Model VSD 270, 292, 351, 385, 419, 424, 503, 608, 658, 704 LVD
Contents
1.2. 13 Differences for the VSD and model 13 Optispeed Compressor Drive Control System E 13 The Control Center before 2005 13 The Control Center beginning in 2005 14 OptiSpeed and Optional Harmonic Filter Logic Control 14 Microcomputer Control Panel VSD Related Keypad FU rctlons es de gie i e eed 14 OptiView Control Panel VSD Functions 14 VSD Adaptive Capacity 14 Setpoint Requirements ic nire weed Alive elie 15 Stability Requirements arseenia ra ier E diu x need et eei 15 Full Open Vane Operation 15 Effects OP SUIGE pp 15 Drive Not Reducing Speed aee radice reed en AEA AAE ea dace dread 16 Stability Limit Adjustment
3. 29 Warning Harmonic Filter Operation 29 VSD Frequently Asked Questions sororia iiaia e e a rec EI p RE P deos 30 LIST OF FIGURES FIGURE 1 OptiSpeed System 17 FIGURE 2 VSD Logic Board Located on Panel eene 20 FIGURE 3 SCR Trigger Board ee epi tr ele e edle eke de erue ende ede eed tee 20 FIGURE A DG BUS Isolator Board nette teu iint e m 21 FIGURE 5 Gate Driver Board and Power 21 LIST OF TABLES TABLE 1 VSD Part Numbers And 4 TABLE 2 LVD Part Numbers And 8 TABLE 3 Safety Shutdowrls RE ect avene cua ats 22 TABLE 4 Cycling Shutdown 24 TABLE 5 Warning Messages eed dn el pice ud cea ede dA el 29 TABLE 6 SI Metric Conversioni i ete eR e eate Deere eiit rh Ge siet uet eret 31 10 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 GENERAL INFORMATION This instruction is
4. 160 00 04 ISSUE DATE 4 15 2015 The OSCD output suppression network is composed of a series of capacitors and resistors The job of the suppressor network is to increase the time it takes for the output voltage to switch as seen by the motor and reduce the peak voltage applied to the motor windings This network protects the compressor motor from problems commonly associated with PWM motor drives Other sensors and boards are used to provide safe oper ation of the OptiSpeed Compressor Drive The transis tor module and heatsink have thermistors mounted on them to provide temperature information to the OSCD logic board These sensors protect the OSCD from over temperature conditions A Bus Voltage Isolator board is used to ensure that the DC bus capacitors are properly charged Three output current transformers protect the OSCD and motor from over current conditions OptiSpeed Compressor Drive 385 419 503 608 658 704 and 900 Hp The 385 419 503 608 658 704 and 900 Hp OSCD s function in the same manner as the 270 292 351 and 424 Hp and have the same basic components The power requirements of these higher horse power drives require more capacitors in the DC Bus and 3 output transistor sections are needed One section is used for each output phase Each transistor module within the output transistor section contains a thermistor which is connected to the OSCD logic board The transistor gate driver board is mounted
5. 16 Surge MargirvAdj stment ned adden etii 16 i e arse I ES 22 General Information aan Toine be e e i ted ee dd a dA G vete dde 22 Motor or Starter Current Imbalance p C 22 VSD 105 Motor Current 22 VSD High Converter Heatsink 22 VSD High Inverter Baseplate Temperature 270 292 351 and 424 Hp 22 VSD High Phase X Inverter Baseplate Temperature 385 419 503 and 608 Hp drives 23 VSD High Phase X Inverter Baseplate Temperature 658 704 and 900 Hp drives 23 VSD Precharge LoCckoUt Pere bu bete bas 23 Harmonic Filter High Baseplate 23 Harmonic Filter High Total Demand Distortion TEE 23 Cycling ShutdOWwmns ee lesa ae isis een DR RU Mi 24 General Information eicere ti o dea Aan eit eee eas 24 VSD DC Bus Voltage 1 24 VSD High DC Bus Voltage 24 VSD High Internal Ambient Teimperature
6. 26 Harmonic Filter 110 Input Current 27 Harmonic Filter DC Bus Voltage ennemis 27 Harmonic Filter DC Current Transformer TOF 2 b c e Er Pe b LU p Ute E Tr ttn 27 Harmonic Filter High DC Bus 27 Harmonic Filter High Phase or B C 27 Harmonic Filter Logic Board Or Communications sse emm nennen 27 Harmonic Filter Logic Board Power 28 Harmonic Filter Low DC Bus 28 Harmonic Filter Phase Locked 28 Harmonic Filter Precharge Low DC Bus 28 Harmonic Filter Run Slgrnal 2 ne tata e eee reete c D dr e E oe qz Ae btt gud 28 Warning Messages oe n nnt ee 29 General Information ilicis ge t eite be ttl ode el eed deed ded dta pda e ca end de de uae D d de 29 Warning Vanes Uncalibrated Fixed 29 Warning Harmonic Filter Data 1088
7. 52 5 ENA 24 VSD High Phase A or B C Instantaneous GUrrent 2020802225 e o etie ee e dM Ru espe EM RR 25 VSD Initialization Farled rei edere ue eode cago e de He te eo n ed aa e edenda un 25 VSD Invalid Current Scale DCIS CHON ac 25 VSD Logic Board Power Su pply 3 5 iile t petala EE 25 VSD Logic Board Processor tek E eR eR RR M 25 VSD Low Converter Heatsink 25 VSD Low DG Bus Voltage ne Ie RED REB UR 25 JOHNSON CONTROLS 9 160 00 04 ISSUE DATE 4 15 2015 TABLE OF CONTENTS VSD Low Inverter Baseplate Temperature d S dnm et eae e eed Tode ee Dvd aa tee Huc tu edu e 26 VSD or B Gate Driver ode R te Te aee Ere e ein ee eee teen 26 VSD Precharge DC Bus Voltage Imbalance sssssssssseeeneeeeeenen nennen 26 VSD Precharge Low DC Bus 26 VSD Run SINA EN 26 VSD Serial 26 VSD Single Phase Input Power e edet een 26 VSD Stop Contacts Open idle ie RE Leda ete d e CR
8. 400A 06 600A 08 800A 10 1000A 12 1200A 00 None terminal block Not yet defined XI Code Agency Approval L cUL cETL Special X None XII Harmonic Mitigation F Filter Model Z Base Model A 7 Active Front End Model XIII Input Voltage Frequency Per M 527 40 380V 60Hz 50 400V 50Hz 42 400V 60Hz 46 460V 60Hz 68 415V 50Hz 58 575V 60Hz XIV Product Mod Level Suffix A Mod Level A B Mod Level B 160 00 04 ISSUE DATE 4 15 2015 OPTISPEED MODEL PART NUMBERS CONT D The X in the part number below indicates which type of communications is used between the Micropanel and the OSCD 1 YORK Protocol 7 MODBUS Protocol 8 MODBUS w CPC Wuxi 4th position taking place of the first hyphen in the part number TABLE 2 LVD PART NUMBERS AND DESCRIPTIONS 8 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 TABLE OF CONTENTS GENERAL INFORMATION nx 11 Optispeed Harmonic Filter Component 11 OptiSpeed Compressor Drive 270 292 351 and 424 11 OptiSpeed Compressor Drive 385 419 503 608 658 704 and 900 Hp 12 Harmonic Bilten Option 12 Differences for the VSD and model
9. VSD Single Phase Input Power SINGLE PHASE POWER SUPPLY VSD Stop Contacts Open INVERTER INITIATED STOP FAULT 26 A thermistor sensor is located inside the transistor module s on the OSCD power unit Anytime this thermistor detects a temperature of 37 F 3 C or lower a shut down will occur A second level of overcurrent current protection exists on the OSCD gate driver board The collector to emitter voltage of each transistor module is checked while the device is turned on This is called the collector to emitter saturation voltage If the voltage across the transistor module is greater than a set threshold the transis tor module is turned off This fault can also be caused if the transistor is not being turned on when it should The definition for this fault is identical to VSD DC Bus Voltage Imbalance except that the fault has occurred during the precharge period which begins during pre lube Refer to VSD DC Bus Voltage Imbalance shutdown for possible problems This fault has two different timing events First the DC Bus voltage must be equal to or greater than 50 VDC for 460 VAC input voltage 41 VDC for 380 400 and 415 VAC input voltage or 60 VDC for 575 VAC input voltage 4 seconds after pre charge has begun Second the DC Bus voltage must be equal to or greater than 500 VDC for 460 VAC input voltage 414 VDC for 380 400 and 415 VAC input voltage or 600 VDC for 575 VAC input voltage 20 seconds afte
10. YK Centrifugal 160 54 PW8 Wiring Field Connections Variable Speed Drive Model YT Centrifugal 160 55 PW5 Wiring Field Connections Variable Speed Drive Model YK Centrifugal 160 54 PW5 Service Manual Control Panel Model VSD Variable Speed Drive 160 00 M4 Renewal Parts Variable Speed Drive JOHNSON CONTROLS 160 00 RP4 LIB B01A RPB EN 160 00 04 ISSUE DATE 4 15 2015 NOMENCLATURE W VSD351 RKFT 46 Voltage Rating 40 400VAC 60Hz 46 460VAC 60Hz 50 400VAC 50Hz 58 575VAC 60Hz 68 415VAC 50Hz Optional 519 Filter Installed FT or Not _ Chiller Type YK K YT T Retrofit Package R Factory Package Horsepower Rating 270 292 351 385 419 424 503 608 Type of Drive China Design OPTISPEED MODEL PART NUMBERS The X in the part number below indicates which type of communications is used between the Micropanel and the OSCD 1 YORK Protocol 7 MODBUS Protocol 8 MODBUS with W Wuxi W in the 4th position taking place of the first hyphen in the part number TABLE 1 VSD PART NUMBERS AND DESCRIPTIONS PART NUMBER MODEL ez DESCRIPTION 5 VSD270K 40 371 02767 X22 Factory Pack YK Base Model 371 02767 X25 Factory Pack YT Fiter Model vepzrom 4o 371 02767 X32 Revo YK Base Model j x 27 070001 VSD2
11. between the OSCD logic Warning Harmonic Filter and the harmonic filter logic or the ACC boards are interrupted for at least a peri Data Loss od of 20 seconds This message can also occur as a background message when the chiller is running When this message is displayed all harmonic filter related FILTER DATA LOSS values are replaced with X s If communications is re established the message will disappear and normal values will again be displayed Warning Harmonic Filter Operation Inhibited This message is displayed when the function of the Harmonic Filter is inhibited at the Control Center This message is no longer displayed when the function of the Harmonic Filter is enabled at the Control Center The function of the harmonic FILTER OPERATION filter can only be inhibited or turned on when the chiller is not running INHIBITED JOHNSON CONTROLS 29 160 00 04 ISSUE DATE 4 15 2015 VSD FREQUENTLY ASKED QUESTIONS Why doesn t the measured input amps of the OSCD agree with the rated FLA The input current to the OSCD may be considerably lower compared to the output current This is due to the power factor at the input to the OSCD being greater than 95 and nearly unity when the Harmonic Filter option is included Chiller FLA must be measured at the motor terminals where the power factor is the nor mal motor power factor Use a true RMS reading meter to make these measurements Is a Condenser Water
12. first occurs 1 10th of a second after pre charge is initiated and the other occurs 5 seconds after precharge is initiated See table below for specific values NOMINAL INPUT 1st MINIMUM 2nd MINIMUM VOLTAGE VALUE VOLTAGE VALUE VOLTAGE VALUE FLTR PCHARGE LOW BUS V FLT 380 460 VAC 41 VDC 425 VDC 575 VAC 60 VDC 630 VDC Harmonic Filter Precharge Low DC Bus Voltage When a digital run command is received at the harmonic filter logic board from the OSCD logic board a 1 10 second timer is started A redundant run command must also occur on the communication link from the OSCD logic board before the timer FLTR RUN RELAY FLT expires or the OSCD will be shut down Harmonic Filter Run Signal 28 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 WARNING MESSAGES General Information A WARNING message will indicate that the operation of the OptiSpeed Compressor Drive or the Harmonic Filter is affected in some manner but the OptiSpeed Compressor Drive is still functioning TABLE 5 WARNING MESSAGES WARNING DESCRIPTION This message is displayed when the Pre Rotation Vanes are not calibrated or Warning Vanes have failed to calibrate and the OptiSpeed Compressor Drive is enabled Under Uncalibrated Fixed Speed this condition the OSCD will run at a constant maximum speed This message will no longer appear after a successful calibration This message is displayed if the communications link
13. in the process but when it does the Adaptive Capacity Control ACC stores into memory the conditions surrounding the Surge and therefore remembers to avoid the stored operating point anytime in the future Early versions of the ACC software required that the drive always start and run up to full speed ACC soft ware starting with version C ACC 01 04 applies a new slow ramp up of the drive speed This new software lowers the peak current demand from the drive during start up saves additional energy and reduces the pos sibility of the chiller running in a stall condition The new software will ramp the drive speed up to 30 Hz quickly and then takes 5 minutes to ramp up to 60 Hz During this slow ramp up period the vanes will open to meet the cooling demand If the leaving chilled liquid temperature is within 0 5 or lower of the leav ing chilled liquid temperature setpoint then the drive speed will stop increasing speed and start to search for a surge map point On extremely hot days the chiller may surge during the slow ramp period The new soft ware has a method to limit the surging If 2 surges were to occur during the slow ramp period then the speed of the drive will increase to 60 Hz Now that the ACC function is provided by the mi croboard in the OptiView panel future control changes will be covered by the operation manual for the chiller model of interest versions of software require that two conditions be met f
14. logic board generates this shutdown by reading the current from the 3 output current transformers The shutdown is generated when the OSCD logic board has detected that the highest of the three output phase currents has ex ceeded 105 of the programmed 100 full load amps FLA value for more than 40 seconds This shutdown requires a manual reset via the Reset push button on the OSCD logic board VSD 105 Motor Current Overload A thermistor sensor is located of the copper chill plate of the OSCD Power Unit If at anytime this thermistor detects a temperature of 170 F 76 or higher a shut down will occur The cooling fans and coolant pump on the OSCD will continue to run after the shutdown until the thermistor temperature has dropped below 160 F HIGH CONVERTER HEATSINK TEMP 71 This shutdown requires a manual reset via the Reset push button on the OSCD logic board VSD High Converter Heatsink Temperature VSD High Inverter Baseplate A thermistor sensor is located inside the transistor module on the OSCD power Temperature 270 292 351 and 424 Hp drives HIGH INVERTER BASEPLATE TEMPERATURE FLT unit If at anytime this thermistor detects a temperature of 175 F 79 C or higher a shutdown will occur The cooling fans and coolant pump on the OSCD will con tinue to run after the shutdown until the thermistor temperature has dropped below 165 F 74 C This shutdown requires a manual reset via t
15. on top of the transistor section in the same manner as the lower horsepower model but it only contains 2 transistor drivers The modules and the boards are not interchangeable be tween the 270 292 35 and 424 and 419 503 608 658 704 and 900 Hp drives Harmonic Filter Option The VSD model of OptiSpeed Compressor Drive OSCD system may also include an optional harmon ic filter and high frequency trap designed to meet the IEEE Std 519 IEEE Recommended Practices and Re quirements for Harmonic Control in Electrical Power Systems The harmonic filter is offered as a means to improve the input current waveform drawn by the OSCD from the AC line thus reducing the possibility of causing electrical interference with other sensitive electronic equipment connected to the same power source An additional benefit of the optional harmonic filter is that it will correct the system power factor to nearly unity The power section of the Harmonic Filter is composed of three major blocks a pre charge section a three phase inductor and a Filter Power Unit 12 The pre charge section contains pre charge resistors a pre charge contactor and a supply contactor The pre charge network serves two purposes to slowly charge the DC bus capacitors associated with the Filter Power Unit and to provide a means of disconnecting the filter power unit from the AC line When the chiller is turned off both contactors are de energized and the filter
16. sensitivity jumper in the Micro Computer Control Center or program a lower sensitivity on the OptiView Con trol Center Also check the vane motor to see that the fullest possible stroke is being utilized Moving the vane motor arm pivot point closer to center and extending the degrees of travel by adjusting the internal end stops will reduce the amount of vane action for the same period of operation JOHNSON CONTROLS Verify that the condenser is clean e Verify that the liquid level control is working properly and maintaining a refrigerant level in the condenser Ensure that the condenser water temperature is proper for the load on the chiller In many cases the condenser water temperature is still at 85 F Failure to reduce speed may also be due to the system having been placed in Manual Speed when in VSD Ser vice Mode The following factors can be used to convert from English to the most common SI Metric values TABLE 6 SI METRIC CONVERSION MEASUREMENT MULTIPLY ENGLISH UNIT Capacity Tons Refrigerant Effect ton 3 516 Power Horsepower FORM 160 00 O4 ISSUE DATE 4 15 2015 Do I have a problem with my coolant The pink color is no longer visible The coolant normally has a pink or rose color when new After several months of operation this color may dissipate and the coolant may appear almost colorless The lack of the color in the coolant does not necessarily indicate a problem Most colorless samp
17. use of the SCR s in the converter permits pre charge of the DC bus capaci tors when the chiller enters the prelube cycle and it also provides a fast disconnect from the AC line when the chiller enters the coastdown cycle At this time the OSCD is turned off the SCR s in the converter are no longer turned on and remain in a turned off condition until the next pre charge cycle The DC bus capacitors will start to discharge through the bleeder resistors When the chiller enters the prelube cycle the OSCD is commanded to pre charge and SCR s are gradually turned on to slowly charge the DC bus capacitors This is called the pre charge period which last for 20 sec onds At this time SCR are fully turned on The SCR Trigger board provides the turn on commands for JOHNSON CONTROLS the SCR s The OSCD Logic board provides com mand to the SCR trigger board when to precharge Although many of these parts are similar to the parts used in previous Variable Speed Drive VSD designs these parts are only compatible with drives having the base part numbers included on the cover of this form Failure to use the correct parts may cause major damage to these and other components in the drive For example the VSD logic board 031 02077 000 used in this drive is not compatible with 031 01433 000 logic board used in previous designs A new VSD logic board was designed in 2006 The part number of the new board is 031 02506 002 T
18. 00 AMPS PEAK 658 704 1890 AMPS PEAK 900 2750 AMPS PEAK If an Instantaneous Current Fault occurs but the chiller restarts and runs without a problem the cause may be attributed to a voltage sag on the utility power feeding the OSCD that is in excess of the specified dip voltage rating for this product This is especially true if the chiller was running at or near full load If there is a sudden dip in line voltage the current to the motor will increase The chiller vanes cannot close quickly enough to correct for this sudden increase in current and the chiller will trip on this fault At power up the OSCD logic board will go through a process called initialization At this time memory locations are cleared jumper positions are checked and com munications links are established between the OSCD logic board and the Control Center The J1 connector on the OSCD logic board contains jumpers along with wires from the output CTs The jumpers configure the OSCD logic board to the HP rating of the OSCD being used in this application in order to properly scale the output cur rent If the jumper configuration is found by the logic board to be invalid the system will be shut down and the above message will be generated The proper jumper configuration is shown on the wiring label for the OSCD This shutdown is generated by the OSCD logic board and it indicates that one of the low voltage power supplies for the OSCD logic bo
19. 371 03700 X25 Factory Pack YT Filter Model 371 03700 X26 Factory Pack YK Filter Model W VSD292K 68 VSD351RK 46 371 02767 X12 VSD351RTFT 46 371 02767 X15 VSD351RTFK 46 371 02767 X16 371 03789 X21 371 03789 X22 371 03789 X23 385 HP 371 03789 X24 400 VAC 371 03789 X31 VSD385RK 40 371 03789 X32 VSD385RTFT 40 371 03789 X33 VSD385RKFT 40 371 03789 X34 JOHNSON CONTROLS 5 160 00 04 ISSUE DATE 4 15 2015 FIGURE 1 VSD PART NUMBERS AND DESCRIPTIONS CONT D PART NUMBER MODEL DESCRIPTION Factory Pack Base Model Factory Pack YK Base Model Factory Pack YT Fiter Model Factory Pack Fiter YT Base mode Retro YK Base Mode YT Fiter Model Retro YK Fiter Model J Factory Pack YT Base mod Factory Pack YK Base Model Factory Pack YT Fiter Model Factory Pack Fiter Model PRetroft YTBase mode Retrofit YK Base Mod YT Fiter mode YK Fiter Model Factory Pack Base Mod Factory Pack YK Base Mode Factory Pack YT Fiter Model Factory Pack YK Fiter Mode YT Base moce YK Base Mod YTFiter Model Jj YK Fiter Model VSD419RKFT 68 W VSD419K 68 W VSD419KFT 68 371 04881 X01 371 04881 X02 371 04881 X03 424 HP 371 04881 X04 575 VAC 371 04881 X11 VSD424RK 58 371 04881 X12 VSD424RTFT 58 371 04881 X13 VSD424RTFK 58 371 04881
20. 70RKFT 40 371 02767 X36 Retrofit YT Filter Model Retrofit YK Filter Model VSD270RTFT 40 371 02767 35 VSD292RK 50 371 03700 X12 c 371 03700 X15_ Retroft yTFiterModel Dvsomenkrrso 371 03700 X16 Reto YK Filer Model wspasaso 371W06040 X02_ FactoryPack YK Base Model W VSD292KFT 50 371WO06040 X06 Factory Pack YK Filter Model vsp292T 50 371 03700 X01 Factory Pack YT Base Model vsp292k 50 371 03700 02 Factory Pack YK Base Model VSD292TFT O 371 03700 05 Factory Pack YT Filter Model 292 HP oo 4 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 FIGURE 1 VSD PART NUMBERS AND DESCRIPTIONS CONT D PART NUMBER MODEL DESCRIPTION 371 03700 X22 Factory Pack YK Base Model VSD292RKFT 68 VSD351T 46 371 02767 X01 VSD351K 46 371 02767 X02 VSD351TFT 46 371 02767 X05 351 HP VSD351TFK 46 371 02767 X06 460 VAC VSD351RT 46 371 02767 X11 Factory Pack Base Model Factory Pack Base Model Factory Pack YT Fiter Model Factory Pack YK Fiter Model Retro YT Base J Retro YK Base Model YT Fiter Model Retro YK Fiter Model J Factory Pack Base Mod Factory Pack YK Base Mode Factory Pack YT Fiter Model Factory Pack Fiter Model YT Base Model Retro YK Base Model Retrofit YT Fiter mod YK Fiter moa
21. 76 AMPS RMS 658 704 277 AMPS RMS The DC link is filtered by many large capacitors These capacitors are connected in series to achieve a higher DC link voltage then can be supported by a signal capacitor It is important that the voltage is shared equally between the two sets of series capacitors Each set of capacitors must share approximately 1 2 of the total DC link voltage The harmonic filter logic board then measures the voltage of the 2 sets of the bus capacitors If at anytime while the harmonic filter is running that the difference in the voltage between the 2 sets of capacitors is greater than 50 VDC for 380 through 460 VAC input voltage 65 VDC for 575 VAC input voltage then a shutdown will occur During initialization with no current flowing through the Direct Current Current Transducers DCCT s the DCCT s output voltages are measured and compared with a preset limit in the harmonic filter logic board If the measured values exceed the preset limits the DCCT s are presumed to be bad and this shutdown will be generated The harmonic filter logic board continuously monitors the harmonic filter DC link voltage if the level of the DC link voltage exceeds a range of 822 to 900 VDC for 380 through 460 VAC input voltage or 999 to 1099 VDC for 575 VAC input volt age this shutdown is initiated Keep in mind that the harmonic filter has its own DC Link as part of the harmonic filter power unit The harmonic
22. D on the ACC indicating a surge was de tected The chiller may surge 6 to 8 times before the ACC can raise the speed enough to get the chiller back out of surge Each surge is counted on the surge coun ter which may be viewed on the control center This surge counter will always display the total number of surges encountered by the chiller as determined by the ACC Surging which occurs at fixed speed will incre ment the surge counter as well but only surges that oc cur when speed reduction is possible are recorded in the surge map 15 160 00 04 ISSUE DATE 4 15 2015 Drive Not Reducing Speed The ACC may begin the process of reducing speed but may stop speed reduction if instability is encountered This is the same instability discussed as one of the two conditions which must be met to begin reducing speed initially See Stability Requirements Once the sys tem again becomes unstable no additional speed re duction can occur The most common causes for insta bility are High Condenser liquid temperature Dirty Condenser tubes Chillers with very light loads Rapid changes to chilled or condenser liquid flow Valves on air handler coils closing rapidly causing changes in heat load Extremely short chilled liquid loop e Parallel chiller with poor control is causing tem perature variations e Parallel Chiller with poor control of chilled or condenser water flows Improper evap
23. IVER ISOLATOR BOARD BOARD T NER 1 o NOTE Variable Speed Drive Model VSD351 Shown 270 292 424 Models are similar SCR DIODE SCR MODULE TRIGGER BOARD LD13165 FIGURE 1 OPTISPEED SYSTEM ARCHITECTURE CONT D 18 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 LD19198 NOTE Variable Speed Drive Model LVD419 Shown 385 503 608 658 704 AND 900 models are similar LD19199 FIGURE 1 OPTISPEED SYSTEM ARCHITECTURE CONT D JOHNSON CONTROLS 19 160 00 04 ISSUE DATE 4 15 2015 LD13165 LD13166 FIGURE 3 SCR TRIGGER BOARD 20 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 LD13167 FIGURE 4 DC BUS ISOLATOR BOARD e LD13168 FIGURE 5 GATE DRIVER BOARD AND POWER MODULE JOHNSON CONTROLS 21 160 00 04 ISSUE DATE 4 15 2015 SAFETY SHUTDOWNS General Information The Shutdowns are organized in alphabetical order based on the OptiView Control Center messages The Microcomputer Control Center messages are also in cluded under these headings Whenever a Safety Shutdown is generated by the OSCD or Harmonic Filter Logic Board a series of events will occur Ifthe chiller is not running at the time of the shut down the OSCD Logic Board will not turn on the gate drivers The relay on the OSCD logic board will de energize to indicate to the Control Center tha
24. LIQUID COOLED OPTISPEED COMPRESSOR SPEED DRIVE BY JOHNSON CONTROLS OPERATION MANUAL Supersedes 160 00 04 115 Form 160 00 04 415 MODELS VSD 270 292 351 385 419 424 503 608 658 AND 704 MODELS LVD 292 385 419 503 608 658 704 AND 900 ul YORK 00633VIP VSD MODELS 270 60 HZ 400 VAC 292 HP 50 HZ 400 VAC 292 HP 50 HZ 415 VAC 351 HP 60 HZ 460 VAC 385 HP 60 HZ 400 VAC 419 HP 50 HZ 400 VAC 419 HP 50 HZ 415 VAC 424 HP 60 HZ 575 VAC 503 HP 60 HZ 460 VAC 608 HP 60 HZ 575 VAC 658 HP 50 HZ 400 VAC 704 HP 50 HZ 415 VAC LVD MODELS 292 HP 50 HZ 400 VAC 292 HP 50 HZ 415 VAC 385 60 HZ 380 VAC 385 60 HZ 400 419 HP 50 HZ 380 VAC 419 HP 50 HZ 415 VAC 503 HP 60 HZ 460 VAC 608 60 HZ 575 VAC 658 HP 50 HZ 400 704 HP 50 HZ 415 VAC 900 HP 50 HZ 400 VAC 900 HP 50 HZ 415 Issue Date April 15 2015 160 00 04 ISSUE DATE 4 15 2015 IMPORTANT READ BEFORE PROCEEDING GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus During rigging installation operation maintenance or service individuals may be exposed to certain com ponents or conditions including but not limited to heavy objects refrigerants materials under pressure rotating components and both high and low voltage Each of these items has the potential if misused or handled improperly to cause
25. Strainer used with the shell and tube heat exchanger Since the shell and tube heat exchanger can be cleaned with a rifle brush no extra precautions are needed to keep the heat exchanger cleaned No strainer is pro vided with this OSCD The intent is to have the heat exchanger cleaned annually Gaskets are available refer to the service parts list What is the timing of the Anti Recycle when an OSCD is applied The anti recycle time is much quicker with an OSCD than with a starter The reason is the elimination of inrush current on start up The OptiSpeed compres sor drive slowly accelerates the compressor motor so that the motor does not consume more than 10096 of the motors nameplate full load amps The anti recy cle time is five 5 starts in succession followed by a ten minute wait After ten minutes the OSCD can be started five more successive starts This is permitted on OSCD units only due to the low current draw and re duced motor heating during startup Should the customer install isolation between the Power Conduits and the OptiSpeed Compressor Drive We no longer require a section of non metallic conduit at the entrance and exit of the OSCD as we did on pre vious products If any customer or installer wishes to continue to follow this practice we have no objections as long as the OSCD is properly grounded 30 When is a Booster Pump required on a Retrofit Op tiSpeed Compressor Drive Detailed information i
26. W for the design center is a drive that 1s designed to standards that gov ern products built for the Chinese market The way the drive functions protects itself and the motor are the same for both designs The W design takes advantage of local components and local manufacturing The cooling system is the area where most of the changes occur and only effect the 50 Hz application The W design solves the problem of reduce cooling because of 50 Hz power by using a large cooling fan and a differ ent cooling pump The cooling fan and pump require a 230 VAC 50 Hz source This higher power source allows the fan and pump to provide the same amount of cooling as the 60 Hz application The 230 VAC source is provided by an additional voltage tap from the control transformer This new transformer provides the voltage required for the 230 VAC and 120 VAC components DIFFERENCES FOR THE VSD AND LVD MODEL DRIVES The VSD model drives are design so that the harmonic filter system can be included in the drive enclosure The VSD model also contains the control wiring ad ditional cooling capacity and pre charge resistors for the harmonic filter system regardless if the harmonic filter system 15 installed or not This process allowed for an easier method to retrofit the harmonic filter sys tem later if the customer desired The LVD model does not contain any support for the harmonic filter system The enclosure size is reduced and the harmonic fil
27. X14 371 03789 X01 371 03789 X02 371 03789 X03 503 HP 371 03789 X04 460 VAC 371 03789 X11 371 03789 X12 371 03789 X13 371 03789 X14 371 04563 X01 371 04563 X02 371 04563 X03 da 371 04563 X04 371 04563 X11 371 04563 X12 371 04563 X13 371 04563 X14 W VSD704KFT 68 6 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 NOMENCLATURE LVD 0503 G R C 30 B 06 L Z 46 A 1 IV V l Drive Type LVD historical models VSD TM HYP Horsepower and Amp Rating 4 digits fixed length Ill Design Center Source Global W Wuxi local design T 7 Toshiba B Benshaw IV VSD Mounting Method X 7 Unit Mount Factory Pack R Remote Mount Floor Standing V Enclosure Type Rating N01 NEMA 1 N04 4 N3R NEMA 3R 133 IP33 Not yet defined VI Chiller Type H YMC2 YH VII Chiller Cooling Method VSD Cooling Medium C lt Condenser liquid cooled water E Evaporator liquid cooled water D lt Condenser liquid cooled glycol Evaporator liquid cooled glycol B Air cooled glycol A Air cooled air R Refrigerant refrigerant Not yet defined JOHNSON CONTROLS VIII X X XI XIII XIV VIII Liquid DWP 15 2 150 PSIG 30 300 PSIG Not yet defined IX Input Connection D Disconnect Switch B Circuit Breaker T Terminal Block Not yet defined X Input Connection Rating 04
28. ard has dropped below their allowable operating limits The power supplies for the logic boards are derived from the secondary of the 120 to 24 VAC transformer which in turn is derived from the 480 to 120 VAC control transformer This shutdown is generated by the OSCD logic board If a communications problem occurs between the two microprocessors on the OSCD logic board this shutdown will occur A thermistor sensor is located on the SCR Diode block side of the copper chill plate on the OSCD Power Unit Anytime this thermistor detects a temperature of 37 F 3 C or lower a shutdown will occur If the line voltage were to quickly drop the current seen by the motor could exceed it s rating The low bus voltage shutdown will prevent this from happening The shutdown is generated when the DC link voltage drops below 500 VDC for 460 VAC input voltage 414 VDC for 380 400 and 415 VAC input voltage or 600 VDC for 575 VAC input voltage 25 160 00 04 ISSUE DATE 4 15 2015 TABLE 2 CYCLING SHUTDOWN MESSAGE MESSAGE DESCRIPTION VSD Low Inverter Baseplate Temperature LOW INVERTER BASEPLATE TEMPERATURE FLT VSD Phase A or B C Gate Driver PHASE A B C GATE DRIVER FLT VSD Precharge DC Bus Voltage Imbalance PRECHARGE BUS V IMBALANCE VSD Precharge Low DC Bus Voltage PRECHARGE LOW VOLTAGE FAULT VSD Run Signal RUN RELAY FAULT VSD Serial Communications SERIAL RECEIVE FAULT
29. ard which could lead to damage to the machine damage to other equipment and or environmental pollu tion if proper care is not taken or instruc tions and are not followed CAUTION Highlights additional information useful to the technician in completing the work being performed properly NOTE External wiring unless specified as an optional connection in the manufacturer 5 product line is not to be connected inside the control cabinet Devices such as relays switches transducers and controls and any external wiring must not be installed inside the micro panel All wiring must be in accor WARNING dance with Johnson Controls published specifications and must be performed only by a qualified electrician Johnson Controls will NOT be responsible for damage problems resulting from improper connections to the controls or application of improper control signals Failure to follow this warn ing will void the manufacturer 5 warranty and cause serious damage to property or personal injury JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for con tinuous product improvement the information con tained in this document 15 subject to change without notice Johnson Controls makes no commitment to update or provide current information automatically to the manual or product owner Updated manuals if applicable can be obtained by contacting the near
30. bodily injury or death It is the obligation and responsibility of rigging instal lation and operating service personnel to identify and recognize these inherent hazards protect themselves and proceed safely in completing their tasks Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated as well as severe personal injury or death to themselves and people at the site This document is intended for use by owner authorized rigging installation and operating service personnel It is expected that these individuals possess independent training that will enable them to perform their assigned tasks properly and safely It is essential that prior to performing any task on this equipment this individual shall have read and understood the on product labels this document and any referenced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken DANGER Indicates a potentially hazardous situa tion which will result in possible injuries or damage to equipment if proper care is not taken WARNING Identifies a haz
31. d Bleeder resistors are mounted on the side of the Filter Power Unit to provide a discharge path for the DC bus capacitors Other sensors and boards are used to provide safe op eration of the harmonic filter The transistor module contains a temperature sensor that provides tempera ture information back to the Filter Logic Board This sensor protects the filter transistor module from over temperature conditions A Bus Isolator board is used to ensure that the DC bus capacitors are properly charged and that the voltage is balanced Two output current sensors are used to protect the filter against an over current or an overload condition Input current trans formers sense the input current drawn by the OSCD s AC to DC converter The Line Voltage Isolation board provides AC line voltage information to the Harmonic Filter Logic board This information is used to deter mine the proper bus voltage value JOHNSON CONTROLS The trap filter is standard on all OSCD s that contain an optional Harmonic Filter The trap filter is com posed of a series of capacitors inductors and resis tors The trap filter is used to reduce the effects of the PWM switching frequency of the filter DIFFERENCES FOR THE VSD AND LVD MODEL NUMBERS Within the drive model number nomenclature there are 2 different letters for the design center of the drive A for the design center is a drive that is designed to the UL and CE requirements A
32. e VSD Shutdown Requesting Fault Data will be displayed when the Control Center is requesting the fault data from the OSCD The OSCD or Harmonic Filter Logic Board will send a shutdown code to the Control Center The Micro Board will interpret the shutdown code and display a shutdown message on the display of the Control Center After the coastdown period has timed out the chiller will automatically restart if the shutdown is no longer active Leave the Compressor Switch in the Run posi tion The chiller will start if no faults are active MESSAGE DESCRIPTION The DC link is filtered by many large capacitors which are rated for 450 VDC VSD DC Bus Voltage Imbalance These capacitors are connected in series to achieve a 900 VDC capability for the DC link It is important that the voltage is shared equally between the 2 sets of series capacitors Each set of capacitors must share approximately 1 2 of the total VCR emo ae Salama link voltage If the difference in the voltage between the 2 sets of capacitors is greater than 88 VDC then this shutdown will occur VSD High DC Bus Voltage The DC bus voltage is continuously monitored and a shutdown will occur if the DC bus voltage exceeds 745 VDC for 400 VAC amp 460 VAC units or 909 VDC for 575 BUS OVER VOLTAGE FAULT their rating VSD High Internal Ambient Temperature VAC units This shutdown will protect the capacitors from a voltage that exc
33. e OSCD initiates a fault it first opens the fault relay on the OSCD logic board When the relay opens a message is sent to the ACC board detailing the cause of the fault If this circuit ever opens without receiving an accompanying cause for the fault over the communication link within 11 communication tries ap proximately 22 seconds this message will be displayed This fault may be replaced with a Serial Communications fault if the serial link has failed JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 TABLE 2 CYCLING SHUTDOWN MESSAGE MESSAGE DESCRIPTION Harmonic Filter 110 Input Current Overload FLTR OVERLOAD FLT Harmonic Filter DC Bus Voltage Imbalance FLTR BUS V IMBALANCE FLT Harmonic Filter DC Current Transformer 1 2 FILTER DCCT 1 OR 2 Harmonic Filter DC Bus Voltage FLTR BUS OVER VOLTAGE FLT Harmonic Filter High Phase A or B C Current FLTR PHASE A B C OVERCURRENT Harmonic Filter Logic Board Or Communications IEEE 519 FILTER FAULT JOHNSON CONTROLS The three phases of RMS filter current are measured by the output DCCTs This information is sent to the harmonic filter logic board If any one phase of filter cur rent exceeds a threshold for 40 seconds a shutdown will occur Refer to the chart below for the shutdown threshold value DRIVE HP RATING THRESHOLD SHUTDOWN VALUE 270 292 351 424 128 AMPS RMS 385 419 503 608 1
34. eeds The ambient temperature of the OSCD is monitored by a temperature sensor mounted on the OSCD logic board The high ambient trip threshold is 145 F 63 C for all HP units except 424 HP which has a trip threshold of 153 F 67 C If this fault occurs the fans and coolant pump will remain on until the internal ambient temperature has fallen to 137 F 58 C for all HP units except 424 HP which will run the fans and coolant pump until the internal ambient has fallen to 145 F 63 C 24 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 TABLE 2 CYCLING SHUTDOWN MESSAGE MESSAGE DESCRIPTION VSD High Phase A or B C Instantaneous Current PHASE A OVERCURRENT FAULT VSD Initialization Failed VSD INITIALIZATION FAILED VSD Invalid Current Scale Selection INVALID CURRENT SCALE FAULT VSD Logic Board Power Supply MAIN BOARD POWER SUPPLY VSD Logic Board Processor PWM COMMUNICATIONS FAULT VSD Low Converter Heatsink Temperature LOW CONV HEATSINK TEMP VSD Low DC Bus Voltage LOW DC BUS VOLTAGE FLT JOHNSON CONTROLS This shutdown is generated by the OSCD logic board If any one phase of motor current as measured by the Output Current Transformers exceeds a threshold Refer to the chart below for the shutdown threshold value DRIVE HP RATING THRESHOLD SHUTDOWN VALUE 270 292 351 424 771 AMPS PEAK 385 419 503 608 12
35. enter via a software communication link The Microcomputer Control Cen ter communicates in a parallel fashion via two ribbon cables connecting the ACC board to the Microboard The OptiView Control Center communicates through communications port via a bi directional serial port via a three wire cable connecting the ACC board to the Microboard In order to achieve the most efficient operation of a centrifugal compressor the speed of the compressor must be reduced to match the lift or head of the load This lift or head is determined by the evapo rator and condenser refrigerant pressures However if the compressor speed is reduced too much the refrig erant gas will flow backwards through the compressor wheel causing the compressor to surge an undesir able and extremely inefficient operating condition Thus there exists one particular optimum operating speed on the edge of surge for a given head which provides the optimum system efficiency The compres sors inlet guide vanes which are used in fixed speed applications to control the amount of refrigerant gas flowing through the compressor are controlled togeth er with the compressor speed on an OSCD chiller sys tem to obtain the required chilled liquid temperature while simultaneously requiring minimum power from the AC line 13 160 00 04 ISSUE DATE 4 15 2015 The ACC board automatically generates its own Adap tive three dimensional surge
36. est Johnson Controls Service office or accessing the John son Controls QuickLIT website at http cgproducts johnsoncontrols com Itis the responsibility of rigging lifting and operating service personnel to verify the applicability of these documents to the equipment If there is any question regarding the applicability of these documents rig ging lifting and operating service personnel should verify whether the equipment has been modified and If current literature is available from the owner of the equipment prior to performing any work on the chiller CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made These revisions are to technical in formation and any other changes in spelling grammar or formatting are not included ASSOCIATED LITERATURE MANUAL DESCRIPTION Operation Manual Unit Model YT Centrifugal FORM NUMBER 160 55 O1 Operation Manual Unit Model YK Centrifugal 160 54 O1 Operation Manual Control Panel Model YT Centrifugal 160 55 O1 Operation Manual Control Panel Model YK Centrifugal 160 54 O1 Service Manual Control Panel Model YT Centrifugal 160 55 M1 160 54 M1 Wiring Diagram Control Panel Model YT Centrifugal 160 55 PW2 Service Manual Control Panel Model YK Centrifugal Wiring Diagram Control Panel Model YT Centrifugal Model
37. filter DC Link is not connected in any way with the drive s DC Link The output current of the harmonic filter is read by the Direct Current Current Transducer DCCT This current information is sent to the harmonic filter logic board where it is compared against a threshold If the output current of the har monic filter power unit is greater than the threshold then the harmonic filter will turn off for 5 6 line cycles After that time the filter operation will resume If the harmonic filter operation is stopped 3 times within a period of 60 line cycles then the filter and VSD power units are shut down and this message is generated DRIVE HP RATING THRESHOLD SHUTDOWN VALUE 270 292 351 424 378 59 AMPS Pk 385 419 503 608 523 84 AMPS Pk 658 704 782 118 AMPS Pk This shutdown states that the hardware on the harmonic filter logic board is indicat ing a fault but the software on the harmonic filter logic board does not state why The harmonic filter logic board signals a fault condition to the OSCD logic board but does not respond to a software request for fault information 27 160 00 04 ISSUE DATE 4 15 2015 TABLE 2 CYCLING SHUTDOWN MESSAGE MESSAGE DESCRIPTION Harmonic Filter Logic Board This shutdown indicates that one of the low voltage power supplies on the harmon ic filter logic board have dropped below their permissible operating voltage range The harmonic filter logic b
38. ge criteria refer to pre charge faults the VSD Precharge Lockout pre charge circuit will wait for a period of 10 seconds before another pre charge attempt The unit s cooling fans and coolant pump shall remain energized during this time period Following this 10 second period the pre charge shall again be PRE CHARGE FAULT LOCKOUT initiated The unit shall attempt to meet the pre charge criteria three consecutive times before the OCSD will shutdown lockout and display this message A thermistor sensor is located inside the transistor module on the harmonic filter power unit If at anytime this thermistor detects a temperature higher then the Harmonic Filter High threshold value a shutdown will occur Refer to the chart below for the shutdown threshold values A manual reset is required by pressing the Overtemp Reset pushbutton located on the Filter Logic board DRIVE HP RATING THRESHOLD SHUTDOWN VALUE HIGH FILTER BASEPLATE IRE TEMPERATURE FAULT 1940 385 419 424 503 608 190 F 88 C 658 704 194 F 90 C Baseplate Temperature The control center determines this shutdown by using data supplied from the harmonic filter logic board This shutdown indicates that the filter is not operating correctly or the input current to the OSCD filter system is not sinusoidal This shut Harmonic Filter High Total down will occur if the Total Demand Distortion TDD in any one phase exceeds Demand D
39. he part number of the new board for the 575 VAC application is 031 02506 003 The software is not interchangeable be tween the 575 VAC version and all other applications Also the software is not interchangeable between the 031 01433 031 02077 or the 031 02506 boards The DC Bus filter section of the drive consists of one basic component a series of electrolytic filter capaci tors The capacitors provide a large energy reservoir for use by the DC to AC inverter section of the OSCD The capacitors are contained in the OSCD Power Unit Bleeder resistors are mounted on the side of the Pow er Unit to provide a discharge path for the stored en ergy in the capacitors The DC to AC inverter section of the OSCD serves to convert the DC voltage to AC voltage at the proper magnitude and frequency as commanded by the OSCD Logic board The inverter section is actually composed of one power unit This power unit contains one very fast switching transistor module mounted on the same liquid cooled heatsink as the converter modules the DC Bus capacitors and an OSCD Gate Driver board The gate driver board provides the turn on and turn off commands to the output transistors The OptiSpeed Compressor Drive Logic board determines when the turn on and turn off commands should occur The gate driver board is mounted directly on top of the tran sistor module and it is held in place with mounting screws and soldered to the transistor module 11
40. he Options Key the following changes will be displayed VSD PHASE A INVERTER HEATSINK TEMP F VSD PHASE INVERTER HEATSINK TEMP F VSD PHASE C INVERTER HEATSINK TEMP F These three temperature values are replaced with VSD For 270 292 351 424 Hp drives The 385 419 503 608 658 704 and 900 Hp drives will display 3 phases of Baseplate temperature When the Filter is present the following data will change FILTER HEATSINK TEMP F This temperature data will now be called FILTER BASEPLATE TEMP The names for above data were changed because temperature sensor is now inside the transistor module instead on the chill plate where the transistor modules are mounted This new sensor gives a better indication of true temperature of the power electronics OptiView Control Panel VSD Functions Refer to the specific OptiView Control Panel service book for detailed information of the OSCD related information is contained under the Motor and Com pressor Screens VSD ADAPTIVE CAPACITY CONTROL The YORK OptiSpeed Compressor Drive utilizes a different approach to speed reduction compared to earlier variable speed products There is no longer a pre programmed surge map the YORK adaptive system experiments with the speed and vanes to find JOHNSON CONTROLS optimum speed for any given condition It does not always encounter a Surge
41. he Reset push button on the OSCD logic board 22 JOHNSON CONTROLS 160 00 04 ISSUE DATE 4 15 2015 TABLE 1 SAFETY SHUTDOWNS CONT D MESSAGE DESCRIPTION The X will indicate thermistor sensor is located inside the the phase that the transistor module on the OSCD power unit VSD High Phase X Inverter high temperature f at anytime this thermistor detects Baseplate Temperature 385 has occurred temperature of 175 F 79 C or higher a hutdown will occur The cooling fans and 41 n Hp S 2 009 And BOB Pp drives coolant pump on the OSCD will continue to run after the shutdown until the thermistor temperature has dropped below 165 F TEMPERATURE FAULT 74 C This shutdown requires a manual reset via the Reset push button on the OSCD logic board The X will indicate thermistor sensor is located inside the the phase that the transistor module on the OSCD power unit VSD High Phase X Inverter high temperature f at anytime this thermistor detects a Baseplate Temperature 658 has occurred H 2 704 an driv shutdown will occur The cooling fans an 04 And soU coolant pump on the OSCD will continue to run after the shutdown until the thermistor temperature has dropped below 165 F TEMPERATURE FAULT 74 This shutdown requires a manual reset via the Reset push button on the OSCD logic board If the OSCD fails to meet the pre char
42. istortion 2596 continuously for 45 seconds TDD is an acronym for Total Demand Distortion a term defined by the IEEE Std 519 1992 standard as the total root sum square harmonic current distortion in percent of the maximum demand load current 15 or 30 min demand The harmonic filter option was designed to provide an input current TDD level of 896 or less for the OSCD system A standard OSCD less the optional filter typically has an input current TDD level on the order of 28 30 JOHNSON CONTROLS 23 160 00 04 ISSUE DATE 4 15 2015 CYCLING SHUTDOWNS General Information The Shutdowns are organized in alphabetical order based on the OptiView Control Center Panel messages The Microcomputer Control Panel messages are also included under these headings Whenever the OSCD or Harmonic Filter Logic Board generates a Cycling Shutdown a series of events will oc cur Ifthe chiller is not running at the time of the shut down the OSCD Logic Board will not turn on the output transistors The KI relay on the OSCD logic board will de energize This action will indicate to the Control Center that the OSCD has shutdown The K1 re lay will remain de energized until the cause of the shutdown has been corrected TABLE 4 CYCLING SHUTDOWN MESSAGE If the chiller is running at the time of the shut down the Control Center will start a coastdown period 150 seconds for centrifugal chillers The messag
43. les test above 1000 PPM nitrite which is normal There is no need to flush the system unless you find the coolant becoming opaque or cloudy In this case we suggest you obtain a sample for analysis then flush the system with coolant and install fresh coolant The coolant must be changed every year regardless of color or test results The cool ant is required to be changed every year BY FACTOR TO OBTAIN METRIC UNIT Kilowatts KW Kilowatts KW Flow Rate Gallons Minute gpm Liters Second 1 5 Feet ft Meters m Length Inches in Millimeters mm Weight Pounds Ibs Velocity Feet Second fps Kilograms kg Meters Second m s Feet of Water ft Kilopascals kPa Pressure Drop Pounds Square Inch psi TEMPERATURE To convert degrees Fahrenheit F to degrees Celsius C subtract 32 and multiply by 5 9 or 0 5556 Example 45 0 F 32 x 0 5556 27 2 C To convert a temperature range i e a range of 10 F from Fahrenheit to Celsius multiply by 5 9 or 0 5556 Example 10 0 F range x 0 5556 5 6 C range JOHNSON CONTROLS Kilopascals kPa 31 5 Y Controls P O Box 1592 York Pennsylvania USA 17405 1592 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2015 www johnsoncontrols com ALL RIGHTS RESERVED Form 160 00 04 415 Issue Date April 15 2015 Supersedes 160 00 04 115
44. longer needed in new production The new microboard is also compatible with the older designs microboards used in the OptiView panel The new OSCD logic also added this new communication port but also retained all of the functions required to still communicate with the ACC board OptiSpeed and Optional Harmonic Filter Logic Control Boards Within the enclosure of the VSD model drive the OSCD logic board and optional Harmonic Filter logic board are interconnected via a 16 position ribbon ca ble This cable provides power for the Filter logic board and a method of communications between the two boards The OSCD Logic board performs numerous functions control of the OSCD s cooling fans and pumps when to pre charge the bus capacitors and generates the PWM The OSCD Logic board also determines shutdown conditions by monitoring the three phases of motor 14 current heatsink temperature baseplate temperature internal ambient temperature and the DC bus voltage The optional Harmonic Filter logic board determines when to precharge the harmonic filter power unit when to switch the transistors in the harmonic filter power unit and collects data to determine power cal culations This board also uses this data to determine shutdown conditions Microcomputer Control Panel VSD Related Keypad Functions Refer to 160 00 MA for related keypad functions Some of the displayed data in this form is different from the 160 00 M1 Under t
45. oard receives its power from the OSCD logic board The power supplies for the OSCD logic board are in turn derived from the secondary of FLTR POWER SUPPLY FLT the 120 to 24 VAC transformer The harmonic filter dynamically generates its own filter DC link voltage by the inter action of the harmonic filter inductor and switching its transistors This DC level is actually higher than the level obtained by simply rectifying the input line voltage Power Supply The DC link voltage is always higher on the harmonic filter power unit then on the Harmonic Filter Low DC Bus OSCD VSD power unit Voltage FLTR LOW BUS VOLTAGE FLT Thus the harmonic filter actually performs a voltage boost function This is neces sary in order to permit current to flow into the AC line from the harmonic filter when the AC line is at its peak level This particular shutdown and its accompanying mes sage are generated when the harmonic filter s DC link voltage drops to a level less than 80 VDC for 380 through 460 VAC input voltage and 110 VDC for 575 VAC input voltage below the harmonic filter DC link voltage setpoint Harmonic Filter Phase Locked Loop PHASE LOCK LOOP FLT This shutdown indicates that a circuit called a phase locked loop on the harmonic filter logic board has lost synchronization with the incoming power line for a period of time Two minimum voltage thresholds must be met in order to complete the precharge cycle The
46. or speed reduction to occur These two conditions are Setpoint Requirements The leaving chilled liquid temperature must be within 0 5 F or lower from the leaving chilled liquid tem perature setpoint A programmable value is now avail able through the OptiView panel on software versions C OPT 01 21 307 for the YK chiller This program mable value is not available on the YT chiller Speed reduction will not occur until the leaving chilled liquid temperature reaches this range Stability Requirements The leaving chilled liquid temperature must be stable Lack of stability will be indicative of the vanes hunt ing the leaving chilled liquid temperature varying and the green LED on the ACC will be on Once the above conditions are met the ACC may begin to lower the JOHNSON CONTROLS FORM 160 00 O4 ISSUE DATE 4 15 2015 speed of the compressor motor 1 10 ofa hertz at a time As the ACC lowers the speed the leaving chilled liq uid temperature will begin to creep up As this occurs the control center will begin to open the vanes slightly just enough to maintain the leaving chilled liquid tem perature within 0 5 F of the leaving chilled liquid temperature setpoint The ACC will continue to lower speed with the leaving chilled liquid temperature con trol in turn driving the vanes to a more open position This process will continue until one of three following situations occur This setting is no longer available after sof
47. orator refrigerant level If you experience a problem with an OSCD not re ducing speed at all make certain the system is not in manual speed control or locked into fixed speed Ei ther situation will cause the chiller to maintain full speed If the OSCD is reducing speed but not running 16 as slow as you expect it should it is likely because it is either in an unstable condition or running just above a mapped surge point As described above the chiller must achieve stability which is evidenced by the Green LED being extinguished before speed reduction will commence Instability will cause the Green LED to be illuminated Stability Limit Adjustment Stability Limit Adjustment allows the system to prop erly function with larger amounts of temperature insta bility Consult YORK Service to make this adjustment Surge Margin Adjustment Surge Margin Adjustment allows the Service Techni cian to increase the speed of the drive for all mapped surge points This parameter is rarely used and it de creases the efficiency of the OSCD chiller system JOHNSON CONTROLS FORM 160 00 04 ISSUE DATE 4 15 2015 COOLING COOLING COIL FANS INPUT BREAKER NOTE Variable Speed Drive Model VSD351 Shown CONTROL INDUCTOR 270 292 424 Models are similar TRANSFORMER LD13164 FIGURE 1 OPTISPEED SYSTEM ARCHITECTURE JOHNSON CONTROLS 17 160 00 04 ISSUE DATE 4 15 2015 COOLING COOLING GATE IGBT DC BUS FANS COIL DR
48. power unit is disconnected from the AC line When the chiller starts to run the pre charge resistors are switched into the circuit via the precharge contactor for a fixed time period of 5 seconds This permits the filter capacitors in the filter power unit to slowly charge After the 5 second time period the supply contactor is energized and the pre charge contactor is de energized permitting the fil ter power unit to completely charge Three power fuses connect the filter power components to the AC line Very fast semiconductor power fuses are utilized to ensure that the transistor module does not rupture if a catastrophic failure were to occur on the DC bus of the filter power unit The three phase inductor provides some impedance for the filter to work against It effectively limits the rate of change in current at the input to the filter to a rea sonable level The Filter Power Unit is the most complicated power component in the optional filter Its purpose is to gener ate the harmonic currents required by the OSCD s AC to DC converter so that these harmonic currents are not drawn from the AC line The Filter Power Unit is identical to the OSCD s Power Unit in the 351 Hp drive except for 2 less capacitors in the filter capacitor bank and a smaller transistor module and modified gate driv er board The Harmonic Filter Gate Driver board pro vides turn on and turn off commands as determined by the Harmonic Filter Logic boar
49. r pre charge has begun Two run signals are generated by the Control Center one via hardware and the second via the communications link Upon receipt of either of the two run signals by the OSCD logic board a 5 second timer will begin If the missing run signal is not received within the 5 second window the OSCD logic board will shut down and the Control Center will display the shutdown message This message is generated when communications between the micro board and the ACC board or the ACC board and OSCD logic board is disrupted for a least 22 seconds If the optional Harmonic Filter is installed then the fault can be generated when the communications between the OSCD logic board and the Harmonic Filter logic board or the Harmonic Filter logic board and the ACC board is disrupted This shutdown is generated by the SCR Trigger board and relayed to the OSCD logic board to initiate a system shutdown The single phase control uses circuitry to detect the loss of any one of the three input phases The trigger board will detect the loss of a phase within one half line cycle of the phase loss An LED on the SCR Trigger board will indicate that the board is detecting the fault and not a wiring problem between the trigger board and the OSCD logic board This message is also displayed every time power to the OSCD is restored or if the input power dips to a very low level Usually it indicates that someone has opened the circuit breaker Whenever th
50. s supplied in Form 160 05 N4 In general the OSCD requires 8 ft of head for proper wa ter flow to the OSCD heat exchanger If this amount of head is not available then a booster pump is required Can I apply an OptiSpeed Compressor Drive to a generator Yes the OSCD can be applied to a generator No modi fications are required for a generator application We have several OSCD installations running on generator power without difficulty It is necessary that the gen erators output voltage and frequency be maintained within the specified range for that particular OSCD This is usually not a problem for most generators since motor current at startup is limited to less than 1X the Full Load Amps FLA My chiller will not slow down why The OSCD will not reduce the motor speed until the leaving chilled water temperature is below 0 5 degree from setpoint Once in this window the speed still can not be reduced until the operation is deemed to be sta ble based upon the vanes are not continually moving open and closed to maintain temperature This hunting effect is normally due to one of the following e Chilled water and Condenser water flows are not at design GPMs The rate of change in flow maybe too fast for the chiller to be determined as stable Return water temperature is varying due to 3 way valves or other system configuration and the chiller is simply following changes in load e Vane stroke is too large Remove the
51. surface map while the chiller system is in operation This Adaptive op eration is accomplished through the use of a patented surge detection algorithm The novel surge detection system utilizes pressure information obtained from the chiller s two pressure transducers or the OSCDS instan taneous power output to determine if the system is in surge Thus the adaptive system permits construction of a customized compressor map for each individual chiller system Benefits of this new adaptive system in clude 1 a customized compressor map for each chiller which eliminates inefficient operation due to the safety margin built into the previous designs to compensate for compressor manufacturing tolerances 2 the abil ity to update the system s surge surface as the unit ages and 3 automatic updating of the compressor map if changes in refrigerant are implemented at a later date The Control Center beginning in 2005 A major change in the control system took place in 2005 Several redesigns took place in the OptiView panel and the OSCD The redesign replaced micropro cessors that were becoming obsolete This was a time to take advantage of new components that were now available An additional communications port was added so that the communications between the mi croboard and the OSCD logic board was faster In the changes to the microboard the function of the Adaptive Capacity Board was placed into the microboard and the ACC board was
52. t the OSCD has shutdown The 1 relay will remain de energized until the cause of the shutdown has been corrected If the chiller is running at the time of the shut down the Control Center will start a coastdown period 150 seconds for centrifugal chillers or shorter for those chillers that contain the optional Ouick Start feature The message VSD Shutdown Requesting Fault Data will be displayed when the Control Center is requesting the fault data from the OSCD The OSCD or Harmonic Filter Logic Board will send a shutdown code via the communications link to the Control Center The Micro Board will interpret the shutdown code and display a shut down message on the display of the Control Cen ter After the coastdown period has timed out the chiller may be restarted if the shutdown is no longer active Place the Compressor Switch in the Stop Reset posi tion and then into the Start position and release The chiller will start if no faults are active TABLE 3 SAFETY SHUTDOWNS MESSAGE DESCRIPTION Motor or Starter Current Imbalance The OSCD logic board generates this shutdown This shutdown will become active when the highest of the three motor currents exceeds 80 of the programmed FLA After these conditions are met if any one phase of motor current exceeds Leste S 30 of the average current for 45 seconds a Safety shutdown will be activated IMBALANCE The OSCD
53. ter cannot be added as an option later The function of the drive 15 identical between 2 designs OPTISPEED COMPRESSOR DRIVE CONTROL SYSTEM OVERVIEW The OSCD control system can be connected to a Mi crocomputer Control Center or to an OptiView Con trol Center Regardless of which control center is used each component performs the same function JOHNSON CONTROLS FORM 160 00 O4 ISSUE DATE 4 15 2015 The OSCD control system is composed of various com ponents located within both the Control Center and the OSCD Thus integrating the Control Center with the OSCD The OSCD system utilizes various micro processors which are linked together through a net work of communications links The Control Center before 2005 The Control Center contains two boards that act upon OSCD related information the Microboard and the Adaptive Capacity Control board ACC The ACC board performs two major functions in the OSCD con trol system 1 to act as a gateway for information flow between the Control Center and the OSCD 2 To determine the optimum operating speed for maximum chiller system efficiency The ACC board acts as an information gateway for all data flowing between the OSCD and the Control Cen ter The ACC board has a communication link to the OSCD logic board and one communication link from the optional Harmonic Filter logic board Once the ACC board receives the information the information is then passed onto the Control C
54. to be used in conjunction with the Operation Instructions for YORK Centrifugal chillers furnished with an optional OptiSpeed Compressor Drive OSCD OPTISPEED HARMONIC FILTER COMPONENT OVERVIEW OptiSpeed Compressor Drive 270 292 351 and 424 Hp The YORK OptiSpeed Compressor Drive OSCD is a liquid cooled transistorized PWM inverter in a high ly integrated package This package is small enough to mount directly onto the chiller motor and small enough to be applied in many retrofit chiller applica tions The power section of the drive is composed of four major blocks an AC to DC rectifier section with an integrated pre charge circuit a DC bus filter section a three phase DC to AC inverter section and an output suppression network An electronic circuit breaker with ground fault sens ing connects the AC line to an AC line inductor and then to the DC converter The line inductor will limit the amount of fault current so that the electronic circuit breaker is sufficient for protecting the OSCD Input fuses to the OSCD are no longer needed The follow ing description of operation is specific for the 351 Hp OSCD unless otherwise noted The AC to DC converter uses 3 Silicon Controlled Rec tifiers SCR s and 3 diodes One SCR and one diode are contained in each module Three modules are re quired to converter the 3 phase input AC voltage into DC voltage The modules are mounted on the bottom of the liquid cooled heatsink The
55. tware version C OPT 01 21 307 for the YK chiller Full Open Vane Operation Once the vanes reach the full open position the ACC knows it can no longer reduce speed and maintain the leaving chilled liquid temperature setpoint The ACC will maintain operation at this point with the vanes full open and the speed at the last point reached when the vanes hit 10096 If there is an increase in load while at this point the ACC will increase speed until the vanes are closed to 9596 of open The ACC will then be al lowed to continue to reduce speed again Effects of Surge If in the process of reducing speed and opening vanes the compressor should surge the ACC will boost the speed up by 0 8 Hz The ACC will store in memory a value that represents the ratio of condenser pressure to evaporator pressure the vane position and the speed of the drive The ratio of condenser pressure to evaporator pressure is displayed as Delta P P on the Control Panel The ACC will then know not to reduce speed this low again if the same delta pressure and the vane posi tion conditions are encounter again in the future As the chiller encounters various conditions which result in surge it will store more points and eventually this storing of points creates a Surge Surge may detected in two ways by monitoring the pressure dif ferential across the compressor or by monitoring the compressor motor current Either detection will light the Red LE
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