iomm starter 3

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

2 IOMM Starter-3

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 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

LED Display

Incoming Lugs

Surge Capacitor

Terminal Strip

D3 Controller

Control Transformer and Fuses

Contactors

Transition Resistors

4 IOMM Starter-3

Figure 2, Solid State Starter, Remote Mounted

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.

Terminal Strip

Disconnect Switch

Primary Control Circuit

Fuses

Control Transformer

SCRs (Behind)

D3 Controller

Bypass Contactor

LED Display

IOMM Starter-3 5

Locked rotor amps (LRA): The amount of current that a specific motor will draw at start-

up, 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 motor’s 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 unit’s 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 factory-

installed 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 customer’s responsibility and can be subcontracted to McQuay

Factory Service if desired.

6 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 Factory- Mounted

Free-Standing

Brackets & Cables

WSC/WDC 050 X X

WSC/WDC 063 X X

WSC/WDC 079 X X

WSC/WDC 087 X X

WSC 100 - 126 X X

WDC 100 - 126 X

WCC 100 - 126 X

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.

IOMM Starter-3 7

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 32°F (0°C) or exceeds 104°F (40°C) enclosed, or 122°F (50°C) 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 158°F (70°C) 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 122°F (50°C) or the starter could be damaged or the life of

the starter could be reduced. Storage temperature limits are -4°F to 155°F (-20°C to 70°C).

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 SCR’s 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.

8 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

NOTES:

1. Free-standing Models RVST47 to RSVT 82 have 6-inch high feet not shown in photograph.

2. 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.

Terminal Strip

Disconnect Switch

Primary Transformer

Fuses

Motor Control

Relays (MCR)

Control

Transformer

Secondary

Transformer Fuses

Bypass Contactor

Access for

factory wiring

to motor

Grounding Lug

Line Side Lugs

Removable Cable

Entrance Panel

Remote Switch

Operator (to Door)

(3) Current

Transformers

SCRs

Motor Lugs

IOMM Starter-3 9

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.

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

L.SIDE VIEW

TOP VIEW

16.0 (406.4)

48

.0 (

12

19.2

)

16.0

(4

06

.4)

1.5

(3

8.1

)

38.0 (965.2)18.1 (458.5)

9.4 (240.5)

CUTOUT: 4" x 10 15/16"THROUGH TOP WITH COVER(CUSTOMER MOTOR LEADS)

38.0 (965.2)

66

.0 (

16

76.4

)5

8.0

(14

73.2

)18

.0 (

406

.4)

(W/ OPTIONAL MOUNTING LEGS)

FRONT VIEW

McQuay

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 unit’s Technical Data Sheet to size any upstream protection devices required by local code.

Starter Model No.

Incoming Lug Size to Standard

Power Block

Outgoing Connectio

n Size

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.

Optional

Starter Model Size

Breaker

Size (Amps)

Incoming Lug Size

Circuit Breaker

Incoming Lug Size

Disconnect Switch

RVSS14 250 #6-350 #6-350

RVSS17 250 #6-350 #6-350

RVSS20 300 (2) #3/0-500 (2) #3/0-500

RVSS27 400 (2) #3/0-500 (2) #3/0-500

RVSS34 500 (2) #3/0-500 (2) #3/0-500

RVSS41 600 (2) #3/0-500 (2) #3/0-500

10 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.

ALTERNATECABLEEXIT PANEL

6.0 (152.4)

0.00 (00.0)

0.00(00.0)

38.0(965.2)

FRONT VIEW

54.0 (1371.6)

78.0 (1981.2)

16.0(406.4)

R. SIDE VIEW

¼ TURN LATCHES(SLOT HEAD)

TYP. 3 PLACES

17.4(441.9)

16.0 (406.4)

12.0 (304.8)

4.0 (101.6)

00.0 (00.0)

00.0(00.0)

18.0(457.2)

34.0(863.6)

38.0(965.2)

CUTOUT: 8.0 (203.2) x 16.0 (406.4)THROUGH TOP

TOP VIEW

7.5(190.5)

00.0(00.0)

00.0(00.0)

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 unit’s

Technical Data Sheet to size any

upstream protection devices

required by local code.

Starter Model

(All) Outgoing Incoming to Starter Model

Incoming to Incoming to

RVSS14 0.5 (2) #6 - 300 RVSS14

#6-350 #6-350

RVSS17 0.5 (2) #6 - 300 RVSS17

#6-350 #6-350

RVSS20 0.5 (2) #6 - 300 RVSS20

(2) #3/0-500 (2) #3/0-500

RVSS27 0.5 (2) #6 - 300 RVSS27

(2) #3/0-500 (2) #3/0-500

RVSS34 0.5 (2) #6 - 300 RVSS34

(2) #3/0-500 (2) #3/0-500

RVSS41 0.5 (2) #6 - 300 RVSS41

(2) #3/0-500 (2) #3/0-500

RVSS47 0.5 (2) #6-350 RVSS47

(3) #1/0-500 (2) #1/0-500

RVSS57 0.5 (4) 1/0 750 RVSS57

(3) #1/O-500 (2) #1/0-500

RVSS67 0.5 (4) 1/0-750 RVSS67

(4) #250-500 (4) #250-500

RVSS82 0.5 (4) 1/0-750

RVSS82

(4) #250-500 (4) #250-500

NOTE: Outgoing connection is NEMA 2-hole pattern

IOMM Starter-3 11

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


6.0 (152.4)

0.00 (00.0)

0.00(00.0)

38.0(965.2)

FRONT VIEW

54.0 (1371.6)

78.0 (1981.2)

16.0(406.4)

R. SIDE VIEW


TYP. 3 PLACES

17.4(441.9)

16.0 (406.4)

12.0 (304.8)

4.0 (101.6)

00.0 (00.0)

00.0(00.0)

18.0(457.2)

34.0(863.6)

38.0(965.2)

CABLE ACCESS: 8.0 (203.2) x 16.0 (406.4)THROUGH TOP

TOP VIEW

7.5(190.5)

00.0(00.0)

00.0(00.0)

16.7 (425.4)

18.5(469.9)



3. The optional 6-inch feet are for free-standing starters only.

4. Weight of free-standing models is 600 lbs (272 kg)


6. For free-standing starters, the outgoing connections can be made through the top of the enclosure or through the upper-left rear area.


Starter Model No.

Incoming Lug Size, to

Standard Power Block

Outgoing Connection

Size

RVSS47 (2) #6 - 350 0.66 RVSS57 (4) 1/0-750 0.5 RVSS67 (4) 1/0-750 0.66 RVSS82 (4) 1/0-750 0.66

Optional

Starter Model Size

Breaker Size

(Amps)

Incoming Lug Size

Circuit Breaker

Incoming Lug Size

Disconnect Switch

RVSS47 800 (3) #1/0-500 (2) #1/0-500

RVSS57 800 (3) #1/O-500 (2) #1/0-500

RVSS67 1200 (4) #250-500 (4) #250-500

RVSS82 1200 (4) #250-500 (4) #250-500

12 IOMM Starter-3

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

72.0 (1828.8)

TOP VIEW

FRONT VIEWRIGHT SIDE VIEW

90.0

(2286

.0)

24.0 (609.6)25.3 (642.6)

(2) REMOVABLELIFTING EYES

1.0 (25)

25.3 (642.6)

Standard Optional

Starter Model No.

Breaker

Size (Amps)

Incoming Lug Size, to

Power

Block

Incoming Lug Size

Disconnect

Switch

Incoming Lug Size Circuit

Breaker

Outgoing Connection

Size

RVSS96 1600 #2 - 600 (5) #300-600 (5) #300-600 0.5

RVSS2K 2000 #2 - 600 (5) #300-600 (5) #300-600 CSO

RVSS4K 2000 #2 - 600 (5) #300-600 (5) #300-600 CSO

NOTE

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 unit’s Technical Data

Sheet to size any upstream protection devices required by local code.

IOMM Starter-3 13

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


L.SIDE VIEW

TOP VIEW

16.0 (406.4)

48.0

(1

219

.2)

16.0

(40

6.4

)1.5

(38

.1)

38.0 (965.2)18.1 (458.5)

9.4 (240.5)


38.0 (965.2)

48.0

(12

19.2

)40

.0 (

1016

.0)

FRONT VIEW

McQuay







Starter Model

Incoming to Standard

Power Block

RVST14 (2) #6-300

RVST17 (2) #6-300

RVST20 (2) #6-300

RVST27 (2) #6-300

RVST34 (2) #6-300

RVST41 (2) #6-300

NOTES:

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

Optional

Starter Model Size

Breaker Size

(Amps)

Incoming Lug Size

Circuit Breaker

Incoming Lug Size

Disconnect Switch

RVST14 250 #6-350 #6-350

RVST17 250 #6-350 #6-350

RVST20 300 (2) #3/0-500 (2) #3/0-500

RVST27 400 (2) #3/0-500 (2) #3/0-500

RVST34 500 (2) #3/0-500 (2) #3/0-500

RVST41 600 (2) #3/0-500 (2) #3/0-500

14 IOMM Starter-3

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



3. Weight of free-standing models is 600 lbs (272 kg)


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 unit’s Technical Data Sheet to size any upstream protection devices required by local code

Starter Model No.

Incoming Lug Size, to Std. Power Block

Outgoing Connection

Size

RVST47 (2) #6 - 350 0.66

RVST57 (4) 1/0-750 0.5

RVST67 (4) 1/0-750 0.66

RVST82 (4) 1/0-750 0.66

Optional

Starter Model Size

Breaker Size

(Amps)

Incoming Lug Size

Circuit Breaker

Incoming Lug Size

Disconnect Switch

RVST47 800 (3) #1-500 (2) #1-500

RVST57 800 (3) #1-500 (2) #1-500

RVST67 1200 (4) #250-500 (4) #250-500

RVST82 1200 (4) #250-500 (4) #250-500

IOMM Starter-3 15

Low Voltage, Wye-Delta (D3DW & D3dt)

Figure 10, Models D3WD62 – D3WD65, D3WT62 – D3WT65

Wye-Delta, Closed Transition, Low Voltage Starter

NOTE: Models D3WD11 – D3WD43 and D3WT11 – D3WT43 are similar in appearance, but in a

shorter cabinet.

Grounding Lug

TB4 Terminal

Board

Disconnect Switch

Incoming Power

Connection

(3) Current

Transformers

(CTs)

Disconnect Handle

Primary Control

Power Fuses

Control Transformer Transition

Resistors

Start & Run

Contactors

(6) Motor Leads

Opening to Motor

Terminal Box for

Factory-Mounted

and Wired Starters

Resistor Contactor for

Closed Transition

Y-Connection

Starting Contactor

Control Module with

Digital Readout (Front)

Motor Control Relays

(Behind)

16 IOMM Starter-3

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.


L.SIDE VIEW

TOP VIEW

16.0 (406.4)

48.0

(1

21

9.2

)

16

.0 (

40

6.4

)1

.5 (

38.1

)

38.0 (965.2)18.1 (458.5)

9.4 (240.5)


38.0 (965.2)

66

.0 (

167

6.4

)58

.0 (

147

3.2

)1

8.0

(4

06

.4)

(W/ OPTIONAL MOUNTING LEGS)

FRONT VIEW

McQuay

NOTES:


2. Free-standing Models RSVT have optional 18-inch legs as shown in front view.




Starter Model No.

Incoming Lug Size,

Std. Power Block

Outgoing Conn. Hole

Size

D3WD11 (2) #6 - 300 0.45”

D3WD12 (2) #6 - 300 0.45”

D3WD14 (2) #6 - 300 0.45”

D3WD15 (2) #6 - 300 0.45”

D3WD25 (2) #6 - 300 0.45”

D3WD31 (2) #6 - 300 0.45”

D3WD34 (2) #6 - 300 0.45”

D3WD43 (2) #6 - 350 0.45”

Optional

Starter Size

Breaker Size

(Amps)

Incoming Lug Size

Circuit

Breaker

Incoming Lug Size

Disconnect

Switch D3DW11 200 #6-350 #6-350

D3DW12 250 #6-350 #6-350

D3DW14 250 #6-350 #6-350

D3DW15 300 (2) #3/0-500

#6-350

D3DW25 400 (2) #3/0-500

(2) #3/0-500 D3DW31 400 (2) #3/0-

500 (2) #3/0-

500 D3DW34 500 (2) #3/0-500

(2) #3/0-500 D3DW43 600 (2) #3/0-

500 (2) #3/0-

500

IOMM Starter-3 17

Starter Model

No.

Incoming Lug Size,

Std. Power Block

Outgoing Connection Hole Size

D3WD11 (2) #6 - 300 0.45

D3WD12 (2) #6 - 300 0.45

D3WD14 (2) #6 - 300 0.45

D3WD15 (2) #6 - 300 0.45

D3WD25 (2) #6 - 350 0.45

D3WD31 (2) #6 - 300 0.45

D3WD34 (2) #6 - 300 0.45

D3WD43 (2) #6 - 350 0.45

D3WT62 (4) #1/0-750

0.45

D3WT65 (4) #1/0-750

0.45

Optional

Starter Size

Breaker Size

(Amps)

Incoming

Lug Size Circuit

Breaker

Incoming Lug Size

Disconnect Switch

D3DW11 200 #6-350 #6-350

D3DW12 250 #6-350 #6-350

D3DW14 250 #6-350 #6-350

D3DW15 300 (2) #3/0-500

#6-350

D3DW25 400 (2) #3/0-500

(2) #3/0-500 D3DW31 400 (2) #3/0-

500 (2) #3/0-

500 D3DW34 500 (2) #3/0-500

(2) #3/0-500 D3DW43 600 (2) #3/0-

500 (2) #3/0-

500 D3DW62 800 (2) #1-500 (2) #1-500

D3DW65 1000 (2) #1-500 (2) #1-500

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.


6.0 (152.4)

0.00 (00.0)

0.00(00.0)

38.0(965.2)

FRONT VIEW

54.0 (1371.6)

78.0 (1981.2)

16.0(406.4)

R. SIDE VIEW


TYP. 3 PLACES

17.4(441.9)

16.0 (406.4)

12.0 (304.8)

4.0 (101.6)

00.0 (00.0)

00.0(00.0)

18.0(457.2)

34.0(863.6)

38.0(965.2)


TOP VIEW

7.5(190.5)

00.0(00.0)

00.0(00.0)

16.7 (425.4)

18.5(469.9)

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.


5. The outgoing connections can be made through the top of the enclosure or the upper-left rear area.


18 IOMM Starter-3

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


6.0 (152.4)

0.00 (00.0)

0.00(00.0)

38.0(965.2)

FRONT VIEW

54.0 (1371.6)

78.0 (1981.2)

16.0(406.4)

R. SIDE VIEW


TYP. 3 PLACES

17.4(441.9)

16.0 (406.4)

12.0 (304.8)

4.0 (101.6)

00.0 (00.0)

00.0(00.0)

18.0(457.2)

34.0(863.6)

38.0(965.2)


TOP VIEW

7.5(190.5)

00.0(00.0)

00.0(00.0)

16.7 (425.4)

18.5(469.9)

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.


5. The outgoing connections can be made through the top of the enclosure or through the upper-left rear area.


Starter Model

No.

Incoming Lug Size,

Std. Power Block

Outgoing Conn.

Hole Size

D3WD62 (4) #1/0-750 0.45”

D3WD65 (4) #1/0-750 0.45”

Optional

Starter Size

Breaker Size

(Amps)

Incoming Lug Size

Circuit Breaker

Incoming Lug Size

Disconnect Switch

D3DW62 800 (2) #1-500 (2) #1-500

D3DW65 1000 (2) #1-500 (2) #1-500

IOMM Starter-3 19

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

72.0 (1828.8)

TOP VIEW

FRONT VIEW

HANDLE3-PTLATCHING(PADLOCKABLE)MULTI-DOORINTERLOCK

65

.9 (

1673

.9)

RIGHT SIDE VIEW

90

.0 (

22

86

.0)

24.0 (609.6)25.3 (642.6)

(2) REMOVABLELIFTING EYES

6.0 (152)

27.1 (687.1)

Starter Model No.

Incoming Lug Size,

Std. Power Block

Outgoing Conn. Size

D3WD86 #2 - 600 0.66” D3WD1K #2 - 600 0.66” D3WD2K #2 - 600 0.66”

Standard

Starter Size

Breaker Size

(Amps)

Incoming Lug Size

Circuit Breaker

Incoming Lug Size

Disconnect Switch

D3DW86 1200 (4) #250-

500 (4) #250-

500

D3DW1K 1600 (5) #300-

600 (5) #300-

600

D3DW2K 2000 (5) #300-

600 (5) #300-

600

NOTES:

1. All dimensions 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 unit’s Technical Data Sheet to size any

upstream protection devices required by local code.

20 IOMM Starter-3

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

NOTES:



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.


Starter Model No.

Incoming Lug Size,Std.

Power Block

D3WT11 (2) #6 - 350 D3WT12 (2) #6 - 350 D3WT14 (2) #6 - 350 D3WT15 (2) #6 - 350 D3WT25 (2) #6 - 350 D3WT31 (2) #6 - 350 D3WT34 (2) #6 - 350 D3WT43 (2) #6 - 350

Standard

Starter Size

Breaker

Size (Amps)

Incoming

Lug Size Circuit

Breaker

Incoming

Lug Size Disconnect

Switch

D3DT11 200 #6-350 #6-350 D3DT12 250 #6-350 #6-350 D3DT14 250 #6-350 #6-350

D3DT15 300 (2) #3/0-

500 #6-350

D3DT25 400 (2) #3/0-

500 (2) #3/0-

500

D3DT31 400 (2) #3/0-

500 (2) #3/0-

500

D3DT34 500 (2) #3/0-

500 (2) #3/0-

500 (2) #3/0- (2) #3/0-

IOMM Starter-3 21

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

NOTES:



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.


Starter Model No.

Incoming Lug Size, Standard Power Block

D3WT62 (4) #1/0-750 D3WT65 (4) #1/0-750

Optional

Starter Size

Breaker Size

(Amps)

Incoming Lug Size

Circuit Breaker

Incoming Lug Size

Disconnect Switch

D3DT62 800 (2) #1-500 (2) #1-500

D3DT65 1000 (2) #1-500 (2) #1-500

22 IOMM Starter-3

Medium Voltage, Solid State (MVSS & HVSS)

Figure 17, Solid-state, Free-Standing Only, Medium Voltage,

All Models MVSS 2300V to 4160V

36.0 (914.4)

30.0(762.0)

LANDING PAD

2640:1 CT1,2,3

ASSEMBLY

FUSES

REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.

CABLE ENTRY/EXIT AREA. NO CUTOUT SUPPLIED.

3. ENCLOSURE COLOR: ANSI 61 GREY

NOTES:

2

1

FU

3

FU

2

FU

1

DISCONNECTSHIELD

VIEW FROM TOP

1

FRONT INTERIOR VIEW

R RATED

92.5(2349.5)

CONTACTORBYPASS

CONTACTORINLINE

DISCONNECT400A

CUSTOMER TO CUT AS REQUIRED.

2

24.0(609.6)

3.0 (76.2)

8.0 (203.2)21.0 (533.4)

5/8-11

95

STEEL BOLT TORQUE IN FOOT-POUNDS

5/16-181/4-20

5 12

1/2-13

20

3/8-16

50

TIGHTEN BOLTS PER CHART BELOW4.

STARTER WEIGHT: APPOXIMATELY 1800LBS5.

6. 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

Figure 18, Solid-state, Free-Standing Only, Medium Voltage,

All Models HVSS 5100V to 7200V

45.0 (1143.0)

36.0(914.4)

FRONT INTERIOR VIEW

VIEW FROM TOP

CABLE EXIT AREA. NO CUTOUT SUPPLIED. CUSTOMER TO CUT AS REQUIRED.


ENCLOSURE COLOR: ANSI 61 GREY.3.

2

NOTES: 1

92.5

(2349.5

)

30.0 (762.0)

FUSINGR RATED

DISCONNECT

7.12KV 400A

CONTACTOR

INLINECONTACTOR

BYPASS ASSEMBLYLANDING PAD

(T1, T2, T3)

CT'S 1-3, 2640:1

STACK ASSEMBLY

TOTAL WEIGHT IS APPROXIMATELY 2400LBS.4.

SIDE CONNECTIONCUSTOMER LOAD

XFMRT1

30.0(762.0)TYP.

3.0 (76.2) TYP.

8.0 (203.2) TYP.2.0 (50.8) TYP.

2

TYPICAL LAYOUT FOR EACH STARTER.5.

FU

1

FU

2

FU

3

1/4-20

TIGHTEN BOLTS PER CHART AT RIGHT.6.

STEEL BOLT TORQUE IN FOOT-POUNDS

5/16-18

5 12

3/8-16

20

5/8-111/2-13

50 95

SHIPPING SUPPORTSSEE CAUTION! NOTE

DISCONNECT BARRIER

1 1

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

24 IOMM Starter-3

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.

IOMM Starter-3 25

Figure 20 Across-the-Line, Medium Voltage, Free-Standing Only ,

Model HVAT27, 5100V to 7200V

CABLE ENTRY/EXIT AREA. NO CUTOUT SUPPLIED. CUSTOMER TO CUT AS REQUIRED.


ENCLOSURE COLOR: ANSI 61 GREY

VIEWING

WINDOW

LOCKOUT

OFF

ON

92.50

24.00

FRONT VIEW

2

4.

1

VIEW FROM TOP

NOTES:

2300 VAC

2300 VAC

SWITCH MAY BE

ENERGIZED BY

BACKFEED

! WARNING

LOW VOLTAGESECTION

MEDIUM VOLTAGESECTION

.25

MATERIAL: .25" THICK TIN PLATED COPPER

1.75

0.50 THRU, (2 PLACES)FOR CUSTOMER CONNECTIONS

.63

1.50

3.00

3.00

3.50

3.00

LANDING PAD DETAIL "A”

HAZARDOUS VOLTAGE INSIDE

DANGER

APPROXIMATE WEIGHT: 1200 LBS5.

LOW VOLTAGE DOORIDENTIFICATION:

1.) RUN PILOT LIGHT (RED)2.) FAULT PILOT LIGHT (AMBER)3.) OFF PILOT LIGHT (GREEN)

1 2 3

2.00 8.00

3.00

24.00 2

4 5

4.) RUN BUTTON (RED)5.) STOP BUTTON (GREEN)

30.00

FRONT INTERIOR VIEW

XFMR

SEE DETAIL "A”SIDE LANDING PADS

CUSTOMER LOAD

CT1, CT2, CT3500:5 CTS

SIDE LANDING PADS

T1

M CONATACTOR400A

CUSTOMER LOAD

SEE DETAIL "A”

CT1, CT2, CT3500:5 CTS

"R" RATED FUSES

DISCONNECT

DISCONNECTSHIELD

FU

1

FU

2

SIDE CONNECTIONSCUSTOMER LINE

FU

3

LOW VOLTAGE

SECTION

MEDIUM VOLTAGEBARRIER

1 1

T2

T1 T3

8.00

1.00

4.5020.00

TYPICAL BOTH SIDESWITH COVER PLATESIDE ACCESS AREA

RIGHT SIDE INTERIOR VIEW

XFMRT1

3 MODEL BSR MVAT36 IS 36 INCHES WIDE.

332.00

26 IOMM Starter-3

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 60/75°C.

• 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).

IOMM Starter-3 27

• 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 problem-

free 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, ½-inch, 1 ¾-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 Comp. Size Terminal Size

Low Voltage to 750 A, to 575V CE 063-126 0.635-11 UNC-2A, 1.88 in. long

Med. Voltage to 275 A, to 4160 V CE 063-126 0.375-16 UNC-2A, 0.97 in. long

Hi Voltage to 275 A, to 7200 V CE 063-126 0.375-16 UNC-2A, 1.00 in. long

28 IOMM Starter-3

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 60/75°C.

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.

IOMM Starter-3 29

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)

0 (0) to 50 (15.2) 12 120 (36.6) to 200 (61.0) 6

50 (15.2) to 75 (22.9) 10 200 (61.0) to 275 (83.8) 4

75 (22.9) to 120 (36.6) 8 275 (83.8) to 350 (106.7) 3

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 chiller’s 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

30 IOMM Starter-3

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.

IOMM Starter-3 31

Figure 23, Control and Power Field Wiring

80

CP2

CP1

H

O

A

C4

H

A

O

C3

H

A

O

79

78

77

74

73

54

CF

86

EF

86

C

25

1

2

11

11

12

22

1

2

6

11

12

22

NOTE 2

NOTE 2

(115V) (24V)

25

55

70

H

A

O

H

A

O

H

O

A C

H

O

A C

H

O

A C

C2

C1 T3-S

PE

L1

L2CP2

CP1

24

23(5A)

24(5)

23

3

4

3

4

76

75

PE

85

86

81

84

A82(NO)

83(NC)

POWER

EP2

EP1

L1 L2 L3

GND

T4 T5 T6T1 T2 T3

T4 T5 T6T1 T2 T3

T1 T2 T3

T3T1 T2

U V W

T4 T3 T5T1 T6 T2

T1 T2 T3

T4 T3 T5T1 T6 T2

GND

LESSTHAN30VOR24VAC

53

71

71

52

1-10 VDC

1-10 VDC

MICROTECH CONTROLBOX TERMINALS

* COOLINGTOWER

FOURTHSTAGE

STARTER

* COOLINGTOWER

THIRDSTAGE

STARTER

* COOLINGTOWER

SECONDHSTAGE

STARTER

* COOLINGTOWER

FIRSTSTAGE

STARTER

COOLING TOWERBYPASS VALVE

COOLING TOWER VFD

ALARM RELAY(NOTE 4)

MICROTECHCOMPRESSOR CONTROL

BOX TERMINALSCTB1

-LOAD-

COMPRESSORMOTOR

STARTER(NOTE 1)

115 VAC

STARTER LOAD SIDE TERMINBALSVFD

STARTER LOAD SIDE TERMINBALSWYE-DELTA

STARTER LOAD SIDE TERMINBALSSOLID STATE

STARTER LOAD SIDE TERMINBALSMEDIUM AND HIGH VOLTAGE

COMPRESSOR TERMINALS




NOTE 12

- 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

* FIELD SUPPLIED ITEM

* NOTE 7

* NOTE 10

* NOTE 10

* NOTE 10

* NOTE 10

330387901-0A

COMMON

NEUTRAL

POWER

See notes on the following page.

32 IOMM Starter-3

NOTES for Wiring Diagram

1. Compressor motor starters are either factory-mounted and wired, or shipped separate for field-mounting 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.

2. 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.

3. Main power wiring between starter and motor terminal is factory-installed when chillers are supplied with unit-mounted starters.

4. 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.

5. The “Full Metering” option will require some field wiring when free-standing starters are used,

as shown in Figure 22 on page 30.

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.

IOMM Starter-3 33

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.

34 IOMM Starter-3

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: Status 1: Ave RMS Current 2: L1 RMS Current 3: L2 RMS Current 4: L3 RMS Current 5: Current Imbalance % 6: 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: PF 13: KW

14: KVA 15: KWh 16: MWh 17: Phase Rotation 18: Line Frequency 19: Analog Input

Analog Output Function (P28) (RVSS) 0: OFF (no output) 1: Ave Current (0 – 200% RLA) 2: Ave Current (0 – 800% RLA) 3: Ave Voltage (0 – 750VAC) 4: Thermal Overload% 5: KW (0 - 10KW)

6: KW (0 – 100KW) 7: KW (0 – 1MW) 8: KW (0 – 10MW) 9: Analog Input 10: Output Voltage (% of FV) 11: Calibrate (full 100% output)

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

FLA in Amps Setting

864:1 CTs 2640:1 CTs 5760:1 CTs 8000:1 CTs SW1 SW2

24 to 42 73 to128 160 to 280 223 to 390 Off Off 42 to 50 128 to 151 280 to 330 390 to 465 Off On

50 to 108 151 to 330 330 to 720 465 to 1000 On Off 108 to 190 330 to 590 720 to 1280 1000 to 1800 On On

Parameters (RVSS)

DESCRIPTION Values DEFAULT SET TO:

P1 Motor FLA 1 to 9999 Amps 10 P2 Motor RLA 1 to 9999 Amps 10 P3 Motor Service Factor 1.00 to 1.99 1.08 P4 Motor Overload Class OFF, 1 to 40 10 P5 Initial Motor Current 50 to 400 %FLA 250 P6 Maximum Motor Current 100 to 800 %FLA 300 P7 Ramp Time 0 to 300 seconds 10 P8 UTS Time 1 to 900 seconds 15

P9 Stop Mode CoS: Coast

dcL: Voltage Decel CoS

P10 Decel Begin Level 100 to 0 %Volts 40

Continued on next page.

IOMM Starter-3 35

DESCRIPTION Values DEFAULT SET TO:

P11 Decel End Level 50 to 0 %Volts 20 P12 Decel Time 1 to 180 seconds 15 P13 Default Meter Display 0 to 19 1 P14 Overcurrent Trip Level OFF, 50 to 800 %RLA OFF

P15 Overcurrent Trip Delay

Time 0.1 to 90.0 seconds 2.0

P16 Rated RMS Voltage

100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480,

575, 600, 660, 1000 Volts

480

P17 Over Voltage Trip Level OFF, 1 to 40 % rated Volts 10 P18 Under Voltage Trip Level OFF, 1 to 40 % rated Volts 10

P19 Over/Under Voltage

Delay Time 0.1 to 90.0 seconds 1.0

P20 Current Imbalance Trip

Level 5 to 40 % 10

P21 Controlled Fault Stop OFF, On OFF P22 Auto Fault Reset Time OFF, 1 to 120 seconds 60

P23 CT Ratio 72, 96, 144, 288, 864,

2640, 2880, 5760, 8000 2640

P24 Control Source TEr: Terminal NEt: Network

tEr

P25 Modbus Address 1 to 247 1 P26 Modbus Baud Rate 1.2, 2.4, 4.8, 9.6, 19.2 Kbps 19.2 P27 Modbus Timeout OFF, 1 to 120 seconds 3 P28 Analog Output Function 0 to 11 1 P29 Analog Output Span 1 to 125 % 100 P30 Analog Output Offset 0 to 99 % 0 P31 Passcode 0 to 9999 – P32 Fault Log xFyy –

Fault/Alarm Codes (RVSS)

Description Controlled

Stop Auto Reset

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

36 IOMM Starter-3

Description Controlled

Stop Auto Reset

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


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.


Fault Log • 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.

Resetting a Fault • Press RESET to reset from a fault.

IOMM Starter-3 37

Resetting Parameters

• Press and hold PARAM and ENTER on power up to reset parameters to default values.

Emergency Thermal Reset • Press RESET and DOWN to perform an emergency thermal reset.

Messages (D3YD) 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%.


allowed until the motor overload

level cools below 60%.

Control Power Lockout – A start is

not allowed because the control

power is too low.


DOWN to toggle.




clear.


RESET to clear.



Default Meter Display (P5) (D3YD) 0: Status 1: Ave RMS Current 2: L1 RMS Current 3: L2 RMS Current 4: L3 RMS Current 5: Current Imbalance % 6: 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: PF 13: KW

14: KVA 15: KWh 16: MWh 17: Phase Rotation 18: Line Frequency 19: Analog Input

Analog Output Function (P20) (D3YD) 0: OFF (no output) 1: Ave Current (0 – 200% RLA) 2: Ave Current (0 – 800% RLA) 3: Ave Voltage (0 – 750VAC) 4: Thermal Overload% 5: KW (0 - 10KW)

6: KW (0 – 100KW) 7: KW (0 – 1MW) 8: KW (0 – 10MW) 9: Analog Input 10: Reserved 11: Calibrate (full 100% output)

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

RLA in Amps Setting

864:1 CTs 2640:1 CTs 5760:1 CTs 8000:1 CTs SW1 SW2

24 to 42 73 to 128 160 to 280 223 to 390 Off Off 42 to 50 128 to 151 280 to 330 390 to 465 Off On

50 to 108 151 to 330 330 to 720 465 to 1000 On Off 108 to 190 330 to 590 720 to 1280 1000 to 1800 On On

Parameters (D3YD)

DESCRIPTION Values DEFAULT

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


38 IOMM Starter-3

DESCRIPTION Values DEFAULT

P6 Sequence Complete Delay Time

0.1 to 5.0 seconds 2.0

P7 Overcurrent Trip Level OFF, 50 to 800 %RLA OFF

P8 Overcurrent Trip Delay Time

0.1 to 90.0 seconds 2.0

P9 Rated RMS Voltage

100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480,

575, 600, 660, 1000 Volts

480

P10 Over Voltage Trip Level OFF, 1 to 40 % rated Volts 10 P11 Under Voltage Trip Level OFF, 1 to 40 % rated Volts 15

P12 Over/Under Voltage Delay Time

0.1 to 90.0 seconds 1.0

P13 Current Imbalance Trip Level

5 to 40 % 20

P14 Auto Fault Reset Time OFF, 1 to 120 seconds 60

P15 CT Ratio 72, 96, 144, 288, 864,

2640, 2880, 5760, 8000 2640

P16 Control Source TEr: Terminal NEt: Network

tEr

P17 Modbus Address 1 to 247 2 P18 Modbus Baud Rate 1.2, 2.4, 4.8, 9.6, 19.2 Kbps 19.2 P19 Modbus Timeout OFF, 1 to 120 seconds 3 P20 Analog Output Function 0 to 11 1 P21 Analog Output Span 1 to 125 % 100 P22 Analog Output Offset 0 to 99 % 0 P23 Passcode 0 to 9999 – P24 Fault Log xFyy –

Fault/Alarm Codes (D3YD)

Description Auto

Reset

00 No fault -

02 Motor Thermal Overload Trip N

10 Phase Rotation Error, not ABC Y

12 Low Line Frequency Y

13 High Line Frequency Y

15 Input power not three phase Y

21 Low Line L1-L2 Voltage Y



24 High Line L1-L2 Voltage Y



27 Phase Loss Y

28 No Line Voltage Y

30 I.O.C. (Instantaneous Overcurrent) N

31 Overcurrent N

37 Current Imbalance Y

38 Ground Fault N

39 No Current at Run Y

40 Open Line or Motor Lead N

41 Current While Stopped N

48 2M Feedback Fault (on DIN#2) N

50 Control Power Low Y

51 Current Sensor Offset Error N

IOMM Starter-3 39

Description Auto

Reset

52 Burden Switch Error N

60 Thermistor Trip (on DIN#1) N

71 Analog Input Trip Y

82 Modbus Timeout Y

94 CPU Error – Software Fault N

95 CPU Error – Parameter Storage Fault N

96 CPU Error – Illegal Instruction Trap N

97 CPU Error – Software Watchdog Fault N

98 CPU Error – Spurious Interrupt N

99 CPU Error – Program Storage Fault 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 starter’s 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.

40 IOMM Starter-3

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.

IOMM Starter-3 41

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.

42 IOMM Starter-3

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 chiller’s operator

interface touchscreen, as explained below.

Figure 24, Optional Starter View Screen

The ability to view the starter’s 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.

IOMM Starter-3 43

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.

44 IOMM Starter-3

Figure 26, Optional Starter Setpoint Screen

Table 3, Starter Setpoints

Description No. Default Range Pass- word

Comments

Ground Fault Current Trip

8 1 % 1 to 100% RLA M Sets the value for ground current above which the compressor will be shut down

Ground Fault Enable 7 OFF On or OFF M Turns the ground fault option on or off

Maximum Current Unbalance

6 10% 5% to 40% T Sets the value for current unbalance above which the compressor will be shut down

Starter Ramp Time 5 15 sec. 0 to 30

seconds T

Sets the time the starter ramps up the motor current

Maximum Starter Current

4 600% 100% to 800% of FLA (SP1)

T Sets the maximum current when the compressor starts

Initial Starter Current 3 100% 50% to 400% of FLA (SP1)

T Sets the initial current when the compressor starts

Rated load Amps 2 1 A Factory set at

design conditions

T Value that gives the 100% RLA value and used for motor protection

Full Load Amps 1 1 A Factory set to

motor max current rating

T Value used to compute SP3 and SP4

1. 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.

2. Do not change these setpoints after McQuay startup.

3. Do not remove the D3 control wiring. If accidentally disconnected, contact McQuay service.

IOMM Starter-3 45

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

The LED display and keypad is used to:

1. Perform operations

2. View and set parameters (setpoints)

3. View operating messages

4. View faults and alarms

Special Messages Displayed

The keypad’s display may show the following special information under certain conditions.

Table 4, LED Special Characters Displayed

PARAM DOWN UP ENTER

RESET

LED Display

Operating

Keys

Reset Key

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

Phase order meter showing ABC

Phase order meter showing CBA

Phase order meter showing Single Phase

xxx xxx = overload content.

xx xx = Parameter code.

xx xx = Alarm code. If the condition persists,

a fault will occur.

xx 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

46 IOMM Starter-3

Display Operation

LED Display • View parameters, messages and faults.


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.


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.

Resetting a Fault

• First correct the cause of the fault.

Then press RESET to reset from a

fault.

Resetting Parameters • Press and hold PARAM and ENTER on

power up to reset parameters to

default values.

Emergency Thermal Reset • Press RESET and DOWN to perform an

emergency thermal reset.

IOMM Starter-3 47

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:

1. At the default meter display, press the PARAM key to enter parameter mode.

2. Use the UP and DOWN keys to scroll through the available parameters.

3. The value of the parameter can be viewed by pressing the ENTER key.

4. 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. 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

Description Values Default

P1 Motor RLA 1 to 9999 Amps 1

P2 Motor Service Factor 1.00 to 1.99 1.08

P3 Motor Overload Class OFF, 1 to 40 10

P4 Transition Time 1 to 30 seconds 10

P5 Default Meter Display 0 to 19 0

P6 Sequence Complete Delay Time 0.1 to 5.0 seconds 2.0



48 IOMM Starter-3


P8 Overcurrent Trip Delay Time 0.1 to 90.0 seconds 2.0

P9 Rated RMS Voltage 208, 220, 230, 240, 380, 415,

440, 460, 480, 575 Volts 480

P10 Over Voltage Trip Level OFF, 1 to 40 % rated Volts 10

P11 Under Voltage Trip Level OFF, 1 to 40 % rated Volts 15

P12 Over/Under Voltage Delay Time 0.1 to 90.0 seconds 1.0

P13 Current Imbalance Trip Level 5 to 40 % 20


P15 CT Ratio 72, 96, 144, 288, 864, 2640,

2880, 5760, 8000 2640

P16 Control Source TEr: = Terminal, NEt: =

Network TEr

P17 Modbus Address 1 to 247 2

P18 Modbus Baud Rate 1.2, 2.4, 4.8, 9.6, 19.2 Kbps 19.2

P19 Modbus Timeout OFF, 1 to 120 seconds 3

P20 Analog Output Function 0 to 11 1

P21 Analog Output Span 1 to 125 % 100

P22 Analog Output Offset 0 to 99 % 0

P23 Passcode (See Note) 0 to 9999 Disabled

P24 Fault Log xFyy –

Table 6, Setpoints, Solid State Starter


P1 Motor FLA 1 to 9999 Amps 10

P2 Motor RLA 1 to 9999 Amps 10

P3 Motor Service Factor 1.00 to 1.99 1.08

P4 Motor Overload Class OFF, 1 to 40 10

P5 Initial Motor Current 50 to 400 %FLA 100

P6 Maximum Motor Current 100 to 800 %FLA 600

P7 Ramp Time 0 to 300 seconds 15

P8 UTS Time (Up To Speed) 1 to 900 seconds 30

P9 Stop Mode CoS: Coast

dcL: Voltage Decel CoS

P10 Decel Begin Level 100 to 0 %Volts 40

P11 Decel End Level 50 to 0 %Volts 20

P12 Decel Time 1 to 180 seconds 15

P13 Default Meter Display 0 to 19 0


P15 Overcurrent Trip Delay Time 0.1 to 90.0 seconds 2.0

P16 Rated RMS Voltage 208, 220, 230, 240, 380, 415, 440,

460, 480, 575 Volts 480

P17 Over Voltage Trip Level OFF, 1 to 40 % rated Volts 10

P18 Under Voltage Trip Level OFF, 1 to 40 % rated Volts 15

P19 Over/Under Voltage Delay Time 0.1 to 90.0 seconds 1.0

P20 Current Imbalance Trip Level 5 to 40 % 35

P21 Controlled Fault Stop OFF, On OFF


P23 CT Ratio 72, 96, 144, 288, 864, 2640, 2880,

5760, 8000 2640

P24 Control Source Ter: Terminal, Net:

Network tEr

P25 Modbus Address 1 to 247 2


IOMM Starter-3 49


P26 Modbus Baud Rate 1.2, 2.4, 4.8, 9.6, 19.2 Kbps 19.2

P27 Modbus Timeout OFF, 1 to 120 seconds 3

P28 Analog Output Function 0 to 11 1

P29 Analog Output Span 1 to 125 % 100

P30 Analog Output Offset 0 to 99 % 0

P31 Passcode (See Note) 0 to 9999 Disabled

P32 Fault Log xFyy –

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%.


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 = Fault code. Press RESET to clear.


RESET to clear.



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%.


allowed until the motor overload level

cools below 100%.

Control Power Lockout – A start

is not allowed because the

control power is too low.


DOWN to toggle.

xx xx = Alarm code. If the

condition persists, a fault will

occur.


clear.

Instantaneous Overcurrent –

Press RESET to clear.

Default – Flashes when

parameter defaults are loaded.

50 IOMM Starter-3

Table 9, Default Meter Display

0: Status Message

1: Ave RMS Current

2: L1 RMS Current

3: L2 RMS Current

4: L3 RMS Current

5: Current Imbalance %

6: Ground Fault Current

7: Ave L-L Voltage RMS

8: L1-L2 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. Voltage (RMS) KVA

Avg. RMS current L1-L2 Voltage (RMS) KWh

Phase 1 RMS current L2-L3 Voltage (RMS) MWh

Phase 2 RMS current L3-L1 Voltage (RMS) Phase Rotation

Phase 3 RMS current Overload % Line Frequency

Current Imbalance % Power Factor

GF Current (% FLA) KW

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.

IOMM Starter-3 51

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 Toggle between the programmed meter display and the starter operational

status display (rdY, run, utS, dcL, etc) by pressing the ENTER key.

Overload Meter 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”.

Phase Order Meter 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.

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.

52 IOMM Starter-3

Figure 28, Wye Delta Motor Connection to the D3 Control

MechanicalInterlock

T1

T2

T3 T6

T5

T4

Resistor

Resistor

Resistor

1M

L1 L2 L3

2M2S

1S

1S

2S

1M

2M

2S

Control Power

2M

1S

1M 1S

Run

MX

UTS

MX

2M MX

Input Common

To TB3, C1+ (White W ire)



To TB3, C1- (B lack W ire)



Current Feedbacks to MX

Line

Voltage &

Frequenc

y to MX

To TB4 (SCR 1) K1

To TB6 (SCR 2) K2

To TB8 (SCR 3) K3

2M Confirm

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

IOMM Starter-3 53

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 Wye-

Delta 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.

54 IOMM Starter-3

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

100%

200%

300%

400%

500%

600%

0% 100%% speed

Wye-Delta Closed Transition Current Profile

% Full

Load Motor Current

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.

IOMM Starter-3 55

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.

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.

F01

UTS Time

Limit

Expired

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, P35-

38) and motor service factor setting (QST 02, P2).

Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch

settings are correct.

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 CT’s.

F02

(F OL)

Motor

Thermal

Overload

Trip

Reset overload when content falls below 15%.

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. F10

Phase

Rotation

Error, not

ABC 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. F11

Phase

Rotation

Error, not

CBA Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67).

Line frequency below 23 Hz was detected.

Verify input line frequency.

If operating on a generator, check generator speed governor for malfunctions.

Check input supply for open fuses or open connections

F12 Low Line

Frequency

Line power quality problem / excessive line distortion.

56 IOMM Starter-3


Line frequency above 72 Hz was detected.

Verify input line frequency.

If operating on a generator, check generator speed governor for malfunctions.

F13 High Line

Frequency

Line power quality problem / excessive line distortion.

Three-phase power has been detected when the starter is expecting single-phase power.

Verify that input power is single phase.

Verify that single-phase power is connected to the L1 and L2 inputs. Correct wiring if

necessary.

F14

Input power

not single

phase

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.

Verify that input power is three phase. Correct wiring if necessary.


F15

Input power

not three

phase

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).

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.

F21 Low Line L1-

L2

On medium voltage systems, verify wiring of the voltage measurement circuit.






F22 Low Line L2-

L3







F23 Low Line L3-

L1


IOMM Starter-3 57


High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was


Verify that the actual input voltage level is correct. F24

High Line

L1-L2


Line power quality problems/ excessive line distortions.




High Line

L2-L3






High Line

L3-L1



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.

Check power supply wiring for open or intermittent connections.

Check motor wiring for open or intermittent connections.


F27 Phase Loss

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.


F28 No Line


58 IOMM Starter-3

Fault


During operation, the D3 controller detected a very high level of current in one or more

phases.

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.

F30

I.O.C.

(Instantaneous

Overcurrent

Current)



Motor current exceeded the Over Current Trip Level setting (PFN 01, P24) for longer

than the Over Current Trip Delay Time setting (PFN 02, P25). F31 Overcurrent

Check motor for a jammed or an overload condition.

Motor current dropped under the Under Current Trip Level setting (PFN 03, P26) for

longer than the Under Current Trip Delay time setting (PFN 04, P27). F34 Undercurrent

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.

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.

F37 Current

Imbalance

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.

Megger motor and cabling (disconnect from starter before testing).



Verify that the CTs are installed with all the White dots towards the input line.

F38 Ground Fault

Motor current went below 10% of FLA while the starter was running.

Verify Motor Connections.

Verify the CT wiring to the D3 control board.

F39 No Current at

Run



IOMM Starter-3 59

Fault


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. F39

No Current at

Run (Cont’d)

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.

Check all SCRs with ohmmeter for shorts.

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.

F40 Shorted / Open

SCR

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.

Examine bypass contactor (if present) to verify that it is open when starter is stopped. F41 Current at Stop



The D3 electronic power stack OL protection has detected an overload condition.

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.

F47

Stack

Protection

Fault (stack

thermal

overload)

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.

Verify that the relay output that is connected to the bypass/2M contactor(s) is

programmed to the UTS function.

Verify that the bypass/2M contactor power supply is present.

Verify that the appropriate Digital Input Configuration parameter has been programmed

correctly.

F48

Bypass /2M

Contactor

Fault

Verify that the bypass contactor(s) are actually not damaged or faulty.


60 IOMM Starter-3

Fault


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

be significant line voltage drop.

Check control power transformer tap setting (if available).

Check control power transformer fuses (if present).

F50 Control

Power Low

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.



Verify that no actual current is flowing through any of the starter’s CTs when the starter is

not running.

F51

Current

Sensor

Offset Error

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

condition is present.


correctly.

F60

External

Fault on

DI#1 Input

Verify wiring and level of input.

DI#2 has been programmed as a fault type digital input and input indicates a fault condition

is present.


correctly.

F61

External

Fault on

DI#2 Input


DI#3 input has been programmed as a fault type digital input and input indicates a fault

condition is present.


correctly.

F62

External

Fault on

DI#3 input



IOMM Starter-3 61

Fault


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.

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.

F71 Analog Input

Level Fault Trip.

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.

F81

SPI

Communication

Fault

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.

Verify communication parameter settings (FUN 10-12, P59-P61).

Check wiring between the remote network and the D3 control card.

F82 Modbus

Timeout Fault

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. F94

CPU Error –

SW fault

Fault can also occur if the D3 control has detected an internal software problem.

Consult factory.

The non-volatile user parameter values have been found to be corrupted. Typically

occurs when the D3 control is re-flashed with new software. F95

CPU Error –

Parameter

EEPROM

Checksum Fault Perform a Factory Parameter reset and then properly set all user parameters before

resuming normal operation.

62 IOMM Starter-3

Fault


If fault persists after performing a Factory Parameter reset, consult factory.

F96 CPU Error The D3 control has detected an internal CPU problem. Consult factory.

F97

CPU Error –

SW Watchdog

Fault

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

F98 CPU Error The D3 control has detected an internal CPU problem. Consult factory.

The non-volatile program memory has been corrupted.

F99

CPU Error –

Program

EPROM

Checksum Fault

Consult factory. Control software will need to be reloaded in to the D3 control card

before normal operation can resume.

IOMM Starter-3 63

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 Cause Solution

Control voltage absent. Check for proper control voltage input.

Verify fuses and wiring. Display Blank, CPU Heartbeat

LED on D3 board not blinking. D3 control board problem. Consult factory.

Fault Displayed. Fault Occurred. See fault code troubleshooting table for

more details.

Start/Stop control input problems. Verify that the start/stop wiring and start

input voltage levels are correct. Start command given but nothing

happens. Control Source parameters ( P4-5)

not set correctly.

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

properly connected to the D3 control

board.

On medium voltage systems, verify

wiring of the voltage feedback

measurement circuit.

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.

See fault code troubleshooting table for

more details.

During starting, motor rotates but does not reach full speed


Fault Displayed. Fault Occurred. See fault code troubleshooting table for

more details.

Maximum Motor Current setting

( P7) set too low. Review acceleration ramp settings.

Motor loading too high and/or

current not dropping below 175%

FLA indicating that the motor has

not come up to speed.

Reduce load on motor during starting.

Motor FLA ( P1) or CT ratio ( P1 &

P15) parameter set incorrectly.

Verify that Motor FLA and CT ratio

parameters are set correctly.

Abnormally low line voltage. Fix cause of low line voltage.

Display shows Accel or Run.

A mechanical or supplemental brake

is still engaged.

Verify that any external brakes are

disengaged.

Initial current to low Increase initial current Motor Hums before turning

FLA or CT incorrect Verify FLA or CT’s

64 IOMM Starter-3

Acceleration not operating as desired


Ramp time ( P8) too short. Increase ramp time.

Initial current ( P6) set too high. Decrease Initial current.

Maximum current ( P7) set too high. Decrease Maximum current.

Kick start current ( P13) too high. Decrease or turn off Kick current.

Kick start time ( P14) too long. Decrease Kick time.

Motor RLA ( P1) or CT ratio ( P15)

parameter set incorrectly.



Motor accelerates too quickly.

Starter Type parameter ( P64) set

incorrectly.

Verify that Starter Type parameter is

set correctly.

Maximum Motor Current setting

( P7) set too low. Review acceleration ramp settings.

Motor loading too high. Reduce load on motor during

starting.

Motor RLA ( P1) or CT ratio ( P15)

parameter set incorrectly.



Abnormally low line voltage. Fix cause of low line voltage.

Motor accelerates too slowly

Ramp time to long Decrease ramp time

Motor stops unexpectedly while running


Fault Displayed. Fault Occurred. See fault code troubleshooting table

for more details.

Verify start command input signal is

present or serial communications

start command is present. Ready Displayed. Start command lost.

Check any permissives that may be

wired into the run command

(Start/Stop)

Control voltage absent. Check for proper control voltage

input. Verify wiring and fuses. Display Blank, Heartbeat LED on D3

board not blinking. D3 control board problem. Consult factory.

IOMM Starter-3 65

Metering incorrect


CTs installed or wired incorrectly.

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.

Verify that the CT ratio parameter is

set correctly.

Power Metering not reading

correctly.

Burden switches set incorrectly. Verify that the burden switches are

set correctly.

PF Meter not reading correctly. CTs installed or wired incorrectly.




side.

Energy Saver active. Turn off Energy Saver if not desired.

Loose connections. Shut off all power and check all

connections.

SCR fault.

Verify that the SCRs gate leads are

connected properly and the SCRs are

ok.

Load actually not steady.

Verify that the load is actually steady

and that there are not mechanical

issues.

Motor Current or Voltage meters

fluctuating with steady load.

Other equipment on same power feed

causing power fluctuations and/or

distortion.

Fix cause of power fluctuations

and/or distortion.

Voltage Metering not reading

correctly.

In medium voltage systems, Rated

Voltage parameter (FUN 05, P66) set

incorrectly.

Verify that Rated Voltage parameter

is set correctly.


set incorrectly.


set correctly.


set correctly. Current Metering not reading

correctly.





side.


set incorrectly.


set correctly.


set correctly. Ground Fault Current Metering not

reading correctly.





side.

66 IOMM Starter-3

Other Situations


If input phasing correct, exchange

any two output wires. Motor Rotates in Wrong Direction Phasing incorrect

If input phasing incorrect, exchange

any two input wires.

Erratic Operation Loose connections Shut off all power and check all

connections.

Motor overloaded Reduce motor load.

Too many starts per hour

Allow for adequate motor cooling

between starts. Set Hot/Cold ratio

higher or lengthen cooling time.

High ambient temperature

Reduce ambient temperature or

provide for better cooling. Set OL

class lower to compensate for

ambient temperature.

Acceleration time too long Reduce starting load and/or review

acceleration ramp settings.

Incorrect motor OL settings Review and correct if necessary

motor OL settings.

Motor Overheats

Motor cooling obstructed/damaged Remove cooling air obstructions.

Check motor cooling fan.

Fan power supply lost Verify fan power supply, check fuses.

Fan wiring problem Check fan wiring. Starter cooling fans do not operate

(When Present) Fan failure Replace fan

Voltage/Current output jumper (JP1)

not set correctly. Set jumper to give correct output.

Wiring problem Verify output wiring.

Analog Output Function parameter

(I/O 12, P50) set incorrectly.

Verify that the Analog Output

Function parameter is set correctly.

Analog Output Offset and/or Span

parameters (I/O 13-14, P51-52) set

incorrectly.

Verify that the Analog Output Span

and Offset parameters are set

correctly.

Load on analog output too high.

Verify that load on analog output

meets D3 control analog output

specifications.

Ground loop or noise problems.

Verify correct grounding of analog

output connection to prevent noise or

ground loops from affecting output.

Analog Output not functioning

properly

IOMM Starter-3 67

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



HVSS42 to HVSS05 Solid State, 5.1KV to 7.2KV, Free-standing

MVAT12 to MVAT36 Across-the-Line, 2300V, 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.

68 IOMM Starter-3

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 starter’s 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.

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.

MENU

ENTER

START

⇑

⇓

STOP

IOMM Starter-3 69

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

inoperative.

70 IOMM Starter-3

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 Motor Protection

Meters & Relays

Starter Modes Overload Class Meters Setup

Forward1 Profile Line Current Standard Relays

Forward2 Profile Line Voltage Extended

Relays

Tachometer Setup Line Frequency

Decel Setup Ground Fault

Port Ctl Setup Shorted Scr

True Torque Ramp Over Curr. Trip

Under Curr. Trip

Start Lockouts

Starting Timers

Permissive Input

Misc.

Fault Classes

Event Recorder Control Config Factory Setup RTD Setup

System Clock Hardware Setup Rtd Module Setup

System Password Bist Setup/Run Rtd Setpnts 1-8

Comm. Settings Factory Control RTD Setpnts 9-16

Options List

Software Part#

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.

Continued

IOMM Starter-3 71

• 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 starter’s 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.

72 IOMM Starter-3

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.

IOMM Starter-3 73

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 Cause Solution

Fault Displayed. Shown on display. See fault code table. Watchdog LED on. CPU card problem. Consult McQuay Factory Service.

Display is blank. Control voltage is absent.

FU1 on power card.

Ribbon Cables.

Check for proper control voltage.

Replace FU1.

Check ribbon cables.

Stopped Control Devices

Display buttons disabled. Check control devices

Enable display buttons. No line Missing at least one phase of main powerCheck power system.

Table 12, Motor rotates but does not reach full speed.


Fault displayed. Shown on display See fault code table.

Accel or Running Mechanical problems.

Abnormally low line voltage. Check for load binding. Check motor.

Fix line voltage problem

Table 13, Deceleration profile not operating correctly.


Motor stops too quickly. Time setting. or improper level

setting.

Contact McQuay Factory

Service

Time seems correct but motor surges at start of

decel.

Decel level 1


Service

Time seems correct but motor stops before cycle

complete.

Decel level 2.

TruTorque DCL End Torque


Service

Time seems correct but water hammer occurs at

end of cycle.

Decel level 2.

TruTorque DCL End Torque


Service

Table 14, Motor stops while running.


Fault displayed. Shown on display. See fault code table.

Display is blank. Control voltage is absent.

FU1 on power card Check control wiring and voltage.

Replace fuse. Stopped Control devices. Check control system.

74 IOMM Starter-3

Table 15, Other situations.


Power Metering not working. CT installed wrong. Fix CT installation. White dot to line side.

TruTorque Ramp not working. CT installed wrong. Fix CT installation. White dot to line side

Motor current or voltage fluctuates with steady

load.

Motor

Energy saver

Power connection.

Verify motor is operating correctly.

Set energy saver to off.

Shut off power and check connections

Erratic operation. Loose connections. Shut off all power and check connections.

Accelerates too quickly.

Ramp time.

Initial current.

Maximum current setting.

Kick Start.

Improper FLA setting.

Initial torque.

Maximum torque.

Contact McQuay Factory Service

Accelerates too slowly

Ramp time.

Initial current.

Maximum current setting.

Kick Start.

Improper FLA setting.

Initial torque.

Maximum torque.

Contact McQuay Factory Service

Motor overheats.

Duty cycle.

High ambient.

Too long acceleration time.

Wrong overload setting.

Too long jog cycle.

Cool between starts.

Provide better ventilation.

Reduce motor load.

Select correct overload setting.

Jog operation reduces motor cooling and increases

current. Shorten jog cycle.

Motor short circuit. Wiring fault.

Power factor correction capacitors (PFCC) on

starter output.

Identify fault and correct.

Move PFCC to line side of starter.

Fans do not operate

Wiring.

Fuse.

Fan failed.

Check wiring and correct.

Replace fuse.

Replace fan.

Display buttons don’t work. Display ribbon cable.

Display faulty.

Check cable on back of display.

Replace display.

IOMM Starter-3 75

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.

Fault

Class

Fault/Event

Recorder Text Description/Possible Solutions

1 NonC Sequence Not CBA Incoming phase sequence is actually ABC but starter is set to CBA

2 NonC Sequence Not ABC Incoming phase Sequence is actually CBA but starter is set to ABC

3 NonC No Phase Order No phase order detected.

4 NonC High Freq. Trip

Line frequency went above the high freq. trip setting Line power quality problem. Low control power problem. Generator governor is malfunctioning

5 NonC Low Freq. Trip

Line frequency went below the low freq. trip setting Line power quality problem. Low control power problem. Generator governor malfunctioning.

6 NonC Jog Not Allowed 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).

7 NonC 100% Not Allowed

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 command (JC13-4).

9 NonC Dir Change Fault

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 the reversing input (JC13-6).

15 Crit Phase Order Err Phase order error.

16 Crit Bad OP Code Err Bad operating-code error

17 NonC Over voltage L1 The voltage on line 1 went above the high/low voltage setting



20 NonC Low line voltage#1 The voltage on line 1 went below the high/low voltage setting



23 NonC Curr. Imbal. HL1 The current on line 1 went above the current imbalance setting



26 NonC Curr. Imbal. LL1 The current on line 1 went below the current imbalance setting



29 Crit Bad RAM Battery

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 holding the down arrow key until fault 30 appears on the display

30 Crit Def Param Loaded

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.

31 NonC REV Not Allowed Starter is not a reversing unit. Remove reverse command from reverse input (JC13-6).

46 NonC BIST Canceled

The Built-in Self Test was canceled. The disconnect was closed. Line power was applied to the starter.

49 NonC Tach Loss There was no tachometer feedback signal detected when a start was commanded


76 IOMM Starter-3

Fault/

Log No.

Fault

Class

Fault/Event


50 Crit Key Pad Failure

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.

51 Crit TT Overcurrent Limit During TruTorque ramping, the motor current exceeded the TruTorque Overcurrent Trip level

52 Crit Curr. At Stop

Current flow above the no current at run setting was detected while the starter was stopped. Examine starter for shorted SCRs.

53 NonC No Curr. At Run

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.

56 NonC Phase Detection

64 Dis Bad RTD Detected A bad RTD was detected (open or shorted lead).

65 NonC RTD Alarm Limit A RTD alarm set point was exceeded.

66 NonC RTD Comm Loss

Communications with the RTD module was lost. Check RS-485 wiring between the RTD module and card. Check 24VDC RTD module power supply.

67 NonC PWR DIP data Lost PWR DIP data lost

68 NonC Jog Timer Limit The jog timer expired. Examine reason for extended jog operation.

69 NonC Zero Speed Timer The zero speed timer expired. • Check motor for jammed or overloaded condition

70 NonC Low Control PWR

Control power is too low. Examine control power transformer input and output voltages. Check wiring between control power source and starter.

71 NonC Ground Fault A ground fault current above the ground fault setting was detected.

72 Crit DIP SW set Wrong CT burden DIP switch set incorrectly. Set switches correctly.

73 NonC Bypass Fault The bypass contactor failed to stay energized.

Check separate bypass for proper wiring. Check integral bypass (RSxB units) control card fuses.

74 NonC UTS Timer Limit The motor was not at full speed before the UTS time expired. Check motor for jammed or overloaded condition.

75 NonC External Trip

Power was removed from the external trip input on the computer card (JC13-1). Trip input delay is set to short

76 Crit Disconnect Open A start was commanded while the disconnect was open.

77 NonC In-line Fault

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

78 NonC Over Curr Trip The current went above the over-current trip setting

79 NonC Under Curr Trip The current went below the under-current trip setting

80 NonC High Field Curr. 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

81 NonC Field Loss There was no synchronous field current. Check wiring and motor for open field circuit.

82 NonC Loss of SYNC

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

83 NonC High PF Trip The motor power factor went above the high power factor trip setting.84 NonC Low PF Trip The motor power factor went below the low power factor trip setting.87 NonC Incomplete Seq. The motor was not synchronized before the sequence timer expired.90 Crit OL Lock Used to set the operation of the overload.


IOMM Starter-3 77

Fault/

Log No.

Fault

Class

Fault/Event


91 Crit Unauthorized RUN

The start/stop circuitry has failed.

A fast start/stop sequence was performed. Check wire connected to terminal JC13-3.

92 Crit Shorted SCR A shorted SCR on line 1 was detected • Check all 3 SCRs for shorts

93 Crit Shorted SCR A shorted SCR on line 2 was detected. Check all 3 SCRs for shorts

94 Crit Shorted SCR A shorted SCR on line 3 was detected Check all 3 SCRs with ohmmeter for shorts.

95 Crit Shorted SCR Shorted SCRs on line 2 and 3 were detected Check all 3 SCRs with ohmmeter for shorts.



98 NonC No Mains Power A start was commanded while no line power was detected.

99 Crit I. O. C. A very high current was detected. Check the motor and wiring for short circuits.

101 Blank Log Blank Log.

102 Log:Disconnect O Log:Disconnect open.

103 Log:DIR Change The direction of the starter was changed.

104 Start Commanded A start command was given.

105 Stop Commanded A stop command was given.

106 Stop Complete The stop sequence is complete and the starter has removed power from the motor.

107 Log: System UTS Log: System UTS (up to speed).

147 Log:BIST Entered Log:BIST entered.

148 Log:BIST Passed Log:BIST passed.

154 Log:Password CLR Log:Password cleared.

155 Log:Events CLR Log:Event log cleared.

156 Log:System Reset Log:System Reset. 157 Log:Hardware PWR UP Log:Hardware PWR UP.

158 Log:Emerg Reset Log:Emergency reset.

159 Log:Time Changed Log:Time changed. 160 PWR Ret BYP IN Line power returned while the bypass contactor was in.

161 PWR Ret BYP OUT Line power returned after the bypass contactor was dropped out.

162 PWR Loss Voltage PORT mode was entered due to low line voltage.

163 PWR Loss Current PORT mode was entered due to loss of current.

164 PORT BYP Open Bypass contactor was dropped out while in PORT mode.

165 Log:System Reset The unit was reset.

169 RTD Warn Limit One of the RTD warning set points was exceeded.

185 Log:Loss of SYNC Log:Loss of SYNC.

186 Log:If Ctrl Mode Log:If Ctrl Mode.

188 Log:By-Pass Drop The integral bypass contactors dropped out and were re-energized. Possible short term drop in line voltage.

189 Log:OL Warn The thermal overload went above 90% thermal content.

190 Log:OL Lock The thermal overload tripped. Check motor and load for cause of overload.

78 IOMM Starter-3

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 # NAME INDICATION

LEDC1 Watch Dog/Power

Fail/Reset On when reset/CPU failure/control voltage failure.

LEDC2 Control power On if control voltage is present.

NS DeviceNet Network

Status See DeviceNet manual.

Computer

MS DeviceNet Module

Status See DeviceNet manual.

DE Data Enable On when card is transmitting data.

TXD Transmit Data On when card is transmitting data.

RXD Receive Data On when card is receiving data.

LED1 Operation Flashes when card is operating.

Local I/O

Controller Card

LED2 Communication On when valid data is received over the master link.

Indicates forward SCR condition;

Stop - LEDs must be on or the SCR is shorted

Start - LEDs will become dimmer as motor

accelerates. Power

LEDP1

LEDP2

LEDP3

SCR Status

Run - LEDs must be fully off or the SCR is open or

misfiring.

L1 - L6

Condition of SCR’s

L1 and L2 - SCR’s A

and B

L3 and L4 - SCR’s C

and D

L5 and L6 - SCR’s E

and F

Indicates SCR condition;

Stop - LEDs will be off when stopped.

Start - LEDs will be bright when the in-line is

energized. LED’s will go progressively dimmer as

motor accelerates.

Run - LED’s will be off when motor reaches full

voltage.

Pulse Generator

A - F SCR gate voltage These LEDs will be on, while ramping, to indicate

that gate power is reaching the SCR’s.

IOMM Starter-3 79

Maintenance

Preventive Maintenance

During Commissioning

• Torque all power connections during commissioning, including pre-

wired equipment.

• Check all control wiring for loose connections.

• If fans are installed, check for proper operation.

One Month After Commissioning

• Re-torque all power connections, including pre-wired equipment.

• If fans are installed, check for proper operation.

After First Month of 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.

80 IOMM Starter-3

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

IOMM Starter-3 81

82 IOMM Starter-3

• (800) 432-1342 • www.mcquay.com IOMM Starter-3 (12/10)

All McQuay equipment is sold pursuant to McQuay’s 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-to-date product information, please go to www.mcquay.com.

iomm starter 3

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