Starters For Centrifugal Chillers: Installation, Operation and Maintenance Manual

Installation, Operation and Maintenance Manual IOMM Starter-3
Group: Chiller
Part Number: 331375501
Effective: Dec. 2010
Supercedes: March. 2010
Starters for Centrifugal Chillers

Low Voltage, Solid State and Wye-Delta
Medium Voltage, Solid State and Across-the-Line
Table of Contents
General ................................................................................................................... 3
Variable Frequency Drives............................................................................................................ 4
Basic Electrical Terms .................................................................................................................. 4
Model Identification ..................................................................................................................... 5
Starter Field Installation....................................................................................... 5
Mounting Arrangements ............................................................................................................... 5
Receiving and Setting ................................................................................................................... 6
Location and Mounting................................................................................................................. 6
Dimensions & Terminal Sizes ............................................................................... 8
Low Voltage, Solid State (RVSS and RVST) ................................................................................ 8
Low Voltage, Wye-Delta (D3DW & D3dt)................................................................................ 15
Medium Voltage, Solid State (MVSS & HVSS) ......................................................................... 22
Medium Voltage, Across-The-Line (MVAT & HVAT)................................................................ 24
Field Power Wiring.............................................................................................. 26
Field Control Wiring ........................................................................................... 28
Low Voltage Starters .................................................................................................................. 29
Medium/high Voltage Starters..................................................................................................... 30
Startup .................................................................................................................. 33
Low Voltage Solid State (RVSS) ................................................................................................ 33
Low Voltage Wye-Delta (D3YD ................................................................................................. 36
Medium Voltage, Solid State (MVSS, HVSS) ............................................................................ 39
Operation, Low Voltage Starters, 200 – 600 Volts ............................................ 42
Introduction ................................................................................................................................ 42
Viewing Data .............................................................................................................................. 42
Changing Parameters .................................................................................................................. 47
Fault Code Troubleshooting Chart.............................................................................................. 55
General Troubleshooting Chart................................................................................................... 63
Operation, Medium/High Voltage Starters, 2300V – 7.2KV............................ 67
Introduction ................................................................................................................................ 67
Viewing Data .............................................................................................................................. 67
Changing Parameters .................................................................................................................. 68
Quick Start .................................................................................................................................. 71
Troubleshooting .......................................................................................................................... 73
Fault/Log Codes.......................................................................................................................... 75
LED Diagnostics......................................................................................................................... 78
Maintenance......................................................................................................... 79
Index of Figures & Tables................................................................................... 80
"McQuay" is a registered trademark of McQuay International2010

"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".
2 IOMM Starter-3
General
These starters are completely automatic and require no operator intervention (other than
clearing and resetting faults) to perform their function of providing a controlled connection
of the compressor motor to the power supply.
The Wye-Delta and solid-state starters have similar software characteristics and are
discussed together in their operating section. However, some parameters and data are
different. Where this occurs, separate tables and figures are provided.
The low voltage (200-600 volts) starters are characterized by their control software, known
as “D3 Control”. Certain electrical operating data for these low voltage starters is
transmitted to the chiller and can be viewed on the operator touch screen if the “Full
Metering Option” has been ordered. See page 42 for details.
Medium voltage (2300-72,000 volts) starters share common software known as “MX3”
control.
Figure 1, Wye-Delta Starter
Incoming Lugs
Terminal Strip
Surge Capacitor
LED Display
D3 Controller
Control Transformer and Fuses
Contactors
Transition Resistors
IOMM Starter-3 3
Figure 2, Solid State Starter, Remote Mounted
Terminal Strip
Disconnect Switch
Primary Control Circuit

Fuses
D3 Controller
LED Display
SCRs (Behind)
Bypass Contactor
Control Transformer
Variable Frequency Drives

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

Bypass contactor: Contactors that bypass auto-transformers, reactors, or SCRs, and allow
full power to reach the motor directly.
Closed transition: A reduced voltage starter characteristic when the motor is NOT
temporarily disconnected from the line during the transition from starting mode to
operating mode. The electrical load is transferred to resistors during the transition phase
and the second inrush spike is suppressed
Full load amps (FLA): The maximum amps the motor is designed for.
Inrush current: The amount of current that a specific motor and starter combination will
draw during start-up. Normal inrush current will be substantially less than LRA for all
starter types, except for across-the-line starters.
Interrupting capacity: The maximum fault current that a circuit breaker or fused
disconnect can successfully interrupt. As the rating increases, the construction becomes
heavier duty. For disconnect switches with fuses, the rating is based on 0 to 600 volts.
For circuit breakers, the voltage and amperage relationship is considered with interrupting
capacity decreasing as voltage increases.
4 IOMM Starter-3
Locked rotor amps (LRA): The amount of current that a specific motor will draw at 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.
IOMM Starter-3 5
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
Factory- Free- Brackets &
Size
Mounted Standing 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.
6 IOMM Starter-3
Standard NEMA 1 and NEMA 12 starters must be installed indoors in an area that is not
exposed to direct water spray. Do not install in areas where the ambient temperature falls
below 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.
IOMM Starter-3 7
Dimensions & Terminal Sizes
Low Voltage, Solid State (RVSS and RVST)
Figure 3, Solid-state Starter with Circuit Breaker/ Disconnect
Models RVSS47 – RVSS82, RVST47 – RVST82
Removable Cable
Entrance Panel
Terminal Strip
Grounding Lug
Line Side Lugs
Access for
factory wiring
to motor
Disconnect Switch
Motor Lugs
Remote Switch
Operator (to Door)
SCRs
(3) Current
Transformers
Bypass Contactor
Primary Transformer
Fuses
Motor Control
Relays (MCR)
Secondary
Transformer Fuses
Control
Transformer
NOTES:
1. 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.
8 IOMM Starter-3
Figure 4, Solid-state, Free-standing Models RVSS14 to RVSS41
NOTE: For starters equipped with optional power factor correction capacitors and/or fused disconnect
switches, use Drawing RVSS 14 – 82, which is 78 inches high rather than this 66-inch high unit.
38.0 (965.2)
CUTOUT: 4" x 10 15/16" 18.1 (458.5) CUTOUT: 8" x 16"
THROUGH TOP WITH COVER THROUGH TOP
9.4 (CUSTOMER SUPPLIED "VAC")
(CUSTOMER MOTOR LEADS)
(240.5)
Incoming
16.0 (406.4)
Outgoing
1.5 (38.1)
Starter Lug Size to
Connectio
Model No. Standard
n Size
Power Block
TOP VIEW
RVSS14 (2) #6 - 300 0.5
RVSS17 (2) #6 - 300 0.5
RVSS20 (2) #6 - 300 0.5
38.0 (965.2)
RVSS27 (2) #6 - 300 0.5
16.0 (406.4)
RVSS34 (2) #6 - 300 0.5
RVSS41 (2) #6 - 300 0.5
NOTES:
McQuay
1. Outgoing lugs are NEMA 2 hole pattern.
48.0 (1219.2)
Optional
Starter Breaker Incoming Incoming
66.0 (1676.4)
Model Size Lug Size Lug Size

58.0 (1473.2)
Size (Amps) Circuit Disconnect

Breaker Switch
RVSS14 250 #6-350 #6-350
RVSS17 250 #6-350 #6-350
RVSS20 300 (2) #3/0-500 (2) #3/0-500
L.SIDE VIEW
RVSS27 400 (2) #3/0-500 (2) #3/0-500
18.0 (406.4)
RVSS34 500 (2) #3/0-500 (2) #3/0-500

RVSS41 600 (2) #3/0-500 (2) #3/0-500
FRONT VIEW
(W/ OPTIONAL MOUNTING LEGS)
NOTES:
1. All dimensions are in inches (mm).
2. The location of factory-mounted starters is shown on the chiller unit dimension drawing.
3. Free-standing Models RSVT have optional 18-inch legs as shown in front view.
4. Power factor correction capacitors cannot be mounted in this size enclosure.
5. Weight of free-standing model is 450 lbs (204 kg).
6. Incoming connections can be made through the removable plate on the top of the enclosure. If drilling is to be
performed, the plate should be removed to avoid drill chips entering the enclosure.
7. For free-standing starters, the outgoing connections can be made through the top of the enclosure or through the
upper-left rear area.
8. The breaker sizes shown are for the breaker installed in the starter and used as a unit disconnect switch. Use the
MOCP shown in the unit’s Technical Data Sheet to size any upstream protection devices required by local code.
IOMM Starter-3 9
Figure 5, Free-Standing, Solid-state Starter Models RVSS14 to RVSS82
NOTE: For RVSS 14 – 41 starters without p.f. correction or fused disconnects, use CD RVSS 14 – 41.
00.0 18.0 34.0 38.0

(00.0) (457.2) (863.6) (965.2)
Notes:
00.0 (00.0)
CUTOUT: 8.0 (203.2) x 16.0 (406.4) 1. All dimensions in inches (mm).
4.0 (101.6) THROUGH TOP
2. Enclosure is NEMA 1.
3. Cable entrance and exit through
12.0 (304.8) 8.0 (203.2) x 18.0 (457.2) cutout
TOP VIEW
on top.
16.0 (406.4)
4. Shown with optional mounting
7.5 legs.
(190.5)
00.0 17.4
5. The breaker sizes shown are for
(00.0) (441.9) ¼ TURN LATCHES the breaker installed in the
(SLOT HEAD)
TYP. 3 PLACES starter and used as a unit
78.0 (1981.2) disconnect switch. Use the
MOCP shown in the unit’s
Technical Data Sheet to size any
ALTERNATE
CABLE upstream protection devices
EXIT required by local code.
PANEL
54.0 (1371.6)
R. SIDE VIEW
6.0 (152.4)
0.00 (00.0)
FRONT VIEW
0.00 38.0 16.0 00.0
(00.0) (965.2) (406.4) (00.0)
Starter (All) Outgoing Incoming to Starter Incoming to Incoming to

Model Model
RVSS1
RVSS14 0.5 (2) #6 - 300 #6-350 #6-350
RVSS17 0.5 (2) #6 - 300 4
RVSS1 #6-350 #6-350
RVSS20 0.5 (2) #6 - 300 7
RVSS2 (2) #3/0-500 (2) #3/0-500
RVSS27 0.5 (2) #6 - 300 0
RVSS2 (2) #3/0-500 (2) #3/0-500
RVSS34 0.5 (2) #6 - 300 7
RVSS3 (2) #3/0-500 (2) #3/0-500
RVSS41 0.5 (2) #6 - 300 4
RVSS4 (2) #3/0-500 (2) #3/0-500
RVSS47 0.5 (2) #6-350 1
RVSS4 (3) #1/0-500 (2) #1/0-500
RVSS57 0.5 (4) 1/0 750 7
RVSS5 (3) #1/O-500 (2) #1/0-500
RVSS67 0.5 (4) 1/0-750 7
RVSS6 (4) #250-500 (4) #250-500
RVSS82 0.5 (4) 1/0-750 7
RVSS8 (4) #250-500 (4) #250-500
NOTE: Outgoing connection is NEMA 2-hole pattern 2
10 IOMM Starter-3
Figure 6, Free-Standing, Solid-state Starter Models RVSS47 to RVSS82
00.0 18.0 34.0 38.0

(00.0) (457.2) (863.6) (965.2) Incoming Lug
Outgoing
Starter Size, to
00.0 (00.0) CABLE ACCESS: Connection
8.0 (203.2) x 16.0 (406.4)
Model No. Standard Power
4.0 (101.6) Size
THROUGH TOP Block
RVSS47 (2) #6 - 350 0.66
12.0 (304.8) TOP VIEW RVSS57 (4) 1/0-750 0.5
16.0 (406.4) RVSS67 (4) 1/0-750 0.66
16.7 (425.4) RVSS82 (4) 1/0-750 0.66
7.5
(190.5)
00.0 17.4
(00.0) (441.9) ¼ TURN LATCHES
(SLOT HEAD)
TYP. 3 PLACES
78.0 (1981.2) Optional
ALTERNATE
CABLE
EXIT Breaker Switch
PANEL
RVSS47 800 (3) #1/0-500 (2) #1/0-500
RVSS57 800 (3) #1/O-500 (2) #1/0-500
54.0 (1371.6)
RVSS67 1200 (4) #250-500 (4) #250-500
RVSS82 1200 (4) #250-500 (4) #250-500
R. SIDE VIEW
6.0 (152.4)
0.00 (00.0)
FRONT VIEW
0.00 38.0 16.0 00.0
(00.0) (965.2) (406.4) (00.0)
18.5
(469.9)
NOTES:
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.
IOMM Starter-3 11
Figure 7, Free-Standing, Solid-state Starter Models RVSS96 to RVSS4K
(2) REMOVABLE
LIFTING EYES
TOP VIEW 25.3 (642.6)
72.0 (1828.8) 25.3 (642.6)
24.0 (609.6)
90.0 (2286.0)
1.0 (25)
FRONT VIEW
RIGHT SIDE VIEW
NOTES:
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.
Standard Optional
Breaker Incoming Incoming Incoming
Starter Outgoing
Size Lug Size, to Lug Size Lug Size
Model No. Connection
(Amps) Power Disconnect Circuit
Size
Block Switch Breaker
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
12 IOMM Starter-3
Figure 8, Unit-Mounted, Solid-state Starter Models RVST14 to RVST41
38.0 (965.2)
CUTOUT: 4" x 10 15/16" 18.1 (458.5) CUTOUT: 8" x 16"
(240.5)
16.0 (406.4)
1.5 (38.1)
Incoming to
Starter
Standard
Model
Power Block
RVST14 (2) #6-300
RVST17 (2) #6-300
TOP VIEW
RVST20 (2) #6-300
RVST27 (2) #6-300
RVST34 (2) #6-300
16.0 (406.4) 38.0 (965.2)
RVST41 (2) #6-300
NOTES:
1. Outgoing lugs are factory-connected to the motor on

unit-mounted starters.
McQuay
Optional
48.0 (1219.2)

48.0 (1219.2)
Breaker Switch
40.0 (1016.0)
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
L.SIDE VIEW RVST41 600 (2) #3/0-500 (2) #3/0-500
FRONT VIEW
NOTES:
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.
IOMM Starter-3 13
Figure 9, Unit-Mounted, Solid-state Starter Models RVST47 to RVST82
Incoming Lug Outgoing

Starter
Size, to Std. Connection
Model No.
Power Block 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
Breaker 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
NOTES:
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.
devices required by local code
14 IOMM Starter-3
Low Voltage, Wye-Delta (D3DW & D3dt)
Figure 10, Models D3WD62 – D3WD65, D3WT62 – D3WT65
Wye-Delta, Closed Transition, Low Voltage Starter
Grounding Lug
TB4 Terminal
Board
Incoming Power
Connection
Opening to Motor
Terminal Box for
Disconnect Switch
Factory-Mounted
and Wired Starters
(3) Current
Transformers
(6) Motor Leads (CTs)
Disconnect Handle
Primary Control
Power Fuses
Start & Run
Contactors
Control Module with
Digital Readout (Front)
Y-Connection
Starting Contactor Motor Control Relays
(Behind)
Resistor Contactor for

Closed Transition
Control Transformer
Transition
Resistors
NOTE: Models D3WD11 – D3WD43 and D3WT11 – D3WT43 are similar in appearance, but in a
shorter cabinet.
IOMM Starter-3 15
Figure 11, Wye-Delta Starter, Free-Standing Models D3WD11 to D3WD43
NOTE: For starters equipped with optional power factor correction capacitors and/or fused disconnect
switches, use Drawing D3WD11-65, which is 78 inches high rather than this 66-inch high unit.
38.0 (965.2)
CUTOUT: 4" x 10 15/16" 18.1 (458.5) CUTOUT: 8" x 16"
(240.5)
Incoming
Outgoing
16.0 (406.4)
1.5 (38.1)
Starter Lug Size,
Conn. Hole
Model No. Std. Power
Size
Block
D3WD11 (2) #6 - 300 0.45”
TOP VIEW D3WD12 (2) #6 - 300 0.45”
D3WD14 (2) #6 - 300 0.45”
D3WD15 (2) #6 - 300 0.45”
16.0 (406.4) 38.0 (965.2) D3WD25 (2) #6 - 300 0.45”
D3WD31 (2) #6 - 300 0.45”
D3WD34 (2) #6 - 300 0.45”
D3WD43 (2) #6 - 350 0.45”
McQuay
48.0 (1219.2)
Optional
Breaker Incoming Incoming
Starter
Size Lug Size Lug Size
66.0 (1676.4)
Size
(Amps) Circuit Disconnect
58.0 (1473.2)
Breaker Switch
D3DW11 200 #6-350 #6-350
D3DW12 250 #6-350 #6-350
D3DW14 250 #6-350 #6-350
D3DW15 300 (2) #3/0- #6-350
D3DW25 400 (2)500
#3/0- (2) #3/0-
L.SIDE VIEW
D3DW31 400 500
(2) #3/0- 500
(2) #3/0-
18.0 (406.4)
D3DW34 500 (2)500

#3/0- (2)500
#3/0-
D3DW43 600 500
(2) #3/0- (2)500
#3/0-
500 500
FRONT VIEW
(W/ OPTIONAL MOUNTING LEGS)
NOTES:
2. Free-standing Models RSVT have optional 18-inch legs as shown in front view.
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.
16 IOMM Starter-3
Figure 12, Wye-Delta Starter, Free-Standing Models D3WD11 to D3WD65,
NOTE: For D3WD11-43 without p.f. correction or fused disconnects, use drawing D3DW11-43.
00.0 18.0 34.0 38.0 Incoming

(00.0)
Starter Outgoing
(457.2) (863.6) (965.2) Lug Size,
Model Connection
00.0 (00.0) CABLE ACCESS: Std. Power
No. Hole Size
4.0 (101.6)
8.0 (203.2) x 16.0 (406.4) Block
THROUGH TOP
D3WD11 (2) #6 - 300 0.45
12.0 (304.8) TOP VIEW D3WD12 (2) #6 - 300 0.45
16.0 (406.4) D3WD14 (2) #6 - 300 0.45
16.7 (425.4)
7.5 D3WD15 (2) #6 - 300 0.45
(190.5)
00.0 17.4
D3WD25 (2) #6 - 350 0.45
(00.0) ¼ TURN LATCHES
(441.9)
(SLOT HEAD) D3WD31 (2) #6 - 300 0.45
TYP. 3 PLACES D3WD34 (2) #6 - 300 0.45
78.0 (1981.2)
D3WD43 (2) #6 - 350 0.45
D3WT62 (4) #1/0- 0.45
ALTERNATE
CABLE D3WT65 (4)750
#1/0- 0.45
EXIT 750
PANEL
54.0 (1371.6)
Optional
Starter
Size
Breaker Switch
D3DW11 200 #6-350 #6-350
D3DW12 250 #6-350 #6-350
D3DW14 250 #6-350 #6-350
D3DW15 300 (2) #3/0- #6-350
D3DW25 400 (2)500
#3/0- (2) #3/0-
R. SIDE VIEW D3DW31 400 (2)500
#3/0- (2)500
#3/0-
D3DW34 500 (2)500
#3/0- (2)500
#3/0-
6.0 (152.4) D3DW43 600 (2)500
#3/0- (2)500
#3/0-
D3DW62 800 500 500
(2) #1-500 (2) #1-500
0.00 (00.0)
FRONT VIEW D3DW65 1000 (2) #1-500 (2) #1-500
0.00 38.0 16.0 00.0
(00.0) (965.2) (406.4) (00.0)
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.
IOMM Starter-3 17
Figure 13, Wye-Delta Starter, Free-Standing Models D3WD62 to D3WD65
00.0 18.0 34.0 38.0

(00.0) (457.2) (863.6) (965.2)
00.0 (00.0) CABLE ACCESS:
8.0 (203.2) x 16.0 (406.4)
4.0 (101.6)
THROUGH TOP Incoming
Starter Outgoing
Lug Size,
12.0 (304.8) TOP VIEW Model Conn.
Std. Power
16.0 (406.4) No. Hole Size
16.7 (425.4)
Block
7.5 D3WD62 (4) #1/0-750 0.45”
(190.5)
00.0 17.4 D3WD65 (4) #1/0-750 0.45”
(00.0) (441.9) ¼ TURN LATCHES
(SLOT HEAD)
TYP. 3 PLACES
78.0 (1981.2)
ALTERNATE
Optional
CABLE Breaker Incoming Incoming
EXIT Starter
PANEL Size
Breaker Switch
54.0 (1371.6)
D3DW62 800 (2) #1-500 (2) #1-500
D3DW65 1000 (2) #1-500 (2) #1-500
R. SIDE VIEW
6.0 (152.4)
0.00 (00.0)
FRONT VIEW
0.00 38.0 16.0 00.0
(00.0) (965.2) (406.4) (00.0)
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.
18 IOMM Starter-3
Figure 14, Wye-Delta Starter, Free-Standing, Models D3WD86 to D3WD2K
Incoming
Outgoing
Starter Lug Size,
Conn.
Model No. Std. Power
Size
Block
D3WD86 #2 - 600 0.66”
D3WD1K #2 - 600 0.66”
TOP VIEW 27.1 (687.1) D3WD2K #2 - 600 0.66”
(2) REMOVABLE
72.0 (1828.8) 25.3 (642.6)
LIFTING EYES
24.0 (609.6)
Standard
Starter
Size
Breaker Switch
(4) #250- (4) #250-
D3DW86 1200
500 500
HANDLE (5) #300- (5) #300-
3-PT D3DW1K 1600
600 600
90.0 (2286.0)
LATCHING
(PADLOCKABLE) (5) #300- (5) #300-
MULTI-DOOR D3DW2K 2000
INTERLOCK 600 600
65.9 (1673.9)
FRONT VIEW
RIGHT SIDE VIEW
6.0 (152)
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.
IOMM Starter-3 19
Figure 15, Wye-Delta Starter, Unit Mounted, Models D3WT11 to D3WT43
Incoming Lug
Starter
Size,Std.
Model No.
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 Switch
D3DT11 200 #6-350 #6-350
D3DT12 250 #6-350 #6-350
D3DT14 250 #6-350 #6-350
(2) #3/0-
D3DT15 300 #6-350
500
(2) #3/0- (2) #3/0-
D3DT25 400
500 500
(2) #3/0- (2) #3/0-
D3DT31 400
500 500
(2) #3/0- (2) #3/0-
D3DT34 500
500 500
(2) #3/0- (2) #3/0-
NOTES:
3. Incoming power connection is through the 8’ x 16” plate at the right rear corner. Remove plate prior to
drilling any holes.
4. The starter location is shown on the chiller unit dimension drawing.
5. Outgoing lugs are factory-connected to the motor on unit-mounted starters.
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 16, Wye-Delta Starter, Unit Mounted, Models D3WT62 to D3WT65
Incoming Lug
Starter
Size, Standard
Model No.
Power Block
D3WT62 (4) #1/0-750
D3WT65 (4) #1/0-750
Optional
Starter
Size
Breaker Switch
D3DT62 800 (2) #1-500 (2) #1-500
D3DT65 1000 (2) #1-500 (2) #1-500
NOTES:
3. Incoming power connection is through the 8’ x 16” plate at the right rear corner. Remove plate
prior to drilling any holes.
4. The starter location is shown on the chiller unit dimension drawing.
5. Outgoing lugs are factory-connected to the motor on factory-mounted starters.
IOMM Starter-3 21
Medium Voltage, Solid State (MVSS & HVSS)
Figure 17, Solid-state, Free-Standing Only, Medium Voltage,
All Models MVSS 2300V to 4160V
3.0 (76.2)
24.0
30.0
(609.6)
(762.0)
21.0 (533.4) 8.0 (203.2)

VIEW FROM TOP
DISCONNECT
SHIELD
400A
DISCONNECT
FU1
R RATED
FU2
FU3
FUSES
92.5
INLINE BYPASS (2349.5)
CONTACTOR CONTACTOR
2640:1 CT1,2,3
LANDING PAD
ASSEMBLY
36.0 (914.4)
FRONT INTERIOR VIEW

NOTES:
1 REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.
2 CABLE ENTRY/EXIT AREA. NO CUTOUT SUPPLIED.

CUSTOMER TO CUT AS REQUIRED.
3. ENCLOSURE COLOR: ANSI 61 GREY
4. TIGHTEN BOLTS PER CHART BELOW
STEEL BOLT TORQUE IN FOOT-POUNDS
1/4-20 5/16-18 3/8-16 1/2-13 5/8-11
5 12 20 50 95
5. STARTER WEIGHT: APPOXIMATELY 1800LBS
6. Dimensions shown are for standard starters without options that can affect unit
dimensions and weight. Consult the local McQuay sales office for information.
22 IOMM Starter-3
Figure 18, Solid-state, Free-Standing Only, Medium Voltage,
All Models HVSS 5100V to 7200V
3.0 (76.2) TYP.
36.0 30.0
(914.4) (762.0)
TYP.
2.0 (50.8) TYP. 8.0 (203.2) TYP.

VIEW FROM TOP
1 1
7.12KV 400A
DISCONNECT
DISCONNECT
BARRIER
FU1
FU2
FU3
R RATED
FUSING
INLINE STACK ASSEMBLY

CONTACTOR
92.5 (2349.5)
SHIPPING SUPPORTS
SEE CAUTION! NOTE
LANDING PAD
BYPASS ASSEMBLY
CONTACTOR (T1, T2, T3)
CUSTOMER LOAD
SIDE CONNECTION
CT'S 1-3, 2640:1
T1
XFMR
30.0 (762.0) 45.0 (1143.0)
FRONT INTERIOR VIEW
NOTES: 1 REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.
2 CABLE EXIT AREA. NO CUTOUT SUPPLIED. CUSTOMER TO CUT AS REQUIRED.
3. ENCLOSURE COLOR: ANSI 61 GREY.

STEEL BOLT TORQUE IN FOOT-POUNDS
4. TOTAL WEIGHT IS APPROXIMATELY 2400LBS.
1/4-20 5/16-18 3/8-16 1/2-13 5/8-11
5. TYPICAL LAYOUT FOR EACH STARTER. 5 12 20 50 95
6. TIGHTEN BOLTS PER CHART AT RIGHT.
7. Dimensions shown are for standard starters without options that can affect unit dimensions and
weight. Consult the local McQuay sales office for information.
IOMM Starter-3 23
Medium Voltage, Across-The-Line (MVAT & HVAT)
Figure 19, Across-the-Line, Medium Voltage Free-Standing Only
Models MVAT12-24, MVAT 16-25, MVAT13-26
Model MVAT 36
NOTES:
1. ∆1, Removable lifting eyebolts. Plug holes if
removed
2. ∆2, Cable entry/exit area.
3. ∆3, Alternate cable entry/exit, cut as required.
4. Color is ANSI 61 grey
5. Approximate weight is 1200 lbs.
24 IOMM Starter-3
Figure 20 Across-the-Line, Medium Voltage, Free-Standing Only ,
Model HVAT27, 5100V to 7200V
2.00 8.00
3.00
24.00 2
LOW VOLTAGE DOOR

IDENTIFICATION:
1.) RUN PILOT LIGHT (RED)
2.) FAULT PILOT LIGHT (AMBER)
3.) OFF PILOT LIGHT (GREEN)
4.) RUN BUTTON (RED) VIEW FROM TOP
5.) STOP BUTTON (GREEN)
20.00 4.50
1 1 1.00
SIDE ACCESS AREA

WITH COVER PLATE 8.00
TYPICAL BOTH SIDES
CUSTOMER LINE
SIDE CONNECTIONS
VIEWING ! WARNING
SWITCH MAY BE
ENERGIZED BY
ON
WINDOW
BACKFEED
DISCONNECT
2300 VAC OFF
LOCKOUT
DISCONNECT MEDIUM VOLTAGE
SHIELD BARRIER
1 2 3 "R" RATED FUSES

FU1
FU2
FU3
4 5
LOW VOLTAGE
92.50 LOW VOLTAGE SECTION
SECTION
M CONATACTOR
400A
MEDIUM VOLTAGE
DANGER SECTION CT1, CT2, CT3 CT1, CT2, CT3
HAZARDOUS VOLTAGE INSIDE
500:5 CTS 500:5 CTS

T1 T3
CUSTOMER LOAD
2300 VAC CUSTOMER LOAD SIDE LANDING PADS
SEE DETAIL "A”
SIDE LANDING PADS T2
SEE DETAIL "A”
T1
XFMR
T1
XFMR
24.00 30.00
FRONT INTERIOR VIEW 32.00

3
FRONT VIEW
RIGHT SIDE INTERIOR VIEW

3.50
3.00
.25 NOTES: 1 REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.
2 CABLE ENTRY/EXIT AREA. NO CUTOUT SUPPLIED. CUSTOMER TO CUT AS REQUIRED.

1.50 3.00
3 MODEL BSR MVAT36 IS 36 INCHES WIDE.
1.75 3.00
4. ENCLOSURE COLOR: ANSI 61 GREY
.63
5. APPROXIMATE WEIGHT: 1200 LBS
0.50 THRU, (2 PLACES)
FOR CUSTOMER CONNECTIONS
LANDING PAD DETAIL "A”

MATERIAL: .25" THICK TIN PLATED COPPER
IOMM Starter-3 25
Field Power Wiring
Power wiring between the starter and the compressor motor terminals must be field supplied
and installed on units with remote-mounted, free-standing starters. See the field wiring
diagram on page 31.
Wiring, fuse and wire size must be in accordance with the National Electric Code (NEC).
Standard NEMA motor starters require modification to meet McQuay specifications. Refer to
McQuay Specification 735999901 (latest revision).
! CAUTION
Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the
voltage unbalance per NEMA MG-1, 1998 Standard. This is an important restriction that must
be followed to avoid equipment damage..
Refer to Figure 23 on page 31 for power wiring connections.

Power wiring to compressors must be in proper phase sequence. Motor rotation is set up for
clockwise rotation facing the lead end with phase sequence of 1-2-3. Care must be taken that
the proper phase sequence is carried through the starter to compressor. With the phase
sequence of 1-2-3 and L1 connected to T1 and T6, L2 connected to T2 and T4, and L3
connected to T3 and T5, rotation is proper. See diagram in terminal box cover.
The McQuay start-up technician will check the phase sequence. Note: Do not make final
connections to motor terminals until wiring has been checked and approved by a McQuay
technician.
! CAUTION
Connections to terminals must be made with copper lugs and copper wire to avoid possible
equipment damage. Under no circumstances should a compressor be brought up to speed
until proper sequence and rotation have been established. Serious damage can result if the
compressor starts in the wrong direction. Such damage is not covered by product warranty
General Wiring Practice

Wire groups
Signal wiring refers to wires connected to the control terminals that are low voltage, below
15V.
• Shielded wire is required to prevent electrical noise interference from causing
improper operation or nuisance trips.
• Signal wire should be rated for at least 300V.
• Keep signal wire as far away as possible from control and power wiring.
Control wiring is wiring connected to the control terminal strip that carry 24V to 220V.
• Use only UL or CSA recognized wire.
• Use copper wire rated for 60/75°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).
26 IOMM Starter-3
• Wire runs outside of an enclosure should be run in metallic conduit or have
shielding/armor with equivalent attenuation.
• Different wire groups should cross at 90 degrees whenever power and control wiring
cross.
• Different wire groups should be run in separate conduits.
• Adhere to local electrical codes.
• The National Electrical Code and Canadian Electrical Code requires that an approved
circuit disconnecting device be installed in series with the incoming AC supply in a
location readily accessible to personnel installing or servicing this equipment. If a
disconnect switch is not supplied with the starter, one must be installed.
• Supply and motor wiring will usually enter and leave the enclosure from the top. Wire
connections can be determined to best suit specific installations. Wire runs should be
properly braced to handle both starting and fault currents. Size power cable per local
electrical codes. Long lengths of cable to the motor of over 150 feet must be de-rated.
BEFORE APPLYING MAIN POWER
The starter has been fully tested before leaving the factory to help a rapid and 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
IOMM Starter-3 27
Field Control Wiring
Control wiring is required between the starter and the unit for three purposes:
1. Transmit start and stop commands from the unit to the starter.
2. Transmit electrical information concerning motor operation from the starter to the unit
control system.
3. Supply control power from the starter transformer to the unit control panels.
General Practice
Signal wiring refers to wires connected to the control terminals that are low voltage, below
15V.
• Shielded wire is required to prevent electrical noise interference from
causing improper operation or nuisance trips.
• Signal wire should be rated for at least 300V.
• Keep signal wire as far away as possible from control and power wiring.
Control wiring refers to wires connected to the control terminal strip that carry 24V to 220V.
• Use only UL or CSA recognized wire.
• Use copper wire rated for 60/75°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.
28 IOMM Starter-3
Separate Power Source
Chiller control power usually comes from a control transformer located in the starter and
factory or field wired to the chiller control panel. In the event a separate transformer supplies
control voltage, it must be rated at 3 KVA, with an inrush rating of 12 KVA minimum at 80%
power factor and 95% secondary voltage. For control wire sizing, refer to NEC. Articles 215
and 310. In the absence of complete information to permit calculations, the voltage drop
should be physically measured.
Table 2, Control Power Line Sizing
Maximum Length, ft (m) Wire Size (AWG) Maximum Length, ft (m) Wire Size (AWG)
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
IOMM Starter-3 29
Figure 22, Field Wiring for Optional D3 Communication
NOTES.
1. See Figure 3 for Starter connection location.
2. The compressor controller serial card location is in the lower-center of the compressor
controller, under the operating buttons.
3. The bias block is located on the rail, just to the left of the compressor controller.
4. Note that the connections are (-) to (-), (+) to (+), and SCOM to GND, with a shield
connection on the starter terminal board.
Medium/high Voltage Starters

Control wiring for medium and high voltage solid state and across-the-line starters is per the
wiring diagram on page 31.
30 IOMM Starter-3
Figure 23, Control and Power Field Wiring
MICROTECH CONTROL
BOX TERMINALS
(115V) (24V)
GND PE 54
85
POWER
* NOTE 7
86
NEUTRAL
* NOTE 10 70
H
80
* COOLING O 55
TOWER C4 74 H
A
FOURTH O
86
STAGE
STARTER EP2
A C
86
* NOTE 10
H 79
* COOLING O
TOWER C3 73
A H
THIRD O
STAGE
STARTER EP1
A C
78
77
* NOTE 10
H 76
* COOLING O
TOWER C2 75
A
SECONDH
STAGE
STARTER
H
O
* NOTE 10 A C
H CP2
* COOLING O
C1 T3-S
TOWER A
FIRST EF
STAGE
STARTER CF
81
COMMON
82(NO) ALARM RELAY
A (NOTE 4)
83(NC)
84
POWER
H
52
O
COOLING TOWER
71
BYPASS VALVE 1-10 VDC CP1
A C
71
1-10 VDC
COOLING TOWER VFD 53
MICROTECH STARTER LOAD SIDE TERMINBALS

COMPRESSOR CONTROL VFD
- FOR DC VOLTAGE AND 4-20 MA
L1 L2 L3
BOX TERMINALS CONNECTIONS (SEE NOTE 3)
U V W
CTB1
NOTE 2 - FOR DETAILS OF CONTROL REFER
115 VAC
GND T1 T6 T2 T4 T3 T5 TO UNIT CONTROL SCHEMATIC
PE COMPRESSOR TERMINALS 330342101
CP1 L1
STARTER LOAD SIDE TERMINBALS
CP2 L2 WYE-DELTA - COMPRESSOR CONTROL
23(5A) 23 T1 T2 T3
T4 T5 T6 SCHEMATIC 330342201
COMPRESSOR 24(5) 24
- LEGEND: 330343001
MOTOR 25 25
T1 T2 T3 T4 T5 T6
STARTER COMPRESSOR TERMINALS * FIELD SUPPLIED ITEM
(NOTE 1) 1 1
2 2 SOLID STATE
NOTE 12
T1 T2 T3
3 3
4 4
6 11 T1 T6 T2 T4 T3 T5
COMPRESSOR TERMINALS
11 11
12 12
22 22 MEDIUM AND HIGH VOLTAGE
T1 T2 T3
-LOAD- NOTE 2 LESS
THAN
30V
OR T1 T2 T3
24VAC COMPRESSOR TERMINALS 330387901-0A
See notes on the following page.
IOMM Starter-3 31
NOTES for Wiring Diagram
1. Compressor motor starters are either factory-mounted and wired, or shipped separate for 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.
32 IOMM Starter-3
Startup
General
The startup of McQuay centrifugal chillers, including the starters, is performed by McQuay
authorized and trained technicians. They review the starter connections, phase sequence, and
settings prior to starting the chiller.
Setting a freestanding starter and power and control wiring from it to the chiller is the
responsibility of the owner/contractor. See the installation and power and control wiring
sections of this manual before commencing installation.
In the rare instances where a starter is being replaced after the chiller has been in service,
McQuay service is not automatically involved but can be contracted to supervise the starter
installation.
For general information, brief startup instructions are included on the following pages.
Low Voltage Solid State (RVSS)

LED Display
• Located on the starter control board
• View parameters, messages and faults.
• Shows software revision on power up.
Programming
• Press PARAM to enter the menu and
then UP or DOWN to reach the desired
parameter.
• Press ENTER to show the present value
of the parameter.
• Press UP or DOWN to change the
parameter value.
• Press ENTER to store the new value or PARAM to abandon the change.
Quick Meters
• Press DOWN to display the motor thermal overload content.
• Press UP to display the incoming line phase order.
• Press ENTER to display the status meter.
Fault Log·
• Select P32 and press ENTER. The most recent fault will be displayed as “xFyy”
where x will be 1 to indicate the most recent fault is being displayed and yy is the
fault code.
• Press DOWN to view older faults. Up to 9 faults may be stored in the log.
Resetting a Fault·
• Press RESET to reset from a fault.Resetting Parameters·
• Press and hold PARAM and ENTER on power up to reset parameters to default
values.
IOMM Starter-3 33
Emergency Thermal Reset·
• Press RESET and DOWN to perform an emergency thermal reset.
Messages (RVSS)
No Line Control Power Lockout – A start is
Ready not allowed because the control
Accelerating power is too low.
Up to Speed xxx xxx = overload content. Press
Run – Done with ramp but not yet DOWN to toggle.
Up to Speed. xx xx = Alarm code. If the condition
Decelerating persists, a fault will occur.
Overload Alarm – The motor xx xx = Fault code. Press RESET to
overload level is between 90% and clear.
100%. Instantaneous Overcurrent – Press
Overload Fault – The motor RESET to clear.
overload level has reached 100%. Default – Flashes when parameter
Overload Lockout – A start is not defaults are loaded.
allowed until the motor overload
level cools below 60%.
Default Meter Display (P13) (RVSS)
0: Status 7: Ave L-L Voltage RMS 14: KVA
1: Ave RMS Current 8: L1-L2 Voltage RMS 15: KWh
2: L1 RMS Current 9: L2-L3 Voltage RMS 16: MWh
3: L2 RMS Current 10: L3-L1 Voltage RMS 17: Phase Rotation
4: L3 RMS Current 11: Overload % 18: Line Frequency
5: Current Imbalance % 12: PF 19: Analog Input
6: Ground Fault Current 13: KW
Analog Output Function (P28) (RVSS)
0: OFF (no output) 6: KW (0 – 100KW)
1: Ave Current (0 – 200% RLA) 7: KW (0 – 1MW)
3: Ave Voltage (0 – 750VAC) 9: Analog Input
4: Thermal Overload% 10: Output Voltage (% of FV)
5: KW (0 - 10KW) 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)
SET
DESCRIPTION Values DEFAULT
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
CoS: Coast
P9 Stop Mode CoS
dcL: Voltage Decel
P10 Decel Begin Level 100 to 0 %Volts 40
Continued on next page.
34 IOMM Starter-3
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
Overcurrent Trip Delay
P15 0.1 to 90.0 seconds 2.0
Time
100, 110, 120, 200, 208,
220, 230, 240, 350, 380,
P16 Rated RMS Voltage 480
400, 415, 440, 460, 480,
575, 600, 660, 1000 Volts
P17 Over Voltage Trip Level OFF, 1 to 40 % rated Volts 10
P18 Under Voltage Trip Level OFF, 1 to 40 % rated Volts 10
Over/Under Voltage
P19 0.1 to 90.0 seconds 1.0
Delay Time
Current Imbalance Trip
P20 5 to 40 % 10
Level
P21 Controlled Fault Stop OFF, On OFF
P22 Auto Fault Reset Time OFF, 1 to 120 seconds 60
72, 96, 144, 288, 864,
P23 CT Ratio 2640
2640, 2880, 5760, 8000
TEr: Terminal
P24 Control Source tEr
NEt: Network
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)

Controlled Auto
Description
Stop 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
24 High Line L1-L2 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
IOMM Starter-3 35
Controlled Auto
Description
Stop 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.
36 IOMM Starter-3
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 Control Power Lockout – A start is
Ready not allowed because the control
Running in wye mode. power is too low.
Running in delta mode. xxx xxx = overload content. Press
Overload Alarm – The motor DOWN to toggle.
overload level is between 90% and xx xx = Alarm code. If the condition
100%. persists, a fault will occur.
Overload Fault – The motor xx xx = Fault code. Press RESET to
overload level has reached 100%. clear.
Overload Lockout – A start is not Instantaneous Overcurrent – Press
allowed until the motor overload RESET to clear.
level cools below 60%. Default – Flashes when parameter
defaults are loaded.
Default Meter Display (P5) (D3YD)
0: Status 7: Ave L-L Voltage RMS 14: KVA
5: Current Imbalance % 12: PF 19: Analog Input
Analog Output Function (P20) (D3YD)

0: OFF (no output) 6: KW (0 – 100KW)
3: Ave Voltage (0 – 750VAC) 9: Analog Input
4: Thermal Overload% 10: Reserved
5: KW (0 - 10KW) 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)
P4 Transition Time 1 to 30 seconds 10
IOMM Starter-3 37
Sequence Complete
P6 0.1 to 5.0 seconds 2.0
Delay Time
Overcurrent Trip Delay
P8 0.1 to 90.0 seconds 2.0
Time
100, 110, 120, 200, 208,
220, 230, 240, 350, 380,
400, 415, 440, 460, 480,
575, 600, 660, 1000 Volts
Over/Under Voltage
P12 0.1 to 90.0 seconds 1.0
Delay Time
Current Imbalance Trip
P13 5 to 40 % 20
Level
72, 96, 144, 288, 864,
P15 CT Ratio 2640
2640, 2880, 5760, 8000
TEr: Terminal
NEt: Network
P23 Passcode 0 to 9999 –
Fault/Alarm Codes (D3YD)

Auto
Description
Reset
00 No fault -
02 Motor Thermal Overload Trip N
10 Phase Rotation Error, not ABC Y
12 Low Line Frequency Y
13 High Line Frequency Y
15 Input power not three phase Y
21 Low Line L1-L2 Voltage Y
24 High Line L1-L2 Voltage Y
27 Phase Loss Y
28 No Line Voltage Y
30 I.O.C. (Instantaneous Overcurrent) N
31 Overcurrent N
37 Current Imbalance Y
38 Ground Fault N
39 No Current at Run Y
40 Open Line or Motor Lead N
41 Current While Stopped N
48 2M Feedback Fault (on DIN#2) N
50 Control Power Low Y
51 Current Sensor Offset Error N
38 IOMM Starter-3
Auto
Description
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.
IOMM Starter-3 39
Start Mode
Description
The Start Mode parameter allows for an optimal start of the motor based on the application.
For a description of the possible Start Mode parameters, refer to page 31 in the Operations
chapter.
Values
The Start Mode Parameter can be set to Curr, TT, or Tach.
Default
The default value for the Start Mode is Curr.
Stop Mode
Description
The Stop Mode parameter allows for the most suitable stop of the motor based on the
application. For a description of the possible Stop Mode parameters, refer to page 31 in the
Operations chapter of the starter manual.
Values
The Stop Mode can be set to Coas, VDCL, or TT.
Default
The default value for the Stop Mode is Coas.
Int. Curr. (initial current)
Description
The initial current parameter is set as a percentage of the motor FLA parameter setting. The
initial current parameter sets the current that will initially reach the motor when a start is
commanded.
If the motor does not rotate within a few seconds after a start command, the initial current
should be increased. If the motor takes off too quickly after a start command, the initial
current should be decreased.
The initial current must be set to a value that is lower than the maximum current parameter
setting.
A typical setting for the initial current parameter is from 50% to 175%.
Values
The initial current is adjustable from 50% to 400% in 1% intervals.
Default
The default value for the initial current is 100%.
Max. Curr. (maximum current)
Description
The maximum current parameter is set as a percentage of the motor FLA parameter setting.
The maximum current parameter performs two functions. It sets the current for the end of the
ramp profile and sets the maximum current that is allowed to reach the motor while the motor
is being started.
If the ramp time expires before the motor has reached full speed, the starter will hold the
current at the maximum current level until the stall time expires, the motor reaches full speed,
or the overload trips.
Typically, the maximum current is set to 600% unless the power system or load dictates the
setting of a lower maximum current.
Values
The maximum current is adjustable from 100% to 600% in 1% intervals.
40 IOMM Starter-3
Default
The default value for the maximum current is 600%.
Ramp Time
Description
The ramp time sets the amount of time that it takes for the starter to linearly increase the
current from the initial current level to the maximum current level. A typical ramp time
setting is from 15 to 30 seconds.
Settings
The ramp time is adjustable from 0 to 120 seconds in 1 second intervals.
Default
The default value for the ramp time is 15 seconds.
Overload
Default
The default value for the overload parameter is 10.
Phase Order
Description
The line phasing parameter sets the phase sensitivity of the starter. This can be used to protect
the motor from a possible change in the incoming phase sequence. If the incoming phase
sequence does not match the set phase rotation, the starter will display phs err while stopped
and will fault if a start is attempted.
Values
The line phasing can be set to:
• INS - will run with either phase sequence
• ABC - will only run with ABC phase sequence
• CBA - will only run with CBA phase sequence
Default
The default value for the phase sensitivity parameter is ABC.
IOMM Starter-3 41
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.
42 IOMM Starter-3
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.
IOMM Starter-3 43
Figure 26, Optional Starter Setpoint Screen
Table 3, Starter Setpoints

Pass-
Description No. Default Range Comments
word
Sets the value for ground
Ground Fault Current
8 1% 1 to 100% RLA M current above which the
Trip
compressor will be shut down
Turns the ground fault option on
Ground Fault Enable 7 OFF On or OFF M
or off
Sets the value for current
Maximum Current
6 10% 5% to 40% T unbalance above which the
Unbalance
compressor will be shut down
0 to 30 Sets the time the starter ramps
Starter Ramp Time 5 15 sec. T
seconds up the motor current
Maximum Starter 100% to 800% Sets the maximum current
4 600% T
Current of FLA (SP1) when the compressor starts
50% to 400% Sets the initial current when the
Initial Starter Current 3 100% T
of FLA (SP1) compressor starts
Factory set at Value that gives the 100% RLA
Rated load Amps 2 1A design T value and used for motor
conditions protection
Factory set to
Value used to compute SP3
Full Load Amps 1 1A motor max T
and SP4
current rating
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.
44 IOMM Starter-3
Standard Starter Keypad and Display
When the optional full metering display is not ordered, the LED display located in the starter
provides information on starter operation and programming. The 4-digit, 7-segment display
shows starter meter outputs and programming data. Special symbols provide further
information about the starter operation (see the following section).
Figure 27, Starter-mounted LED
Reset Key
RESET
LED Display
Operating
PARA M DOW N UP ENTER Keys
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
No Line Phase order meter showing ABC

Ready Phase order meter showing CBA
Accelerating or Kicking Phase order meter showing Single Phase
Up to Speed xxx xxx = overload content.
Run – Done with Accel ramp but not yet Up to xx xx = Parameter code.
Speed. xx xx = Alarm code. If the condition persists,
Decelerating Motor a fault will occur.
Overload Alarm – The motor overload level is xx xx = Fault code.
between 90% and 100%. Instantaneous Overcurrent
Overload Fault – The motor overload level has Default – Flashes when parameter defaults
reached 100%. are loaded.
Overload Lockout – A start is not allowed until the Energy Saver
motor overload level cools below 60%. In reflash mode
Control Power Lockout – A start is not allowed In reflash mode, programming
because the control power is too low. In reflash mode, verifying
Lock out State In reflash mode, complete
IOMM Starter-3 45
Display Operation
LED Display Fault Log
• View parameters, messages and faults. • Press PARAM, Select P24 and press
• Shows software revision on power up. ENTER. The most recent fault will be
displayed as “xFyy” where x will be 1
Programming to indicate the most recent fault is
• Press PARAM to enter the menu and then being displayed and yy is the fault
UP or DOWN to reach the desired code.
parameter. • Press DOWN to view older faults. Up
• Press ENTER to show the present value of to 9 faults may be stored in the log.
the parameter.
• Press UP or DOWN to change the Resetting a Fault
parameter value. • First correct the cause of the fault.
• Press ENTER to store the new value or Then press RESET to reset from a
PARAM to abandon the change. fault.
Quick Meters Resetting Parameters

• Press DOWN to display the motor thermal • Press and hold PARAM and ENTER on
overload content. power up to reset parameters to
default values.
• Press UP to display the incoming line
phase order. Emergency Thermal Reset
• Press ENTER to display the status meter. • Press RESET and DOWN to perform an
emergency thermal reset.
46 IOMM Starter-3
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
P4 Transition Time 1 to 30 seconds 10
P6 Sequence Complete Delay Time 0.1 to 5.0 seconds 2.0
IOMM Starter-3 47
P8 Overcurrent Trip Delay Time 0.1 to 90.0 seconds 2.0
208, 220, 230, 240, 380, 415,
440, 460, 480, 575 Volts
P12 Over/Under Voltage Delay Time 0.1 to 90.0 seconds 1.0
P13 Current Imbalance Trip Level 5 to 40 % 20
72, 96, 144, 288, 864, 2640,
P15 CT Ratio 2640
2880, 5760, 8000
TEr: = Terminal, NEt: =
P16 Control Source TEr
Network
P23 Passcode (See Note) 0 to 9999 Disabled
Table 6, Setpoints, Solid State Starter

P1 Motor FLA 1 to 9999 Amps 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
CoS: Coast
P9 Stop Mode CoS
dcL: Voltage Decel
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
P15 Overcurrent Trip Delay Time 0.1 to 90.0 seconds 2.0
208, 220, 230, 240, 380, 415, 440,
460, 480, 575 Volts
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
72, 96, 144, 288, 864, 2640, 2880,
P23 CT Ratio 2640
5760, 8000
Ter: Terminal, Net:
Network
48 IOMM Starter-3
P31 Passcode (See Note) 0 to 9999 Disabled
NOTE: Passcode is a numerical password that can be entered in P31. The factory default is
to disable the password requirement. It is recommended that a Passcode not be entered.
Messages
Setpoint P5 for Wye-Delta or P13 for solid state can be set to establish what message is
shown on the LED. Selecting meter display “0” (which is the default) will display the active
status message as shown in Table 7 or Table 8, except if there is a fault (requiring a message)
or some other information has been requested.
Alternatively, parameter P5 or P13 can be set to select a message (1 to 19 as shown in
Table 9).
Table 7, Status Messages, Wye-Delta Starter

No Line Control Power Lockout – A start is not
Ready allowed because the control power is
Running in wye mode. too low.
Running in delta mode. xxx xxx = overload content. Press DOWN to
Overload Alarm – The motor overload toggle.
level is between 90% and 100%. xx xx = Alarm code. If the condition
Overload Fault – The motor overload persists, a fault will occur.
level has reached 100%. xx xx = Fault code. Press RESET to clear.
Overload Lockout – A start is not Instantaneous Overcurrent – Press
allowed until the motor overload level RESET to clear.
cools below 100%. Default – Flashes when parameter
defaults are loaded.
Table 8, Status Messages, Solid State Starter
No Line Control Power Lockout – A start
Ready is not allowed because the
Accelerating control power is too low.
Up to Speed xxx xxx = overload content. Press
Run – Done with ramp but not yet Up DOWN to toggle.
to Speed. xx xx = Alarm code. If the
Decelerating condition persists, a fault will
Overload Alarm – The motor overload occur.
level is between 90% and 100%. xx xx = Fault code. Press RESET to
Overload Fault – The motor overload clear.
level has reached 100%. Instantaneous Overcurrent –
Overload Lockout – A start is not Press RESET to clear.
allowed until the motor overload level Default – Flashes when
cools below 100%. parameter defaults are loaded.
IOMM Starter-3 49
Table 9, Default Meter Display
0: Status Message 7: Ave L-L Voltage RMS 14: KVA
5: Current Imbalance % 12: Power Factor 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.
50 IOMM Starter-3
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.
IOMM Starter-3 51
Figure 28, Wye Delta Motor Connection to the D3 Control
L1 L2 L3
T o T B 3, C1+ (W hite W ire)

T o T B 3, C 1- (B lack W ire)
T o T B3, C 2+ (W hite W ire ) C urrent F eedbacks
T o T B 3, C 2- (B lack W ire) to M X
T o T B3, C 3+ (W hite W ire )
To TB6 (SCR 2) K2 T o T B 3, C 3- (B lack W ire)
To TB8 (SCR 3) K3
To TB4 (SCR 1) K1
1M 2S 2M
R esistor
R esistor
Voltage &
Frequenc
y to MX
Line
R esistor
T3 T6 1S
T2 T5
T1 T4
C ontrol P ow er
2M C onfirm
Input C om m on
2M MX
2S
UTS
MX
1S
R un 2M 2S
MX M echanical
1M Interlock
1S
2M
1M 1S
The closed transition resistors generally are sized to be in the circuit for a short period of
time. To protect the resistors from over heating, one input should be programmed as a
Bypass/2M contact feedback input and the Bypass/2M confirm parameter must be set.
For the Wye-Delta starter mode to operate properly, one output relay needs to be
programmed to the RUN output function and another output relay needs to be programmed to
the UTS output function. (Refer to parameters I/0 04-06, P42-44 for more information).
Wye-Delta Operation
When the D3 control Starter Type parameter (FUN 07, P64) is set to Wye-Delta, the D3
control is configured to operate an electromechanical Wye-Delta (Star-Delta) starter. When
in Wye-Delta mode, all D3 motor and starter protective functions except bad SCR detection
and power stack overload, are available to provide full motor and starter protection.
The D3 control utilizes an intelligent Wye to Delta transition algorithm. If during starting
the measured motor current drops below 85% of FLA and more than 25% of the UTS /
Transition Time (QST 09, P9) has elapsed then a Wye to Delta transition will occur. The
intelligent transition algorithm prevents unnecessarily prolonged motor starts thereby
52 IOMM Starter-3
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.
IOMM Starter-3 53
The starter will remain in the Delta or running mode until the start command is removed or a
fault occurs.
Usually the D3 intelligent Wye to Delta transition algorithm provides an optimal transition
point that minimizes the transient current and torque surges that can occur. However
sometimes, based on the motor and loading, the Wye to Delta transition will occur only after
the Transition Time has expired. In order to reduce the current surge that can take place
during the transition from Wye to Delta mode, the Transition Time parameter (QST 09, P9)
should be adjusted so that the transition occurs as close to full speed as possible within the
constraints of the load. If the transition time is set too short, a large current and torque surge
may occur during the transition. If the transition time is set too long, the motor may not have
sufficient torque to continue accelerating when in Wye mode and may stop accelerating at a
low speed until the transition to Delta mode occurs. If this occurs, the start is unnecessarily
prolonged and motor heating is increased.
A typical closed transition Wye-Delta starting current profile is shown in Figure 29.
Figure 29, Wye Delta Profile

Wye-Delta Closed Transition Current Profile
600%
500%
% Full 400%
Load
Motor
Current 300%
200%
100%
0% 100%
% speed
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.
54 IOMM Starter-3
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,
UTS Time
P8) is shorter than the UTS timer setting.
F01 Limit
Expired Evaluate acceleration ramp settings. The acceleration ramp settings may be too low to
permit the motor to start and achieve full speed. If so, revise acceleration ramp settings to
provide more motor torque during starting.
Evaluate UTS timer setting and, if acceptable, increase UTS timer setting (QST 09, P9).
The D3 motor thermal overload protection has tripped.
Check motor for mechanical failure, jammed, or overloaded condition.
Verify the motor thermal overload parameter settings (QST 03, P3 and PFN 12-16, P35-
38) and motor service factor setting (QST 02, P2).
Motor Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch
F02 Thermal settings are correct.
(F OL) Overload
Trip If motor OL trip occurs during starting, review acceleration ramp profile settings.
Verify that there is not an input line power quality problem or excessive line distortion
present.
Verify that PF caps, if installed, are ahead of CT’s.
Reset overload when content falls below 15%.
Input phase rotation is not ABC and Input Phase Sensitivity parameter (FUN 04, P67) is
Phase
set to ABC only.
Rotation
F10
Error, not Verify correct phase rotation of input power. Correct wiring if necessary.
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
Phase
set to CBA only.
Rotation
F11
Error, not Verify correct phase rotation of input power. Correct wiring if necessary.
CBA
Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67).
Line frequency below 23 Hz was detected.
Verify input line frequency.

Low Line
F12 If operating on a generator, check generator speed governor for malfunctions.
Frequency
Check input supply for open fuses or open connections
Line power quality problem / excessive line distortion.
IOMM Starter-3 55
Line frequency above 72 Hz was detected.
High Line Verify input line frequency.

F13
Frequency If operating on a generator, check generator speed governor for malfunctions.
Line power quality problem / excessive line distortion.
Three-phase power has been detected when the starter is expecting single-phase power.
Input power Verify that input power is single phase.

F14 not single Verify that single-phase power is connected to the L1 and L2 inputs. Correct wiring if
phase necessary.
Verify that the SCR gate wires are properly connected to the D3 control board.
Single-phase power has been detected when the starter is expecting three-phase power.
Input power Verify that input power is three phase. Correct wiring if necessary.
F15 not three
phase Verify that the SCR gate wires are properly connected to the D3 control board.
On medium voltage systems, verify wiring of the voltage feedback measurement circuit.
Low voltage below the Undervoltage Trip Level parameter setting (PFN 08, P31) was
detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).
Verify that the actual input voltage level is correct.

Low Line L1-
F21
L2 Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Check input supply for open fuses or open connections.
On medium voltage systems, verify wiring of the voltage measurement circuit.

Low Line L2-
F22

Low Line L3-
F23
56 IOMM Starter-3
High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was
High Line
F24
L1-L2 Verify that the actual input voltage level is correct.
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Line power quality problems/ excessive line distortions.
High Line
F25
High Line
F26
The D3 control has detected the loss of one or more input or output phases when the
starter was running. Can also be caused by line power dropouts.
Check input supply for open fuses.
F27 Phase Loss Check power supply wiring for open or intermittent connections.
Check motor wiring for open or intermittent connections.
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.
F28 No Line
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.
IOMM Starter-3 57
Fault
Description Detailed Description of Fault / Possible Solutions
Code
During operation, the D3 controller detected a very high level of current in one or more
phases.
I.O.C. Check motor wiring for short circuits or ground faults.
F30 (Instantaneous
Check motor for short circuits or ground faults.
Overcurrent
Current) Check if power factor or surge capacitors are installed on the motor side of the starter.
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch
settings are correct.
Motor current exceeded the Over Current Trip Level setting (PFN 01, P24) for longer
F31 Overcurrent than the Over Current Trip Delay Time setting (PFN 02, P25).
Check motor for a jammed or an overload condition.
Motor current dropped under the Under Current Trip Level setting (PFN 03, P26) for
F34 Undercurrent longer than the Under Current Trip Delay time setting (PFN 04, P27).
Check system for cause of under current condition.
A current imbalance larger than the Current Imbalance Trip Level parameter setting
(PFN 05, P28) was present for longer than ten (10) seconds.
Current Check motor wiring for cause of imbalance. (Verify dual voltage and 6 lead motors for
F37 correct wiring configuration).
Imbalance
Check for large input voltage imbalances that can result in large current imbalances.
Check motor for internal problems.
Ground current above the Ground Fault Trip level setting (PFN 06, P29) has been
detected for longer than 3 seconds.
Check motor wiring for ground faults.
Check motor for ground faults.
F38 Ground Fault Megger motor and cabling (disconnect from starter before testing).
Verify that the CTs are installed with all the White dots towards the input line.
F39 No Current at Motor current went below 10% of FLA while the starter was running.
Run
Verify Motor Connections.
Verify the CT wiring to the D3 control board.
58 IOMM Starter-3
Fault
Code
Check if load is still connected to starter
No Current at Check if motor may have been driven by the load (a regeneration condition)
F39
Run (Cont’d) Check Gate and Cathode connections to D3 for loose connections.
Check for inline contactor or disconnect.
A shorted or open SCR condition has been detected.
Verify that all SCR gate leads wires are properly connected at the SCR devices and the
D3 control board.
Shorted / Open Check all SCRs with ohmmeter for shorts.
F40
SCR
Verify that the Input Phase Sensitivity parameter setting (FUN 04, P67) is correct.
Verify that the Starter Type parameter setting (FUN 07, P64) is correct.
Verify the motor wiring. (Verify dual voltage motors for correct wiring configuration).
Motor current was detected while the starter was not running.
Examine starter for shorted SCRs.

F41 Current at Stop Examine bypass contactor (if present) to verify that it is open when starter is stopped.
The D3 electronic power stack OL protection has detected an overload condition.

Stack
Protection
F47 Fault (stack Verify Starter Model Number parameter setting (FUN 13, P70) is correct (if available).
thermal
Verify that the CT ratio (FUN 03, P68) and burden switch settings are correct.
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.
Bypass /2M Verify that the relay output that is connected to the bypass/2M contactor(s) is
F48 Contactor programmed to the UTS function.
Fault
Verify that the bypass/2M contactor power supply is present.
Verify that the appropriate Digital Input Configuration parameter has been programmed
correctly.
Verify that the bypass contactor(s) are actually not damaged or faulty.
IOMM Starter-3 59
Fault
Code
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.
Control
F50
Power Low Check control power transformer tap setting (if available).
Check control power transformer fuses (if present).
Check wiring between control power source and starter.
Indicates that the D3 control board self-diagnostics have detected a problem with one or
more of the current sensor inputs.
Current Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch
F51 Sensor settings are correct.
Offset Error Verify that no actual current is flowing through any of the starter’s CTs when the starter is
not running.
Consult factory if fault persists.
Burden The burden switch settings were changed when starter was running. Only change burden
F52
Switch Error 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.
External
F60 Fault on Verify that the appropriate Digital Input Configuration parameter has been programmed
DI#1 Input correctly.
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.
External
DI#2 Input correctly.
DI#3 input has been programmed as a fault type digital input and input indicates a fault
condition is present.
External
DI#3 input correctly.

60 IOMM Starter-3
Fault
Code
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.

Analog Input
F71 Verify settings of all Analog Input parameters (I/O 07-11, P45-49).
Level Fault Trip.
Verify correct positioning of input jumper JP3 (Voltage or Current) on the D3 control
card.
Verify correct grounding of analog input connection to prevent noise or ground loops
from affecting input.
Indicates that communication has been lost with a remote device such as a remote
keypad.
(This fault will normally occur if the remote keypad is disconnected while the D3
control board is powered up. Only connect and disconnect a remote keypad when the
control power is off.)
SPI
F81 Communication Verify that the remote keypad cable has not been damaged and that its connectors are
Fault firmly seated at both the keypad and the D3 Control board.
Verify that the display interface board (when present) is firmly attached to D3 control
card.
Route keypad cables away from high power and/or high noise areas to reduce possible
electrical noise pickup.
Indicates that the starter has lost serial communications. Fault occurs when the starter
has not received a valid serial communications within the Communication Timeout
parameter (FUN 12, P59) defined time.
Modbus
F82 Verify communication parameter settings (FUN 10-12, P59-P61).
Timeout Fault
Check wiring between the remote network and the D3 control card.
Examine remote system for cause of communication loss.
Typically occurs when attempting to run a version of control software that is

incompatible with the D3 control board hardware being used. Verify that the software
CPU Error – is a correct version for the D3 control board being used. Consult factory for more
F94 details.
SW fault
Fault can also occur if the D3 control has detected an internal software problem.
Consult factory.
CPU Error – The non-volatile user parameter values have been found to be corrupted. Typically
F95
Parameter occurs when the D3 control is re-flashed with new software.
EEPROM
Perform a Factory Parameter reset and then properly set all user parameters before
Checksum Fault
resuming normal operation.
IOMM Starter-3 61
Fault
Code
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.
CPU Error –
F97 SW Watchdog The D3 control has detected an internal software problem. Consult factory.
Fault
F98 CPU Error The D3 control has detected an internal CPU problem. Consult factory.
CPU Error – The non-volatile program memory has been corrupted.

Program
F99 Consult factory. Control software will need to be reloaded in to the D3 control card
EPROM
Checksum Fault before normal operation can resume.
62 IOMM Starter-3
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
Check for proper control voltage input.
Display Blank, CPU Heartbeat Control voltage absent.
Verify fuses and wiring.
LED on D3 board not blinking.
D3 control board problem. Consult factory.
See fault code troubleshooting table for
Fault Displayed. Fault Occurred.
more details.
Verify that the start/stop wiring and start
Start/Stop control input problems.
Start command given but nothing input voltage levels are correct.
happens. Control Source parameters ( P4-5) Verify that the parameters are set
not set correctly. correctly.
Check input supply for inline contactor,
open disconnects, open fuses, open
circuit breakers, or disconnected wiring.
Verify that the SCR gate wires are
NOL or No Line is displayed and properly connected to the D3 control
No line voltage has been detected by
a sratr command is given, it will board.
the D3 st is given rterarter.
fault in F28. On medium voltage systems, verify
wiring of the voltage feedback
measurement circuit.
more details.
During starting, motor rotates but does not reach full speed
more details.
Maximum Motor Current setting
Review acceleration ramp settings.
( P7) set too low.
Motor loading too high and/or
current not dropping below 175%
Reduce load on motor during starting.
FLA indicating that the motor has
Display shows Accel or Run. not come up to speed.
Motor FLA ( P1) or CT ratio ( P1 & Verify that Motor FLA and CT ratio
P15) parameter set incorrectly. parameters are set correctly.
Abnormally low line voltage. Fix cause of low line voltage.
A mechanical or supplemental brake Verify that any external brakes are
is still engaged. disengaged.
Initial current to low Increase initial current
Motor Hums before turning
FLA or CT incorrect Verify FLA or CT’s
IOMM Starter-3 63
Acceleration not operating as desired
Ramp time ( P8) too short. Increase ramp time.
Initial current ( P6) set too high. Decrease Initial current.
Maximum current ( P7) set too high. Decrease Maximum current.
Kick start current ( P13) too high. Decrease or turn off Kick current.
Motor accelerates too quickly. Kick start time ( P14) too long. Decrease Kick time.
Motor RLA ( P1) or CT ratio ( P15) Verify that Motor FLA and CT ratio
parameter set incorrectly. parameters are set correctly.
Starter Type parameter ( P64) set Verify that Starter Type parameter is
incorrectly. set correctly.
Maximum Motor Current setting
Review acceleration ramp settings.
( P7) set too low.
Reduce load on motor during
Motor loading too high.
starting.
Motor accelerates too slowly
Motor RLA ( P1) or CT ratio ( P15) Verify that Motor FLA and CT ratio
parameter set incorrectly. parameters are set correctly.
Abnormally low line voltage. Fix cause of low line voltage.
Ramp time to long Decrease ramp time
Motor stops unexpectedly while running

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)
Check for proper control voltage
Display Blank, Heartbeat LED on D3 Control voltage absent.
input. Verify wiring and fuses.
board not blinking.
D3 control board problem. Consult factory.
64 IOMM Starter-3
Metering incorrect
Verify correct CT wiring and verify
that the CTs are installed with all the
CTs installed or wired incorrectly.
White dots towards the input line
Power Metering not reading side.
correctly. CT ratio parameter (FUN 03, P68) Verify that the CT ratio parameter is
set incorrectly. set correctly.
Verify that the burden switches are
Burden switches set incorrectly.
set correctly.
Verify correct CT wiring and verify
PF Meter not reading correctly. CTs installed or wired incorrectly.
side.
Energy Saver active. Turn off Energy Saver if not desired.
Shut off all power and check all
Loose connections.
connections.
Verify that the SCRs gate leads are
SCR fault. connected properly and the SCRs are
Motor Current or Voltage meters ok.
fluctuating with steady load. Verify that the load is actually steady
Load actually not steady. and that there are not mechanical
issues.
Other equipment on same power feed
Fix cause of power fluctuations
causing power fluctuations and/or
and/or distortion.
distortion.
In medium voltage systems, Rated
Voltage Metering not reading Verify that Rated Voltage parameter
Voltage parameter (FUN 05, P66) set
correctly. is set correctly.
incorrectly.
CT ratio parameter (FUN 03, P68) Verify that the CT ratio parameter is
Current Metering not reading set correctly.
correctly. Verify correct CT wiring and verify
side.
CT ratio parameter (FUN 03, P68) Verify that the CT ratio parameter is
Ground Fault Current Metering not set correctly.
reading correctly. Verify correct CT wiring and verify
side.
IOMM Starter-3 65
Other Situations
If input phasing correct, exchange
any two output wires.
Motor Rotates in Wrong Direction Phasing incorrect
If input phasing incorrect, exchange
any two input wires.
Shut off all power and check all
Erratic Operation Loose connections
connections.
Motor overloaded Reduce motor load.
Allow for adequate motor cooling
Too many starts per hour between starts. Set Hot/Cold ratio
higher or lengthen cooling time.
Reduce ambient temperature or
provide for better cooling. Set OL
High ambient temperature
class lower to compensate for
Motor Overheats
ambient temperature.
Reduce starting load and/or review
Acceleration time too long
acceleration ramp settings.
Review and correct if necessary
Incorrect motor OL settings
motor OL settings.
Remove cooling air obstructions.
Motor cooling obstructed/damaged
Check motor cooling fan.
Fan power supply lost Verify fan power supply, check fuses.
Starter cooling fans do not operate
Fan wiring problem Check fan wiring.
(When Present)
Fan failure Replace fan
Voltage/Current output jumper (JP1)
Set jumper to give correct output.
not set correctly.
Wiring problem Verify output wiring.
Analog Output Function parameter Verify that the Analog Output
(I/O 12, P50) set incorrectly. Function parameter is set correctly.
Analog Output Offset and/or Span Verify that the Analog Output Span
parameters (I/O 13-14, P51-52) set and Offset parameters are set
Analog Output not functioning incorrectly. correctly.
properly Verify that load on analog output
Load on analog output too high. meets D3 control analog output
specifications.
Verify correct grounding of analog
Ground loop or noise problems. output connection to prevent noise or
ground loops from affecting output.
66 IOMM Starter-3
Operation, Medium/High Voltage Starters, 2300V – 7.2KV
Introduction
This section contains information on medium voltage, across-the-line and solid state starters
as manufactured by Benshaw Inc. for McQuay centrifugal Chillers. Medium voltage starters
have similar software (Micro II Control) and are grouped together in this manual. Model
numbers are as follows:
Model Number Description
MVSS36 to MVSS30 Solid State, 2300V, Free-standing
HVSS42 to HVSS05 Solid State, 5.1KV to 7.2KV, Free-standing
MVAT12 to MVAT36 Across-the-Line, 2300V, Free-standing
HVAT27 Across-the-Line, 6600V, Free-standing
Figure 30, LED Display/Keypad
Viewing Data
Description of the LEDs on the Keypad
The keypad provides three LED indicators in addition to the 2x16 character display. The LEDs
provide starter status information.
IOMM Starter-3 67
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.

MENU 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.

ENTER 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
START 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
STOP control.
68 IOMM Starter-3
If 2-wire control is used or the Stop button is disabled, this button is
inoperative.
IOMM Starter-3 69
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
Motor Meters &
Quick Start Starter Setup Motor Protection
Nameplate Relays
Starter Modes Overload Class Meters Setup
Standard
Forward1 Profile Line Current
Relays
Extended
Forward2 Profile Line Voltage
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
Continued
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.
70 IOMM Starter-3
• 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.
IOMM Starter-3 71
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.
72 IOMM Starter-3
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.
Control voltage is absent. Check for proper control voltage.
Display is blank. FU1 on power card. Replace FU1.
Ribbon Cables. Check ribbon cables.
Control Devices Check control devices
Stopped
Display buttons disabled. Enable display buttons.
No line Missing at least one phase of main power
Check power system.
Table 12, Motor rotates but does not reach full speed.
Fault displayed. Shown on display See fault code table.
Mechanical problems. Check for load binding. Check motor.
Accel or Running
Abnormally low line voltage. Fix line voltage problem
Table 13, Deceleration profile not operating correctly.

Time setting. or improper level Contact McQuay Factory
Motor stops too quickly.
setting. Service
Time seems correct but motor surges at start of Decel level 1 Contact McQuay Factory
decel. Service
Time seems correct but motor stops before cycle Decel level 2. Contact McQuay Factory
complete. TruTorque DCL End Torque Service
Time seems correct but water hammer occurs at Decel level 2. Contact McQuay Factory
end of cycle. TruTorque DCL End Torque Service
Table 14, Motor stops while running.

Fault displayed. Shown on display. See fault code table.
Control voltage is absent. Check control wiring and voltage.
Display is blank.
FU1 on power card Replace fuse.
Stopped Control devices. Check control system.
IOMM Starter-3 73
Table 15, Other situations.
Power Metering not working. CT installed wrong. Fix CT installation. White dot to line side.
TruTorque Ramp not working. CT installed wrong. Fix CT installation. White dot to line side
Motor Verify motor is operating correctly.
Motor current or voltage fluctuates with steady
Energy saver Set energy saver to off.
load.
Power connection. Shut off power and check connections
Erratic operation. Loose connections. Shut off all power and check connections.
Ramp time.
Initial current.
Maximum current setting.
Accelerates too quickly. Kick Start. Contact McQuay Factory Service
Improper FLA setting.
Initial torque.
Maximum torque.
Ramp time.
Initial current.
Maximum current setting.
Accelerates too slowly Kick Start. Contact McQuay Factory Service
Improper FLA setting.
Initial torque.
Maximum torque.
Duty cycle. Cool between starts.
High ambient. Provide better ventilation.
Motor overheats. Too long acceleration time. Reduce motor load.
Wrong overload setting. Select correct overload setting.
Too long jog cycle. Jog operation reduces motor cooling and increases
current. Shorten jog cycle.
Wiring fault. Identify fault and correct.
Motor short circuit. Power factor correction capacitors (PFCC)
MoveonPFCC to line side of starter.
starter output.
Wiring. Check wiring and correct.
Fans do not operate Fuse. Replace fuse.
Fan failed. Replace fan.
Display ribbon cable. Check cable on back of display.
Display buttons don’t work.
Display faulty. Replace display.
74 IOMM Starter-3
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/ Fault Fault/Event Description/Possible Solutions
Log No. Class Recorder Text
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.
Line frequency went above the high freq. trip setting
Line power quality problem.
4 NonC High Freq. Trip
Low control power problem.
Generator governor is malfunctioning
Line frequency went below the low freq. trip setting
5 NonC Low Freq. Trip Line power quality problem.
Low control power problem.
Generator governor malfunctioning.
Jog input (JC13-4) was energized while the starter was running.
6 NonC Jog Not Allowed Stop the starter by removing the run command before requesting a jog
(JC13-4).
The jog input (JC13-4) was de-energized while the starter was operating
in the jog mode.
7 NonC 100% Not Allowed
Stop the starter by removing the run command before removing the jog comma
(JC13-4).
The jog direction was changed while the starter was operating in the jog
mode.
9 NonC Dir Change Fault
Stop the starter by removing the run command before changing the state of t
reversing input (JC13-6).
15 Crit Phase Order Err Phase order error.
16 Crit Bad OP Code Err Bad operating-code error
17 NonC Over voltage L1 The voltage on line 1 went above the high/low voltage setting
20 NonC Low line voltage#1 The voltage on line 1 went below the high/low voltage setting
23 NonC Curr. Imbal. HL1 The current on line 1 went above the current imbalance setting
26 NonC Curr. Imbal. LL1 The current on line 1 went below the current imbalance setting
Bad RAM battery.
Replace IC16 or computer card to correct problem.
29 Crit Bad RAM Battery
To clear fault, hold the down arrow key and perform a computer reset. Continue holdi
the down arrow key until fault 30 appears on the display
The factory defaults for the parameters have been loaded.
30 Crit Def Param Loaded Reset the computer to clear the fault.
All parameters have to be re-programmed as necessary.
Starter is not a reversing unit.
31 NonC REV Not Allowed
Remove reverse command from reverse input (JC13-6).
The Built-in Self Test was canceled.
46 NonC BIST 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
IOMM Starter-3 75
The door mounted keypad has failed.
50 Crit Key Pad Failure The Stop or Start button was held down while a computer reset was performed or
while power was applied to the unit.
During TruTorque ramping, the motor current exceeded the TruTorque Overcurrent
51 Crit TT Overcurrent Limit
Trip level
Current flow above the no current at run setting was detected while
52 Crit Curr. At Stop the starter was stopped.
Examine starter for shorted SCRs.
The motor current went below the no current at run setting while the
starter was running.
53 NonC No Curr. At Run
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.
Communications with the RTD module was lost.
66 NonC RTD Comm Loss 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
The jog timer expired.
68 NonC Jog Timer Limit
Examine reason for extended jog operation.
The zero speed timer expired.
69 NonC Zero Speed Timer
• Check motor for jammed or overloaded condition
Control power is too low.
70 NonC Low Control PWR 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.
The bypass contactor failed to stay energized.
73 NonC Bypass Fault Check separate bypass for proper wiring.
Check integral bypass (RSxB units) control card fuses.
The motor was not at full speed before the UTS time expired.
74 NonC UTS Timer Limit
Power was removed from the external trip input on the computer card
75 NonC External Trip (JC13-1).
Trip input delay is set to short
76 Crit Disconnect Open A start was commanded while the disconnect was open.
The in-line contactor did not close.
Check wiring to coil of contactor.
77 NonC In-line Fault
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
The field current was above the maximum field current setting.
80 NonC High Field Curr. • Examine parameter settings for improper adjustment.
• Examine field for problem causing the high field current
There was no synchronous field current.
81 NonC Field Loss
Check wiring and motor for open field circuit.
The motor came out of synchronization while it was operating.
Examine the motor load for an overload.
82 NonC Loss of SYNC
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.
76 IOMM Starter-3
The start/stop circuitry has failed.
91 Crit Unauthorized RUN 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
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.
IOMM Starter-3 77
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
Watch Dog/Power
LEDC1 On when reset/CPU failure/control voltage failure.
Fail/Reset
LEDC2 Control power On if control voltage is present.
Computer DeviceNet Network
NS See DeviceNet manual.
Status
DeviceNet Module
MS See DeviceNet manual.
Status
DE Data Enable On when card is transmitting data.
TXD Transmit Data On when card is transmitting data.
Local I/O
RXD Receive Data On when card is receiving data.
Controller Card
LED1 Operation Flashes when card is operating.
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
LEDP1
Start - LEDs will become dimmer as motor
Power LEDP2 SCR Status
accelerates.
LEDP3
Run - LEDs must be fully off or the SCR is open or
misfiring.
Condition of SCR’s Indicates SCR condition;
L1 and L2 - SCR’s A Stop - LEDs will be off when stopped.
and B Start - LEDs will be bright when the in-line is
L1 - L6 L3 and L4 - SCR’s C energized. LED’s will go progressively dimmer as
Pulse Generator and D motor accelerates.
L5 and L6 - SCR’s E Run - LED’s will be off when motor reaches full
and F voltage.
These LEDs will be on, while ramping, to indicate
A-F SCR gate voltage
that gate power is reaching the SCR’s.
78 IOMM Starter-3
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.
IOMM Starter-3 79
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
80 IOMM Starter-3
IOMM Starter-3 81
82 IOMM Starter-3
All McQuay equipment is sold pursuant to McQuay’s Standard Terms and Conditions of Sale and
Limited Product Warranty. Consult your local McQuay Representative for warranty details. Refer
to form 933-430285Y-00-A (09/08). To find your local representative, go to www.mcquay.com
This document contains the most current product information as of this printing. For the most up-to-
date product information, please go to www.mcquay.com.
• (800) 432-1342 • www.mcquay.com IOMM Starter-3 (12/10)

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Starters For Centrifugal Chillers: Installation, Operation and Maintenance Manual

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Installation, Operation and Maintenance Manual IOMM Starter-3

Starters for Centrifugal Chillers

"McQuay" is a registered trademark of McQuay International2010

Figure 1, Wye-Delta Starter

Control Transformer and Fuses

Primary Control Circuit

Variable Frequency Drives

Basic Electrical Terms

Starter Field Installation

Receiving and Setting

Location and Mounting

Power Factor Capacitors, Surge Capacitors and Lightning Arrestors

Line Side Lugs

Model Size Lug Size Lug Size

Size (Amps) Circuit Disconnect

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

00.0 18.0 34.0 38.0

Starter (All) Outgoing Incoming to Starter Incoming to Incoming to

00.0 18.0 34.0 38.0

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

Starter Breaker Incoming Incoming

RVST14 250 #6-350 #6-350

Incoming Lug Outgoing

Resistor Contactor for

D3DW34 500 (2)500

00.0 18.0 34.0 38.0 Incoming

00.0 18.0 34.0 38.0

1. All dimensions in inches (mm)

21.0 (533.4) 8.0 (203.2)

FRONT INTERIOR VIEW

1 REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.

2 CABLE ENTRY/EXIT AREA. NO CUTOUT SUPPLIED.

5. STARTER WEIGHT: APPOXIMATELY 1800LBS

3.0 (76.2) TYP.

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

INLINE STACK ASSEMBLY

30.0 (762.0) 45.0 (1143.0)

FRONT INTERIOR VIEW

NOTES: 1 REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.

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

3. ENCLOSURE COLOR: ANSI 61 GREY.

LOW VOLTAGE DOOR

SIDE ACCESS AREA

2300 VAC OFF

1 2 3 "R" RATED FUSES

500:5 CTS 500:5 CTS

FRONT INTERIOR VIEW 32.00

RIGHT SIDE INTERIOR VIEW

.25 NOTES: 1 REMOVABLE LIFTING EYEBOLTS, PLUG HOLES IF REMOVED.

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

LANDING PAD DETAIL "A”

Refer to Figure 23 on page 31 for power wiring connections.

General Wiring Practice

Medium Voltage, Solid State, Across-the-Line

Compressor Motor Connections

Type/Size Comp. Size Terminal Size

Control Power Wiring

Low Voltage Starters

Wiring for Optional Remote D3 Display Figure 21, Starter Panel

Wiring Connection on Starter for Optional Display

Medium/high Voltage Starters

MICROTECH STARTER LOAD SIDE TERMINBALS