VARIABLE SPEED OIL PUMP DRIVE

FOR STYLE “E” YK CHILLER WITH

STYLE “P” COMPRESSOR
SERVICE INSTRUCTIONS New Release Form 160.00-M3 (601)

VARIABLE SPEED OIL PUMP DRIVE FOR STYLE “E” YK CHILLER WITH
STYLE “P” COMPRESSOR

00579VIP
 IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES

This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, oils,
materials under pressure, rotating components, and both
high and low voltage. Each of these items has the po-
tential, if misused or handled improperly, to cause bodily
injury or death. It is the obligation and responsibility of
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 dam-
age 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
operating/service personnel. It is expected that this indi-
vidual possesses 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
this document and any referenced materials. This indi-
vidual shall also be familiar with and comply with all
applicable governmental standards and regulations per-
taining to the task in question.

SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:

DANGER indicates an imminently CAUTION identifies a hazard which

hazardous situation which, if not
avoided, will result in death or seri-
ous injury.
could lead to damage to the machine,
damage to other equipment and/or en-
vironmental pollution. Usually an in-
struction will be given, together with
a brief explanation.

WARNING indicates a potentially NOTE is used to highlight additional

hazardous situation which, if not information which may be helpful to
avoided, could result in death or seri- you.
ous injury.

External wiring, unless specified as an optional connection in the manufacturer’s product

line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specifications and must be performed ONLY by qualified YORK personnel. YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will void the
manufacturer’s warranty and cause serious damage to property or injury to persons.

2 YORK INTERNATIONAL
 FORM 160.00-M3

TABLE OF CONTENTS

Page

VSD Oil Pump General Information ................................................................................................................. 3

Reference Instructions ....................................................................................................................................... 3
VSD Oil Pump Ratings ...................................................................................................................................... 3
VSD Oil Pump Drive Overview ........................................................................................................................ 3
VSD Oil Pump Drive Detail Information ......................................................................................................... 3
VSD Oil Pump Drive Operation ........................................................................................................................ 4
OptiView Control Center Operation .................................................................................................................. 5
Automatic Speed Control ................................................................................................................................... 5
Manual Speed Control ....................................................................................................................................... 7
Oil Pump Drive Status LEDs ............................................................................................................................ 8
VSOP Drive Okay Relay .................................................................................................................................. 8
Standby Lubrication ........................................................................................................................................... 8
Safety Shutdowns ................................................................................................................................................. 9
Oil – Variable Speed Pump – Setpoint not Achieved ........................................................................................ 9
Oil – Variable Speed Pump – Drive Contacts Open ......................................................................................... 9
Fault Indications by the VSOP Drive ............................................................................................................... 9
Inverter Gate Driver Fault ................................................................................................................................. 9
Overload Fault ................................................................................................................................................. 10
Low DC Link Voltage Fault ............................................................................................................................. 10
Over Temperature Fault .................................................................................................................................. 11
Trouble Shooting Guide .................................................................................................................................... 11
Drive Replacement Instructions .................................................................................................................... 13
Most Frequently Asked Questions ............................................................................................................... 14
Service Parts List ............................................................................................................................................. 15

YORK INTERNATIONAL 3
 VSD OIL PUMP GENERAL INFORMATION

REFERENCE INSTRUCTIONS

Operation (Unit) Wiring Diagram Field Connections

Model YK, Style “E” Chiller, Style “P” Compressor Model YK, Style “E” Chiller, Style “P” Compressor
(Form: 160.54-O1) Electro-Mechanical Starter
(Form: 160.54-PW11)
Operation (OptiView Control Center)
Model YK, Style “E” Chiller, Style “P” Compressor Style “B” Solid State Starter
(Form: 160.54-O1) (Form: 160.54-PW12)
Variable Speed Drive
Service (OptiView Control Center) (Form: 160.54-PW13)
Model YK, Style “E” Chiller, Style “P” Compressor
(Form: 160.54-M1)

Wiring Diagram (OptiView Control Center)

Model YK, Style “E” Chiller, Style “P” Compressor
Electro-Mechanical Starter
(Form: 160.54-PW8)
Style “B” Solid State Starter
(Form: 160.54-PW9)
Variable Speed Drive
(Form: 160.54-PW10)

TABLE 1 – VSD OIL PUMP RATINGS

INPUT VOLTAGE VSOP DRIVE MAXIMUM INPUT MAXIMUM OUTPUT

RANGE (Vrms) PART NUMBER CURRENT (Arms) CURRENT (Arms)
200/208 60 Hz 031-02044-000 6.1 11.0
220/230/240 60 Hz 031-02044-000 5.6 11.0
380 60 Hz 031-02044-000 3.3 11.0
440/460/480 60 Hz 031-02044-000 2.8 11.0
575/600 60 Hz 031-02044-000 2.2 11.0
380/400/415 50 Hz 031-02044-000 3.3 11.0

VSD OIL PUMP DRIVE OVERVIEW

The new YORK Variable Speed Oil Pump Drive
(VSOP drive) for Style “E” YK chillers with a “P” com-
pressor is an air cooled, microprocessor controlled,
PWM inverter utilizing Insulated Gate Bipolar Transis-
tors (IGBT). The VSOP drive has the same four major
components that most AC motor drives have, pre-charge,
input rectifiers, DC bus, and the inverter. The one ma-
jor difference is that the VSOP drive is controlling a 2-
phase motor. The VSOP drive is not repairable, but is
simply replaced if it has failed.
The VSOP drive is now being installed on Style “E” YK
chillers with a “P” compressor. The VSOP drive will
replace the mechanical valve system used in the past on
other chillers to regulate oil pressure. This new system
will improve bearing lubrication by providing a higher oil
pressure during the pre-lube cycle, and provide a method
of regulating oil pressure to a specific programmed value
during the run time of the compressor.

4 YORK INTERNATIONAL

VSD OIL PUMP DRIVE DETAIL INFORMATION
VSD OIL PUMP DRIVE OPERATION
The pre-charge of the VSOP drive takes place as soon
as input power is applied. Instead of using a contactor
and resistor combination used in larger drives, this drive
uses two thermistors for pre-charge. The thermistor is
a device that varies resistance, as it becomes hot or
cold. When input power is applied, the thermistors are
at room temperature and have a high resistance. This
high resistance limits the inrush current required to
charge up the DC bus capacitors. While the drive is
running, the thermistors will remain hot and the low re-
sistance allows the drive to run normally. Without the
pre-charge operation, the DC bus capacitors would re-
quire such a large inrush of current that the input power
fuses and possibly the input rectifiers could fail.
DURING NORMAL RUNNING
CONDITIONS THE THERMISTORS
BECOME VERY HOT. PERSONAL
INJURY MAY RESULT. (REFER TO
FIG. 1)
The input rectifiers are used to convert the AC input volt-
age into a DC voltage, which is stored in the DC bus ca-
pacitors. The input rectifier for this drive is made up of six
diodes. Since diodes are used the DC bus voltage is al-
ways present whenever input power is applied. As
with many small drives the input diodes are integrated into
one power module with the output inverter.
The DC bus is basically made up of capacitors. Typically,
the bus is made up of an even number of capacitors, but
EPROM
TBI VOLTAGE
SCALING
THERMISTORS
TB2 INPUT
POWER
FIG. 1 – LOCATION OF THERMISTORS AND TERMINAL BLOCKS
YORK INTERNATIONAL
FORM 160.00-M3
this drive uses 3. The reason for 3, is that the bus voltage
for this drive can exceed the voltage rating for 2 capaci-
tors. The higher voltage rating gives the VSOP drive the
ability to have a wide input voltage range. This is why only
one drive is being used with an input voltage range of
208VAC to 600VAC.
The output inverter section is made up of six switches.
These switches are insulated gate bipolar transistors (IGBT).
IGBTs are very fast switches used in power electronics.
The IGBT gives the drive the ability to vary the output
voltage and frequency with a constant DC bus voltage
stored in the bus capacitors. In this case the oil pump mo-
tor is rated for 120VAC. The bus voltage will vary based
on the different input voltage supply. At 208VAC input
voltage the bus voltage will be approximately 294VDC,
and with a 575VAC input voltage the bus voltage will be
approximately 813VDC. The reason that the 120VAC
motor can be run with such a high bus voltage is the IGBT
switching duty cycle (being the time that the switch is on
or off). The duty cycle will vary based on the bus voltage
value. At the low bus voltage the IGBTs will be turn on for
a longer period of time, and with a high bus voltage the
IGBTs will be turn on for a shorter period of time.
As already stated the drive is capable of using a wide
input range of voltage. This wide range of input voltage
is automatically addressed in the power section of the
drive. The control circuitry power supply uses an input
transformer to step-down the input voltage to a level
that can be easily regulated. This voltage needs to be
somewhat constant so that the voltage regulator in the
control circuitry power supply will not over heat. Jump-
ers are used to connect the winding of the transformer
GREEN LED
RED LED
TB3 LOGIC
SIGNALS
T1 - T3
OUTPUT WIRES
00577VIP
5
in either a parallel or series configuration to provide a operates the VSOP drive over the same range to main-
somewhat constant AC voltage to the control circuitry tain the oil pressure to the programmed OIL PRES-
power supply. The jumper configuration is shown be- SURE SETPOINT (20 to 45 PSID).
low. Refer to Fig. 1 for the location of TB1.
After the compressor has been running for 15 seconds,
TABLE 1 – JUMPER CONFIGURATION FOR TB1 the TARGET OIL PRESSURE becomes the OIL
PRESSURE SETPOINT (20 to 45 PSID) that has been
Nominal Line Jumper J1 Jumper J2 Jumper J3 programmed by the Service Technician using the proce-
Voltage (VAC) Between Between Between dure stated in Form 160.54-M1. The Microboard then
50 & 60 Hz TB1-1 & TB1-3 TB1-2 & TB1-4 TB1-2 & TB1-3 applies a speed command to the VSOP drive that changes
200, 208, 220, 240 ON ON OFF the output frequency of the VSOP drive as required to
380, 400, 415, achieve the “OIL PRESSURE SETPOINT.” The pro-
OFF OFF ON
440, 480, 575 grammed OIL PRESSURE SETPOINT is the oil pres-
sure for the remainder of “SYSTEM RUN” and through
OPTIVIEW CONTROL CENTER OPERATION “SYSTEM COASTDOWN.”

The OptiView Control Center maintains desired system
oil pressure by controlling the output frequency of
theVSOP drive and thus the speed of the oil pump. The
Microboard applies a speed command to the VSOP drive
to control the output frequency. The speed command is
in the form of a Pulse Width Modulation (PWM) signal
as explained later. Refer to Fig. 2 for the wiring inter-
face between the OptiView Control Center and the
VSOP drive. During the pre-lube period and the first 15
seconds of compressor run, the software in the
Microboard starts the VSOP drive at 45 Hz, and then
operates the VSOP drive over a range of 25 Hz to 60
Hz to maintain the oil pressure at 45 PSID, or the TAR-
GET OIL PRESSURE. Thereafter, the Microboard
During oil pump operation, the actual oil pressure and
the commanded frequency of the VSOP drive can be
monitored on the OIL SUMP SCREEN. Refer to Form
160.54-O1 for details about the OIL SUMP SCREEN.
AUTOMATIC SPEED CONTROL
The Microboard controls the VSOP drive output fre-
quency by applying a Pulse Width Modulation (PWM)
speed command signal to the VSOP drive (Fig. 3). The
signal is applied every 0.7 seconds. Within the 0.7 sec-
ond period, the duration of time that the signal is “low”

TB3
I/O
BOARD 1

TB3

70
J1 6

OIL VARIABLE SPEED PUMP -

DRIVE CONTACTS OPEN LINE
70 1

J19 6
J20
DRIVE OKAY RELAY
1 SPEED COMMAND PWM OPEN ON FAULT

2 +12VDC +V OIL
MICROBOARD 3
START / STOP EN PUMP
VSD

LD04718

FIG. 2 – OIL PUMP VSD - INTERFACE

6 YORK INTERNATIONAL

(0VDC), determines the VSD output frequency between
25 to 60 Hz. If the signal remains “high” (+12VDC) for
the entire 0.7 second period, it is commanding the VSOP
drive’s output frequency to 25 Hz. If the signal is low
for the entire 0.7 second period, it is commanding the
VSOP drive’s output frequency to 60 Hz. Frequencies
between these extremes are achieved by driving the
signal low for a proportionate amount of time within the
0.7 second period. For example, if the signal is low for
50% (0.35 seconds) of the 0.7 second period, it would
command the VSOP drive to operate at an output fre-
quency that is halfway between 25 and 60 Hz, or 42.5
Hz. The resolution or smallest increment of change is
0.01 seconds. This allows the output frequency to be
changed in 0.5 Hz steps. The formula provided in Fig. 3
could be used to calculate the output frequency for a
given PWM signal.
0.7 SEC
+12 VDC OFF
0 VDC ON
+12 VDC OFF
0.17 SEC
0 VDC ON
OFF
ON 0.35 SEC
OFF
0.52 SEC
ON
OFF
ON
+12 VDC "OFF TIME"
0VDC "ON TIME"
OUTPUT FREQUENCY IN HZ = (ON TIME IN SECONDS / 0.02) + 25
SMALLEST INCREMENT OF CHANGE = 0.010 SEC; 0.5 Hz
LD04377
FIG. 3 – PULSE WIDTH MODULATION (PWM)
SPEED CONTROL SIGNAL VOLTAGE
MEASURED TO GROUND
The entire VSOP drive run time is divided into “OIL
PRESSURE CONTROL PERIODS.” They run con-
secutively and continuously; when the first one ends,
the next one begins. This repeats until the oil pump is
shutdown. The duration of the periods are determined
by the “CONTROL PERIOD,” programmed by the
Service Technician using instructions stated in Form
160.54-M1. This setpoint is programmed in increments
of 0.3 seconds over the range of 0.3 to 2.7 seconds, by
programming the actual value. The “CONTROL PE-
RIOD” also determines the magnitude of output fre-
quency correction when the error between the actual
oil pressure and the “PROGRAMMED OIL PRES-
SURE” is > ± 6 PSID. The “CONTROL PERIOD”
YORK INTERNATIONAL
FORM 160.00-M3
is divided by .3 to provide a CONTROL PERIOD VALUE
of (1- 9). This value is multiplied by 0.5 Hz to provide
greater frequency change to more quickly adjust the oil
pressure. If the error is > ± 0.5 PSID & < ± 6 PSID, the
output frequency is increased or decreased 0.5 Hz. At the
end of each “CONTROL PERIOD”, the actual oil pres-
sure is compared to the “PROGRAMMED OIL PRES-
SURE” and the Microboard changes the speed command
as required per the following:
If actual oil pressure is:
a. >setpoint + 0.5 PSID) & <(setpoint + 6 PSID), de-
crease output frequency 0.5 Hz.
b. >(setpoint + 6 PSID), decrease output frequency
0.5 Hz x Control Period Value.
c. <(setpoint – 0.5 PSID) & >(setpoint – 6 PSID),
increase output frequency 0.5 Hz.
d. <(setpoint – 6 PSID), increase output frequency
0.5 Hz x Control Period Value.
25.0 Hz
33.5 Hz
42.5 Hz
51.0 Hz
60.0 Hz
LD06916
MANUAL SPEED CONTROL
The VSOP drive speed can be manually controlled us-
ing the RAISE, LOWER, SET or AUTO keys on the
OIL SUMP SCREEN. Access Level for SERVICE is
required for this function. This features is available dur-
ing manual oil pump operation, and while the compres-
sor is running, but this feature is not available during the
pre-lube operation.
When the chiller is not running the VSOP drive can be
turned on with the “MANUAL OIL PUMP” key on
the OIL SUMP SCREEN. When this key is pressed, a
timer will appear on the same screen. This timer will
indicate the amount of time left that the VSOP drive
will continue to run before automatically turning off. The
maximum time is 10 minutes. The “RAISE” and
7
“LOWER” keys can be used to increase or decrease
the VSOP drive’s output frequency over the range of
25 Hz to 60 Hz. Each time the “RAISE” key is pressed,
the frequency is increased 0.5 Hz. Each time the
“LOWER” key is pressed, the frequency is decreased
0.5 Hz. If the “AUTO” key is pressed, automatic op-
eration as described previously is resumed.
A special feature allows the VSOP drive to output a spe-
cific pre-determined frequency. This permits service to
analyze the oil pressure at various oil pump speeds. This
frequency is programmed when the “SET” key is pressed.
During manual and automatic operation, the OIL SUMP
SCREEN can be used to monitor the VSOP drive’s
commanded output frequency and system oil pressures.
Manual oil pump speed control can be confirmed on the
OIL SUMP SCREEN. View the “VARIABLE SPEED
OIL PUMP CONTROL MODE” for the mode of op-
eration. The text will change from “AUTO” to
“MANUAL” when the “RAISE”, “LOWER”, or “SET”
keys on the OIL SUMP SCREEN are pressed. The
text will change from “MANUAL” to “AUTO” when
the “AUTO” key is pressed.
When the chiller is running the manual speed is con-
trolled in the same manner as when the chiller is not
running. Press the “RAISE”, “LOWER”, or “SET” keys
on the OIL SUMP SCREEN and the “VARIABLE
SPEED OIL PUMP CONTROL MODE” text will
change from “AUTO” to “MANUAL.” The text will
change from “MANUAL” to “AUTO” when the
“AUTO” key is pressed.
Oil Pump Drive Status LEDs
The VSOP drive has a drive status LED, and a fault
LED. The drive status LED is located on the upper
right corner of the control board, and it is noted as
GREEN. The fault LED is located just below the drive
status LED, and it is noted as RED. The panel door for
the VSOP drive must be removed to view these LEDs.
The state and frequency at which the RED LED will
flash will determine the fault of the VSOP drive. If
power is removed the fault condition is no longer dis-
played. The conditions of the LEDs are as follows:
• A constant GREEN LED will indicate that the
VSOP drive is in a running condition.
• A constant RED LED will indicate that the VSOP
drive is in a stopped condition with no faults present.
• If none of the LED’s are lit at all, the input power
has been removed, or VSOP drive has failed.
• A constant GREEN LED and a flashing RED LED,
8 YORK INTERNATIONAL
will indicate that the VSOP drive has faulted since
the power was last applied, and it has restarted.
The fault conditions are explained under the Fault
Indications section of this form.
• A flashing RED LED will indicate that the VSOP drive
is in a faulted condition. The fault conditions are ex-
plained under the Fault Indications section of this form.
STATUS
LEDs
00578VIP
FIG. 4 – LOCATION OF STATUS LEDs ON
CONTROL BOARD
VSOP Drive Okay Relay
The VSOP drive is equipped with a set of normally open
contacts. These contacts are open when the VSOP drive
is in a faulted condition. These contacts are driven
closed when the VSOP drive condition is okay. The
contacts are connected between TB3-70 and TB3-1.
When the contacts are open a voltage of 115VAC will
be measured across these two terminal connections, and
the chiller will initiate a Cycling Shutdown. The follow-
ing message will appear on System Details line of the
display. “OIL – VARIABLE SPEED PUMP -
DRIVE CONTACTS OPEN.” This message will ap-
pear, and the contacts will remain open as long as the
fault is still present. Refer to the fault conditions below
for detailed information about the faults.
Standby Lubrication
To maintain oil seal integrity while the chiller is shut-
down, the oil pump is turned on for 2 minutes every 24
hours if the chiller has not run in the past 24 hours.
While the oil pump is running, the message “WARN-
ING – SEAL LUBRICATION IN PROCESS” is
displayed. The operating oil pressure will be the pro-
grammed OIL PRESSURE SETPOINT, programmed
by the Service Technician. This feature will be inhibited
if the chiller enters the prelube cycle, or if the oil pres-
sure is to low. If the oil pressure is too low the following
message is displayed “WARNING – STANDBY
LUBE – LOW OIL PRESSURE.”

To prevent oil pump damage due to low oil level, an oil
pressure fault has been created to function during the
Standby Lubrication Cycle. This fault will terminate the
Standby Lubrication Cycle, if at least 15 PSID of oil
pressure is not achieved within 30 seconds of turning on
the oil pump, or if the oil pressure drops below 15 PSID
after the first 30 seconds of operation. This fault is iden-
tified when the message “WARNING – STANDBY
LUBE – LOW OIL PRESSURE” is displayed. The
next standby lube cycle will occur only after the warn-
ing has been manually cleared, or by starting the chiller.
Standby lubrication cycles will not be performed if ei-
ther oil pressure transducer is out of range (HOP < 6.8
PSIG, LOP < 0 PSIG). No message will be displayed to
SAFETY SHUTDOWNS
Oil – Variable Speed Pump – Setpoint Not Achieved
If either of the following conditions occur, a Safety shut-
down is initiated and the message “OIL – VARIABLE
SPEED PUMP – SETPOINT NOT ACHIEVED”
is displayed on the System Details line of the display.
a. If the oil pressure is less than 25.0 PSID for 5 con-
tinuous seconds during the last 10 seconds of the
compressor pre-lube or during the first 15 seconds
of SYSTEM RUN.
b. If the oil pressure is less than the programmed OIL
PRESSURE SETPOINT and the speed command to
the VSOP drive is at 60 Hz for 5 continuous seconds,
anytime after the first 30 seconds of SYSTEM RUN.
Typically, this fault occurs during the prelube cycle or
during the automatic seal lubrication cycle. The reason
for the fault is that the cool oil is saturated with refriger-
ant. Oil that is saturated with refrigerant is much thin-
ner then oil that has the refrigerant boiled off. Since, the
oil is thinner it is more difficult to build oil pressure in the
system. This cool oil is generally not the oil in the sump,
but the oil that is laying in the rest of the oil lubrication
system, which cannot be heated by the oil heater mounted
in the sump.
YORK INTERNATIONAL
FORM 160.00-M3
indicate that the lubrication cycle will not be performed
although a Safety message will appear to indicate the
oil pressure transducer will be out of range. The verifi-
cation of correct pressure assures that standby lubrica-
tion cycles will not be performed when the chiller is
opened to atmospheric pressure, or until the chiller has
been charged with refrigerant and chiller commission-
ing has been completed.
These standby lubrication cycles are enabled or disabled
by the Service Technician using the procedure stated in
Form 160.54-M1. It is recommended that the standby
lubrication be enabled on chillers that remain shutdown
for periods of 24 hours or greater.
One solution is a change in the software for the
OptiView Control Center that will cause the oil pump
drive to accelerate to 45 Hz on start, and then regulate
the speed of the drive to the oil pressure requirement.
This software should already be installed.
The second solution is to change the control period.
Lowering the value of the control period will allow the
oil pump drive’s output frequency to change more quickly
in response to the changing oil pressure. This adjust-
ment is important when the chiller compressor first starts
to spin. The oil pressure will drop since the oil can more
freely move in a rotating bearing.
The “OIL – VARIABLE SPEED PUMP –
SETPOINT NOT ACHIEVED” safety check is not
performed during MANUAL SPEED control.
Oil – Variable Speed Pump – Drive Contacts Open
In an effort to have a VSOP drive that is as reliable as
possible, the VSOP drive can only generate 4 faults.
Although this fault is a Cycling shutdown for the chiller,
commonly the chiller will also shutdown on a Low Oil
Pressure Shutdown. The Low Oil Pressure Shut-
down is a Safety shutdown, and it will require a manual
reset of the chiller.
9
 FAULT INDICATIONS BY THE VSOP DRIVE
Inverter Gate Driver Fault
This fault is generated by 2 different conditions. The
first condition is the power supply voltage at the output
gate driver. If this voltage is not high enough, then the
output switch will not turn on properly. This will cause a
great amount of heat, possibly causing the output switch
to fail. The second condition, is a high amount of cur-
rent flowing out of the DC bus. This fault is auto re-
settable, since the condition is cleared when the VSOP
drive turns itself off. The drive will turn back on and try
to start again. If this fault occurs 3 times within 1 minute,
the drive will lockout. After the VSOP drive is locked
out, it may be restarted by placing the COMPRESSOR
SWITCH in the STOP/RESET position, and then in the
START position.
Indications for This Fault
The RED LED will blink on once and then off for 5
seconds. This sequence will repeat until a new fault
occurs, or power has been removed and reapplied.
Possible Problems
• The input supply voltage may not be within specification.
• A component failure on the VSOP drive control board.
• Shorted output switch on the VSOP drive.
• Short from the output of the VSOP drive to ground,
through the output insulator or the oil pump motor.
• Shorted oil pump motor, phase-to-phase.
Possible Solutions
• Verify input voltage to the VSOP drive.
• Verify that the oil filter is clean, and that there are no
oil blockages.
• Verify the jumper position on the TB1 terminal block.
• Verify that the oil pump motor is not locked into po-
sition. Temporarily switch the Main and Auxiliary
wires from the VSOP drive and the motor. This will
cause the oil pump motor to reverse direction, and
possible remove any slag from the oil pump gears.
Properly, reconnect the motor wires.
• Verify that the VSOP drive is not shorted.
• Verify that the oil pump motor is not shorted phase-
to-phase, or phase- to-ground.
10
Overload Fault
In order for the VSOP drive to be compatible with a
wide range of input line voltages, the overload fault is
determined by calculating the average power transferred
from the DC bus to the oil pump motor. If this value
exceeds 1757 watts then a shutdown will occur. Also, if
the DC bus current exceeds 8 amps., then the VSOP
drive will shutdown in 10 seconds. The current flowing
to the pump motor can be verified by measuring the
current in the motor leads. With a two-phase motor the
maximum current flowing in each phase is different.
The red output wire is the main winding, and it’s 100%
rating is 7.0 amps. The blue output wire is auxiliary wind-
ing, and it’s 100% rating is 10.0 amps. The black output
wire is common wire, and it’s 100% rating is 11.0 amps.
When these values exceed 105% of the rated current
value then the overload timer will start. The overload
timer is variable based, on the amount of current that is
flowing.
Indications for This Fault
The RED LED will blink on 2 times and then off for 5
seconds. This sequence will repeat until a new fault
occurs, or power has been removed and reapplied.
Possible Problems
• Dirty oil filter.
• Dirty oil causing the oil pump to bind up.
• Blockage in the oil lines.
Possible Solutions
• Verify that the oil filter is clean.
• Verify that the oil in the chiller is clean and does not
contain any slag from the welding process. Tempo-
rarily switch the Main and Auxiliary wires from the
VSOP drive and the motor. This will cause the oil
pump motor to reverse direction, and possibly re-
move any slag from the oil pump gears. Properly,
reconnect the motor wires.
• Verify that the oil pump motor is free to rotate.
Low DC Link Voltage Fault:
This fault is generated when the DC bus voltage does
not reach 170VDC within 3 seconds of power being
applied, or the DC bus voltage drops below 170VDC
after the Bus voltage has reached a level higher than
170VDC.
YORK INTERNATIONAL
 FORM 160.00-M3

Indications for This Fault Possible Problems

The RED LED will blink on 3 times and then off for 5
seconds. This sequence will repeat until a new fault oc-
curs, or power has been removed and reapplied.
Possible Problems
• Input voltage range outside the specification of the
VSOP drive.
• Input voltage variation due to power factor correction
capacitors.
Possible Solutions
• Provide the proper input voltage for the VSOP drive.
Over Temperature Fault
This fault is generated when the base plate temperature
of the output power device is greater than 255°F
(124°C). The temperature sensor is part of the output
power device. The drive will attempt to restart when
the base plate temperature is below 250°F (121°C).
• Ambient temperature of the chiller room is above
104°F (40°C).
• The heatsink for the VSOP drive is dirty.
• The mounting screws for the output power device
are not properly torqued.
• Blockage in the oil lines.
• The oil is too hot.
Possible Solution
• Reduce the ambient temperature of the chiller room.
• Clean the heatsink of the VSOP drive.
• Properly torque the mounting screws of the output
power device.
• Verify that the oil temperature is not exceeding 180°F
(82°C).

Indications for This Fault

The RED LED will blink on 4 times and then off for 5
seconds. This sequence will repeat until a new fault
occurs, or power has been removed and reapplied.

YORK INTERNATIONAL 11

Problem
Blown Input Fuses, or the
status LEDs are not lit.
System Details on the OptiView Panel 1. Refer to Fault Indications by the VSOP Drive in the
reads Oil – Variable Speed Pump –
Drive Contacts Open, and the fault
RED LED is flashing on the VSOP drive.
System Details on the OptiView Panel 1. Measure the voltage between TB3-1 on the VSOP
reads Oil – Variable Speed Pump –
Drive Contacts Open, but the fault
RED LED is constantly lit on the
VSOP drive.
Start the VSOP drive, but the VSOP
drive will not start and the fault
RED LED is constantly lit.
The VSOP drive will run but the
Oil pressure will not regulate to the
setpoint in automatic mode.
The status GREEN LED is flashing.
VSOP drive is running, but oil
pressure is not increasing or has
remained 0 PSID.
12
TROUBLE SHOOTING GUIDE
Action Required
1. Remove input wires L1-L3 from the VSOP Drive,
measure resistance, input phase to phase
on the VSOP drive.
2. Remove wires T1-T3, measure resistance, output
phase to phase on the VSOP drive.
previous section.
drive and Ground.
2. Measure voltage between TB3-4 on the I/O board
and Ground.
1. Measure voltage between TB3-1 on the VSOP drive
and Ground on the Microboard.
2. Manually start the VSOP drive from the OptiView Panel.
Measure voltage between TB3-2 on the VSOP drive
and Ground.
3. Temporarily disconnect the oil heater. Remove the wire
connected to J20-3 in the Microboard, and connect that
wire to Ground on the Microboard.
1. None
2. Temporarily disconnect the oil heater. Connect the Run
signal to ground. Remove J20-1 and connect it to J20-2
on the Microboard.
Solution
1a. If input is shorted, replace VSOP drive.
1b. If input is not shorted, replace L1-L3 and continue
to the next step.
2a. If output is shorted, replace VSOP drive.
2b. If output is not shorted, replace T1-T3, and replace
the blown input fuses.
2c. If the LEDs still do not light, then the LEDs have
failed. Replace the VSOP drive.
1a. Correct for any of the fault conditions in the
previous section.
1a. If 0VAC is measured, verify wiring of TB3-1 TB6-1
in the OptiView Panel. For details refer to the proper
Wiring Diagram.
1b. If 115VAC is measured continue to the next step.
2a. If 0VAC is measured, verify wiring between
terminalTB3-70 on the VSOP and the I/O board.
Replace wire if required.
2b. If wiring is okay, the relay on the VSOP drive has
failed. Replace the VSOP drive.
2c. If 115VAC is measured, then verify operation of the
I/O board and the Microboard.
1a. If 0VDC is displayed, verify wiring from TB3-1 to the
Microboard.
1b. If 12VDC is measured continue to the next step.
2a. If 12VDC is displayed, verify wiring from TB3-2 to
the Microboard.
2b. If 0VDC is measured continue to the next step.
3a. If VSOP drive starts verify the J20 connector for
broken solder joint or loose connector.
3b. If VSOP drive does not start replace VSOP drive.
Also reconnect the oil heater.
1a. Verify wiring between VSOP drive, and Microboard.
1b. If wiring is okay, continue to the next step.
2a. The oil pressure should be maintained at a minimum
low pressure.
2b. If the oil pressure starts to increase over time, then
replace the oil pump drive. Reconnect the oil heater.
1. Verify wiring between the VSOP drive and the
Microboard.
1. Verify that the Main and Auxiliary wires are properly
connected to the oil pump motor.
YORK INTERNATIONAL

DRIVE REPLACEMENT INSTRUCTIONS
1. Remove power from the chiller at the main power
disconnect.
2. Wait 5 minutes for the DC bus voltage to decay to a
safe level, and the thermistors to cool off.
3. Remove the cover to the VSOP drive. The screws
are captive.
4. Take note of all wiring connected to the VSOP drive.
5. Remove all wiring from the VSOP drive.
6. Remove the nut securing the control transformer,
and the 2 nuts at the top two corners of the VSOP
drive control board. Remove the 2 screws holding
the power module to the heatsink.
7. Carefully, remove the power module from the
heatsink. Do not nick or scratch the heatsink.
FIG. 4 – SYSTEM WIRING DIAGRAM
YORK INTERNATIONAL
FORM 160.00-M3
8. Clean the heatsink with a rag and rubbing alcohol.
9. On the replacement drive verify that the TB1 jump-
ers are properly configured for your application. Refer
to Table 1.
10. Apply a thin coating of Heatsink grease (provide
with replacement drive) to the bottom of the power
module.
11. Replace the VSOP drive and install the hardware.
The 2 screws that hold the power module to the
heatsink should be torqued to 24-28 In-Lbs.
12. Rewire the VSOP drive using Fig. 4 below.
13. Install the cover for the VSOP drive.
14. Reapply power to the chiller at the main power dis-
connect.
LD06915
13
 MOST FREQUENTLY ASKED QUESTIONS
1. Why doesn’t the rotation of the motor change
when I change the input wiring to the VSOP
drive?
The VSOP drive converts the input line voltage into a
DC bus voltage, and then converts the DC bus volt-
age back into an AC voltage with a varying frequency.
So, the output section of the drive is isolated from
the input section of the drive by the capacitor bank.
2. How is oil pressure regulated?
A differential oil pressure setpoint is programmed
through the OptiView panel. This setpoint is then
used to regulate the oil pressure. The speed of the
oil pump motor will increase if the oil pressure is
less than the setpoint by 0.5 PSID. Also, the speed
of the oil pump motor will decrease if the oil pres-
sure is greater than the setpoint by 0.5 PSID.
3. On a 50 Hz installation how can the VSOP drive
still run at 60 Hz?
Normal operation of a motor requires that the increase
in frequency and the increase in voltage occur at the
same rate. This is called a linear volts/Hz curve. If
the supply voltage for 50 Hz is the same as 60 Hz,
then the drive can develop enough voltage to supply
a 60 Hz motor. The gating of the output power de-
vices determines the output frequency not the input
frequency to the VSOP drive.
4. What are the differences between the Solid
Start Starter (SSS) and a VSOP drive?
The SSS reduces the amplitude of the voltage ap-
plied to the motor during start-up, by gradually turn-
ing on SCRs connected to the input line. Inrush cur-
rent is reduced since the voltage applied to the mo-
tor is reduced. This method of controlling a motor
has no effect on the frequency of the voltage. When
14
full voltage is applied to the motor the SCRs are fully
turned on. The VSOP drive is the same as a Variable
Speed Drive. This type of drive employs an input stage,
an energy storage stage, and an output stage. The
input stage converts the AC input into a DC supply
by rectifying the input line voltage. The DC supply is
stored in the energy storage stage, within capacitor
bank. The stored energy is then converted into a vary-
ing voltage and frequency in the output stage. The
output stage uses very fast switches that switch with
a constant frequency (of about 2 kHz) but with a vary-
ing duty cycle. The varying duty cycle allows the out-
put to vary in frequency and voltage.
5. Can the VSOP drive be bypassed and the oil
pump motor powered directly across the line?
No, the oil pump motor is a 2-phase motor with a
voltage rating of 120VAC. Connecting this motor is
the line voltage will burn it up, and it will not rotate.
6. Can I read the VSOP output frequency with a
hand held meter?
Yes, but the meter reading will not be correct. The
output frequency of the VSOP drive is actually sev-
eral kHz. This frequency is what is called the carrier
frequency. The motor acts like a filter to the carrier
frequency and the fundamental frequency or 60 Hz
is what is left. The hand held meter will detect the
carrier frequency, but not the fundamental frequency.
7. Why does the VSOP drive fault when it is not
running?
The line voltage is always applied to the input of the
VSOP drive. Since this is the case, the voltage faults
must be active to protect the VSOP drive and the oil
pump motor.
YORK INTERNATIONAL
 FORM 160.00-M3

SERVICE PARTS LIST

Description Part Number

VSOP Drive with Thermal Grease 371-03704-001
VSOP Drive EPROM 031-02059-001
Input Fuses with an EM-Starter or a Liquid Cooled Solid State Starter
200, 208, 220, 230, 240 Volts 025-25584-000 (FNQ-15)
380, 400, 415, 440, 460, 480 Volts 025-25515-000 (FNQ-7)
550, 575, 600 Volts 025-27971-000 (KTK-10)
Input Fuses with a VSD Compressor Drive 025-25515-000 (FNQ-7)

YORK INTERNATIONAL 15
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by York International Corporation 2001 www.york.com ALL RIGHTS RESERVED
Form 160.00-M3 (601)
New Release