find your local representative, go to www.mcquay.com

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

(800) 432-1342 www.mcquay.com

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