Download - 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
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)
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)
NOTES: 1. All dimensions are in inches (mm).
2. The location of factory-mounted starters is shown on the chiller unit dimension drawing.
3. The optional 6-inch feet are for free-standing starters only.
4. Weight of free-standing models is 600 lbs (272 kg)
5. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure.
6. For free-standing starters, the outgoing connections can be made through the top of the enclosure or through the upper-left rear area.
7. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the 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 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
CUTOUT: 8" x 16"THROUGH TOP(CUSTOMER SUPPLIED "VAC")
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)
CUTOUT: 4" x 10 15/16"THROUGH TOP WITH COVER(CUSTOMER MOTOR LEADS)
38.0 (965.2)
48.0
(12
19.2
)40
.0 (
1016
.0)
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. Power factor correction capacitors cannot be mounted in this size enclosure.
4. Weight of free-standing model is 450 lbs (204 kg).
5. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure.
6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the unit’s Technical Data Sheet to size any upstream protection devices required by local code.
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
NOTES: 1. All dimensions are in inches (mm).
2. The location of factory-mounted starters is shown on the chiller unit dimension drawing.
3. Weight of free-standing models is 600 lbs (272 kg)
4. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure.
5. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the 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.
CUTOUT: 8" x 16"THROUGH TOP(CUSTOMER SUPPLIED "VAC")
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)
CUTOUT: 4" x 10 15/16"THROUGH TOP WITH COVER(CUSTOMER MOTOR LEADS)
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:
1. All dimensions are in inches (mm).
2. Free-standing Models RSVT have optional 18-inch legs as shown in front view.
3. Power factor correction capacitors cannot be mounted in this size enclosure.
4. Weight of free-standing model is 450 lbs (204 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,
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.
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)
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)
NOTES:
1. Optional 6-inch feet can be ordered for free-standing starters.
2. Weight of free-standing unit is 600 lbs (272 kg).
3. Power factor correction capacitors up to 50 KVAR can be mounted internally.
4. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure.
5. The outgoing connections can be made through the top of the enclosure or the upper-left rear area.
6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the unit’s Technical Data Sheet to size any upstream protection devices required by local code.
18 IOMM Starter-3
Figure 13, Wye-Delta Starter, Free-Standing Models D3WD62 to D3WD65
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)
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)
NOTES: 1. Optional 6-inch feet can be ordered for free-standing starters.
2. Weight of free-standing unit is 600 lbs (272 kg).
3. Power factor correction capacitors up to 50 KVAR can be mounted internally.
4. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be performed, the plate should be removed to avoid drill chips entering the enclosure.
5. The outgoing connections can be made through the top of the enclosure or through the upper-left rear area.
6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the unit’s Technical Data Sheet to size any upstream protection devices required by local code.
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:
1. All dimensions are in inches (mm).
2. Power factor correction capacitors cannot be mounted in this size enclosure.
3. Incoming power connection is through the 8’ x 16” plate at the right rear corner. Remove plate prior to drilling any holes.
4. The starter location is shown on the chiller unit dimension drawing.
5. Outgoing lugs are factory-connected to the motor on unit-mounted starters.
6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the unit’s Technical Data Sheet to size any upstream protection devices required by local code.
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:
1. All dimensions are in inches (mm).
2. Power factor correction capacitors cannot be mounted in this size enclosure.
3. Incoming power connection is through the 8’ x 16” plate at the right rear corner. Remove plate prior to drilling any holes.
4. The starter location is shown on the chiller unit dimension drawing.
5. Outgoing lugs are factory-connected to the motor on factory-mounted starters.
6. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the MOCP shown in the unit’s Technical Data Sheet to size any upstream protection devices required by local code.
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.
REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.
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.
REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.
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
COMPRESSOR TERMINALS
COMPRESSOR TERMINALS
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.
• 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 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%.
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 (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
Continued on next page.
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
22 Low Line L2-L3 Voltage Y
23 Low Line L3-L1 Voltage Y
24 High Line L1-L2 Voltage Y
25 High Line L2-L3 Voltage Y
26 High Line L3-L1 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.
• 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 • 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
P7 Overcurrent Trip Level OFF, 50 to 800 %RLA OFF
Continued on next page.
48 IOMM Starter-3
Description Values Default
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
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 (See Note) 0 to 9999 Disabled
P24 Fault Log xFyy –
Table 6, Setpoints, Solid State Starter
Description Values Default
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
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 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
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 2
Continued on next page.
IOMM Starter-3 49
Description Values Default
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%.
Overload Lockout – A start is not
allowed until the motor overload level
cools below 100%.
Control Power Lockout – A start is not
allowed because the control power is
too low.
xxx xxx = overload content. Press DOWN to
toggle.
xx xx = Alarm code. If the condition
persists, a fault will occur.
xx xx = Fault code. Press RESET to clear.
Instantaneous Overcurrent – Press
RESET to clear.
Default – Flashes when parameter
defaults are loaded.
Table 8, Status Messages, Solid State Starter
No Line
Ready
Accelerating
Up to Speed
Run – Done with ramp but not yet Up
to Speed.
Decelerating
Overload Alarm – The motor overload
level is between 90% and 100%.
Overload Fault – The motor overload
level has reached 100%.
Overload Lockout – A start is not
allowed until the motor overload level
cools below 100%.
Control Power Lockout – A start
is not allowed because the
control power is too low.
xxx xxx = overload content. Press
DOWN to toggle.
xx xx = Alarm code. If the
condition persists, a fault will
occur.
xx xx = Fault code. Press RESET to
clear.
Instantaneous Overcurrent –
Press RESET to clear.
Default – Flashes when
parameter defaults are loaded.
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
9: L2-L3 Voltage RMS
10: L3-L1 Voltage RMS
11: Overload %
12: Power Factor
13: KW
14: KVA
15: KWh
16: MWh
17: Phase Rotation
18: Line Frequency
19: Analog Input
Display Output for the Standard Keypad
The display will output different information depending on the operation of the starter. See
Table 4, LED Special Characters Displayed.
Power Up
The software version will be displayed as a series of blinking digits once power has been
applied to the D3 control. If the parameters were being reset on power up, “dFLt” will be
flashed on the display for three seconds, then the software version will be displayed.
Stopped
When the starter is not in the run mode, the display will show the status condition of the
starter, such as “rdY” (ready), “L OL” (Overload Lockout), “noL” (No Line).
Running
When running, the display will show the user selected meter function. The following meters
can be selected using the “Meter” display parameter P13. Status Avg. 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, C2+ (White W ire)
To TB3, C3+ (White W ire)
To TB3, C1- (B lack W ire)
To TB3, C2- (B lack W ire)
To TB3, C3- (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
Code Description Detailed Description of Fault / Possible Solutions
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.
Verify that the SCR gate wires are properly connected to the D3 control board.
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.
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.
F22 Low Line L2-
L3
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.
F23 Low Line L3-
L1
On medium voltage systems, verify wiring of the voltage feedback measurement circuit.
IOMM Starter-3 57
Code Description Detailed Description of Fault / Possible Solutions
High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was
detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).
Verify that the actual input voltage level is correct. F24
High Line
L1-L2
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Line power quality problems/ excessive line distortions.
High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was
detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).
Verify that the actual input voltage level is correct. F25
High Line
L2-L3
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Line power quality problems/ excessive line distortions.
High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was
detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).
Verify that the actual input voltage level is correct. F26
High Line
L3-L1
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Line power quality problems/ excessive line distortions.
The D3 control has detected the loss of one or more input or output phases when the
starter was running. Can also be caused by line power dropouts.
Check input supply for open fuses.
Check power supply wiring for open or intermittent connections.
Check motor wiring for open or intermittent connections.
On medium voltage systems, verify wiring of the voltage feedback measurement circuit.
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.
Verify that the SCR gate wires are properly connected to the D3 control board.
F28 No Line
On medium voltage systems, verify wiring of the voltage feedback measurement circuit.
58 IOMM Starter-3
Fault
Code Description Detailed Description of Fault / Possible Solutions
During operation, the D3 controller detected a very high level of current in one or more
phases.
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)
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch
settings are correct.
Motor current exceeded the Over Current Trip Level setting (PFN 01, P24) for longer
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 motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch
settings are correct.
Verify that the CTs are installed with all the White dots towards the input line.
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
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch
settings are correct.
IOMM Starter-3 59
Fault
Code Description Detailed Description of Fault / Possible Solutions
Check if load is still connected to starter
Check if motor may have been driven by the load (a regeneration condition)
Check Gate and Cathode connections to D3 for loose connections. 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
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch
settings are correct.
The D3 electronic power stack OL protection has detected an overload condition.
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.
Continued on next page.
60 IOMM Starter-3
Fault
Code Description Detailed Description of Fault / Possible Solutions
Low control power (below 90V) has been detected while running, by the D3 controller.
Verify that the control power input level is correct especially during starting when there may
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 the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch
settings are correct.
Verify that no actual current is flowing through any of the 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.
Verify that the appropriate Digital Input Configuration parameter has been programmed
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.
Verify that the appropriate Digital Input Configuration parameter has been programmed
correctly.
F61
External
Fault on
DI#2 Input
Verify wiring and level of input.
DI#3 input has been programmed as a fault type digital input and input indicates a fault
condition is present.
Verify that the appropriate Digital Input Configuration parameter has been programmed
correctly.
F62
External
Fault on
DI#3 input
Verify wiring and level of input.
Continued on next page.
IOMM Starter-3 61
Fault
Code Description Detailed Description of Fault / Possible Solutions
Based on the Analog Input parameter settings, the analog input level has either
exceeded or dropped below the Analog Input Trip Level setting (I/O 08, P46) for
longer than the Analog Input Trip Delay time (I/O 09, P47).
Measure value of analog input to verify correct reading.
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
Code Description Detailed Description of Fault / Possible Solutions
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
Condition Cause Solution
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
Condition Cause Solution
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.
Verify that Motor FLA and CT ratio
parameters are set correctly.
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.
Verify that Motor FLA and CT ratio
parameters are set correctly.
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
Condition Cause Solution
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
Condition Cause Solution
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.
Verify correct CT wiring and verify
that the CTs are installed with all the
White dots towards the input line
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.
CT ratio parameter (FUN 03, P68)
set incorrectly.
Verify that the CT ratio parameter is
set correctly.
Burden switches set incorrectly. Verify that the burden switches are
set correctly. Current Metering not reading
correctly.
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.
Burden switches set incorrectly. Verify that the burden switches are
set correctly. Ground Fault Current Metering not
reading correctly.
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.
66 IOMM Starter-3
Other Situations
Condition Cause Solution
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
MVSS50 to MVSS21 Solid State, 3300V, Free-standing
MVSS40 to MVSS20 Solid State, 4160V, Free-standing
HVSS42 to HVSS05 Solid State, 5.1KV to 7.2KV, Free-standing
MVAT12 to MVAT36 Across-the-Line, 2300V, Free-standing
MVAT16 to MVAT25 Across-the-Line, 3300V, Free-standing
MVAT13 to MVAT26 Across-the-Line, 4160V, Free-standing
HVAT27 Across-the-Line, 6600V, Free-standing
Figure 30, LED Display/Keypad
Viewing Data Description of the LEDs on the Keypad
The keypad provides three LED indicators in addition to the 2x16 character display. The LEDs
provide starter status information.
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.
Display Cause Solution
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.
Display Cause Solution
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
Contact McQuay Factory
Service
Time seems correct but motor stops before cycle
complete.
Decel level 2.
TruTorque DCL End Torque
Contact McQuay Factory
Service
Time seems correct but water hammer occurs at
end of cycle.
Decel level 2.
TruTorque DCL End Torque
Contact McQuay Factory
Service
Table 14, Motor stops while running.
Display Cause Solution
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.
Display Cause Solution
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
18 NonC Over voltage L2 The voltage on line 2 went above the high/low voltage setting
19 NonC Over voltage L3 The voltage on line 3 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
21 NonC Low line voltage#2 The voltage on line 2 went below the high/low voltage setting
22 NonC Low line voltage#2 The voltage on line 3 went below the high/low voltage setting
23 NonC Curr. Imbal. HL1 The current on line 1 went above the current imbalance setting
24 NonC Curr. Imbal. HL2 The current on line 2 went above the current imbalance setting
25 NonC Curr. Imbal. HL3 The current on line 3 went above the current imbalance setting
26 NonC Curr. Imbal. LL1 The current on line 1 went below the current imbalance setting
27 NonC Curr. Imbal. LL2 The current on line 2 went below the current imbalance setting
28 NonC Curr. Imbal. LL3 The current on line 3 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
Continued on next page.
76 IOMM Starter-3
Fault/
Log No.
Fault
Class
Fault/Event
Recorder Text Description/Possible Solutions
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.
Continued on next page.
IOMM Starter-3 77
Fault/
Log No.
Fault
Class
Fault/Event
Recorder Text Description/Possible Solutions
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.
96 Crit Shorted SCR Shorted SCRs on line 1 and 3 were detected Check all 3 SCRs with ohmmeter for shorts.
97 Crit Shorted SCR Shorted SCRs on line 1 and 2 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
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