Professional Documents
Culture Documents
00282VIP
NOTE
UNLESS OTHERWISE NOTED, INFORMATION IN THIS INSTRUCTION
IS APPLICABLE TO ALL STYLE STARTERS OF THE SAME SIZE.
EXAMPLE: 26L-B AND 26LK-B
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. situated, as well as severe personal injury or death to
During installation, operation, maintenance or service, themselves and people at the site.
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, oils, This document is intended for use by owner-authorized
materials under pressure, rotating components, and both operating/service personnel. It is expected that this indi-
high and low voltage. Each of these items has the po- vidual possesses independent training that will enable
tential, if misused or handled improperly, to cause bodily them to perform their assigned tasks properly and safely.
injury or death. It is the obligation and responsibility of It is essential that, prior to performing any task on this
operating/service personnel to identify and recognize equipment, this individual shall have read and understood
these inherent hazards, protect themselves, and proceed this document and any referenced materials. This indi-
safely in completing their tasks. Failure to comply with vidual shall also be familiar with and comply with all
any of these requirements could result in serious dam- applicable governmental standards and regulations per-
age to the equipment and the property in which it is 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:
2 YORK INTERNATIONAL
FORM 160.00-O2
TABLE OF CONTENTS
STYLE “B” LIQUID COOLED SOLID STATE STARTER GENERAL INFORMATION ................... 5
Reference Instructions ..................................................................................................................... 5
Style “B” Liquid Cooled Solid State Starter Variations .................................................................... 5
Style “B” Liquid Cooled Solid State Starter Overview .................................................................... 6
SECTION 1 THEORY OF OPERATION ........................................................................................... 7
General ............................................................................................................................................. 7
System Microprocessors ................................................................................................................. 7
Solid State Starter Cooling Loop ..................................................................................................... 9
Electrical Conditions ....................................................................................................................... 10
Motor Protection ............................................................................................................................ 10
SECTION 2 SYSTEM ARCHITECTURE ........................................................................................ 10
SECTION 3 LOGIC/TRIGGER BOARD ........................................................................................ 12
General Information ........................................................................................................................12
Current Scaling ...............................................................................................................................12
Logic/Trigger Board Indicator LED’s ............................................................................................. 13
Relay Functions ..............................................................................................................................13
Logic/Trigger Board Inputs And Outputs ......................................................................................13
SECTION 4 SAFETY SHUTDOWNS ............................................................................................. 16
General Information ........................................................................................................................16
105% Motor Current Overload .......................................................................................................16
High Temperature ........................................................................................................................... 16
High Instantaneous Current ........................................................................................................... 16
Open SCR ........................................................................................................................................ 17
Output Current Imbalance ............................................................................................................... 17
Phase Rotation ................................................................................................................................17
Shorted SCR ....................................................................................................................................18
SECTION 5 CYCLING SHUTDOWNS .......................................................................................... 18
General Information ........................................................................................................................18
High Supply Line Voltage ............................................................................................................... 18
Initialization Failed ..........................................................................................................................19
Invalid Current Scale ....................................................................................................................... 19
Logic Board Power Supply .............................................................................................................19
Logic Board Processor ....................................................................................................................19
Low Phase Temperature ..................................................................................................................20
Low Supply Line Voltage ................................................................................................................ 20
Phase Locked Loop ........................................................................................................................20
Phase Loss ......................................................................................................................................21
Power Fault .....................................................................................................................................21
Run Relay ....................................................................................................................................... 21
Serial Communications ....................................................................................................................22
Stop Contacts Open ........................................................................................................................22
SECTION 6 START INHIBITS ....................................................................................................... 22
High Temperature ........................................................................................................................... 22
SECTION 7 START UP INSTRUCTIONS ...................................................................................... 24
Start-Up Checklist ........................................................................................................................... 24
Fill Cooling Loop ............................................................................................................................ 24
SECTION 8 TROUBLESHOOTING PROCEDURES .................................................................... 25
General Information ........................................................................................................................25
Verify Shorted SCR .........................................................................................................................25
Verify Open or Shorted SCR Gate ................................................................................................... 25
Verify Gate Driver Output ............................................................................................................... 25
Verify Real Phase Current Imbalance .............................................................................................. 26
Verify False Phase Current Imbalance ............................................................................................. 27
Removing SCR Assemblies ............................................................................................................27
Installing SCR Assemblies .............................................................................................................28
YORK INTERNATIONAL 3
LIST OF FIGURES
FIG. 1 – LIQUID COOLED SOLID STATE STARTER - FRONT VIEW, EXTERIOR ........................... 6
FIG. 2 – LIQUID COOLED SOLID STATE STARTER - BASIC BLOCK DIAGRAM .......................... 7
FIG. 3 – LIQUID COOLED SOLID STATE STARTER - REAR VIEW, EXTERIOR ............................. 8
FIG. 4 – LIQUID COOLED SOLID STATE STARTER - INTERIOR, CONNECTION SECTION
FUSES AND LOGIC TRIGGER BOARD .............................................................................. 11
FIG. 5 – LIQUID COOLED SOLID STATE STARTER - INTERIOR, POWER SECTION ................... 11
FIG. 6 – LIQUID COOLED SOLID STATE STARTER - LOGIC/TRIGGER BOARD DETAIL ............ 13
FIG. 7 – LOGIC/TRIGGER BOARD PIN LOCATION DIAGRAM .................................................... 15
FIG. 8 – CURRENT IMBALANCE DUE TO VOLTAGE IMBALANCE ............................................ 26
FIG. 9 – LIQUID COOLED SOLID STATE STARTER - POWER COMPONENTS ............................ 27
LIST OF TABLES
4 YORK INTERNATIONAL
FORM 160.00-O2
REFERENCE INSTRUCTIONS
Operation (Unit)
Model YT, Style J (Centrifugal) Form 160.55-O1
Model YK, Style E (Centrifugal) Form 160.54-O1
Model YS, Style E (Screw Chiller) Form 160.80-NOM1
Operation (OptiView Control Center)
Model YT, Style J (Centrifugal) Form 160.55-O1
Model YK, Style E (Centrifugal) Form 160.54-O1
Model YS, Style E (Screw Chiller) Form 160.80-O1
Service (OptiView Control Center)
Model YT, Style J (Centrifugal) Form 160.55-M1
Model YK, Style E (Centrifugal) Form 160.54-M1
Model YS, Style E (Screw Chiller) Form 160.80-M1
Wiring Diagram (OptiView Control Center)
Model YT, Style J (Centrifugal) Form 160.55-PW2
Model YK, Style E (Centrifugal) Form 160.54-PW8
Model YS, Style E (Screw Chiller) Form 160.80-PW2
Wiring Field Connections (Solid State Starter)
Model YT, Style J (Centrifugal) Form 160.55-PW5
Model YK, Style E (Centrifugal) Form 160.54-PW5
Model YS, Style E (Screw Chiller) Form 160.80-PW4
Replacement Parts List (Solid State Starter) Form 160.00-RP3
The New Style “B” Liquid Cooled Solid State Starter is also available with a disconnect switch or a circuit breaker. Consult the
sales information for additional part numbers for those models.
YORK INTERNATIONAL 5
HIGH HAT FOR OPTIONAL DISCONNECT
SWITCH AND CIRCUIT BREAKER 1.5 KVA CONTROL
POWER TRANSFORMER
COOLANT
PUMP
OPTIONAL
CIRCUIT
BREAKER
The Style “B” Liquid Cooled Solid State Starter is a This instruction is a description of the operation, start-up
state of the art, soft start for YORK compressor mo- and troubleshooting of the Style “B” YORK Liquid
tors. New features include a combined Logic/Trigger Cooled Solid State Starter. It should be read thoroughly
Board, improved data collection, better generator op- before servicing this product. Due to the integration of
eration, and easier set-up. The Style “B” Liquid Cooled the Solid State Starter with the YORK OptiView Con-
Solid State Starter is to be applied only to the YORK trol Center, an understanding of the OptiView Control
OptiView Control Center. Center is necessary. Therefore, this document should
be used with referenced instructions on page 5.
6 YORK INTERNATIONAL
FORM 160.00-O2
CURRENT
OA TRANSFORMERS
SCR
ASSY.
T
OB SCR COMPRESSOR
ASSY. MOTOR
T
OC SCR
ASSY.
T
CONTROL
POWER HEATSINK
XFMR TEMP.
MOTOR LD05246
SERIAL COMMUNICATIONS LINK CURRENT
MICRO
BOARD
YORK INTERNATIONAL 7
Theory of Operation
and software signal from the OptiView Control Center, the VCON value increases, and the PLD turns the SCRs
for the chiller to be started. If the two signals are not full on. The output of the PLD is sent to a digital driver
received within a certain period of time, a shutdown chip and then to six optical couplers, one for each SCR.
will occur.
The optical couplers are the first stage of the trigger
The main system microprocessor performs many func- portion of the Logic/Trigger Board. They isolate the
tions. It provides the serial communications link between high power circuit from the low power circuit. The
the Logic/Trigger Board, and the Micro Board in the power for the high power circuit is supplied from the J5
OptiView Control Center. It determines the proper cur- connector. The trigger section is made up of six output
rent scaling for the size of starter, and interrogates the drivers, one for each SCR. Each output driver has a
RUN/STOP signal from the OptiView Control Center. dedicated transformer, that steps down the incoming
This processor also interrogates feedback signals to voltage, and provides isolation between each output
determine Open and Shorted SCR, Phase Loss, Phase driver.
Rotation, Motor Overload, High Instantaneous Current,
High Line Voltage, and Low Line Voltage shutdowns. A digital signal processor (DSP) is used for many tim-
ing and calculation functions. Root Mean Square (RMS)
The VCON signal is generated by the main system calculations require that input line voltage and output
microprocessor. It is a digital signal placed on the data current values be calculated on a cycle-by-cycle basis.
bus. This processor compares the starting current value, These calculations are used to display the RMS voltage
programmed at the OptiView Control Center, with the and current for each phase, kW, and kWh on the
current feedback from the three output current trans- OptiView Control Center. The DSP is also used to in-
formers. A new value of VCON is generated every terpret the feedback signals from the thermistors
line cycle. This signal is then sent to the programmable mounted on the SCR’s assemblies. All of these values
logic device (PLD). The PLD determines the proper are placed on the data bus for the main system micro-
firing order for the SCRs to maintain the programmed processor to generate faults, if required, and to send
starting current value. As the speed of the motor ap- data on to the OptiView Control Center via the serial
proaches synchronous speed output current drops off, communication link.
PIPE
PLUG
WATER
RESERVOIR
WATER
PUMP
HEAT EXCHANGER
8 YORK INTERNATIONAL
FORM 160.00-O2
SOLID STATE STARTER COOLING LOOP exchanger prevents the closed loop coolant from mix-
(Refer to Fig 3) ing with the condenser water. The condenser water is
forced through the heat exchanger by the pressure dif-
The SCRs in the Liquid Cooled Solid State Starter gen- ferential across the condenser shell input and output.
erate heat during normal running conditions and become
very hot during start-up of the chiller. This heat is gen- The cooling loop is filled with cool-
erated by the fact that all of the current flowing to the ant at system start-up commissioning
motor is conducted through the SCRs. The SCRs are 1
by the service technician. Refer to
very reliable, but they do have a slight resistance value
start-up instructions. As mainte-
when they are turned on. The resistance, along with
nance, the coolant must be changed
the load current of the motor, generates the heat.
every year. If the coolant is not re-
The heat must be dissipated, or the SCRs will fail from placed within this time interval, a
an overheating condition. Two methods are commonly potential for corrosion of the SCR’s
used to dissipate the heat. The first method, which was heatsink is greatly increased.
employed on older solid state starters was forced air
cooling. This method works well, but requires a larger The Logic/Trigger Board constantly monitors the tem-
cabinet and the addition of many fans. The second perature of the three SCR heatsink assemblies with a
method for dissipating the heat is to employ a water thermistor attached to each assembly. The tempera-
cooling system similar to that used in automobiles. ture of each thermistor is sent to the Micro Board in
the OptiView Control Center via the serial communica-
The cooling system for the Liquid Cooled Solid State tions link. Refer to referenced instructions on page 5
Starter is different from the system in an automobile. for details on where this data can be viewed on the
In automobiles, heat is transferred to the air, but the OptiView Control Center.
starter transfers heat to the condenser water.
If the temperature of any assembly exceeds a high value
Condenser water is used to cool the starter for many during a running condition, the Logic/Trigger Board will
reasons. One, the condenser water will always be avail- initiate a shutdown. Further, anytime the temperature
able since it is part of the chiller system. The cooling is of any assembly exceeds a high value and the starter is
free since the condenser water will be cooled in the not running, the chiller will be prevented from starting
cooling towers for the chiller needs, and does not add and the closed loop coolant pump will be operated until
any load to the chiller. If the chilled water was used to the temperature has fallen. Also, if the temperature of
cool the starter, this would add to the chiller load and any assembly falls below a preset value, the Logic/Trig-
add cost to the customer. In a few applications where ger Board will initiate a shutdown.
chilled water is being used because of extremely high
condenser water pressure, a temperature regulating Changes have been made to the OptiView Control Cen-
valve must be used. The temperature regulating valve ter software to improve the restart time of the starter.
should be set to 85°F so that condensation does not These changes allow for the control of the condenser
occur inside the starter cabinet. Using condenser wa- water pump when a style ‘B’ LCSSS is used with the
ter eliminates the concern for condensation occurring following OptiView Control Center software. On a YK
inside of the starter cabinet, which could damage the chiller, the software is C.MLM.01.04 or later. On a YT
starter. The reliability of the starter is improved from chiller, the software is C.MLM.02.01 or later. On a YS
the standpoint that the three forced air fans are replaced chiller, the software is C.MLM.03.01 or later.
with one circulating pump.
The condenser water pump will be turned on any time
The SCR assemblies are cooled by a pump circulating the chiller is started, and will continue to run until
coolant in a closed loop through the SCR’s heatsink and coastdown is complete. After coastdown is completed,
the outer tube of the tube-in-tube heat exchanger. When the condenser water pump will continue to run if any
the coolant passes through the heatsink, it absorbs heat one of the three thermistors indicated that the SCR as-
from the heatsink. As the coolant passes through the semblies are too hot. Once the temperature has fallen
heat exchanger, it gives up its heat to the system con- to a specified level, the condenser water pump will turn
denser water that is flowing through the inner tube of off.
the tube-in-tube heat exchanger. The design of the heat
YORK INTERNATIONAL 9
System Architecture
This new control will cool down the SCR assemblies gency power, the JP1 jumper may need to be cut. The
more quickly after the chiller has been stopped. Then JP1 jumper changes how the Logic/Trigger Board will
the LCSSS can be started sooner, as long as the anti- track the frequency of the incoming line voltage. (Re-
recycle timer has been satisfied. fer to Fig 6 for location of JP1.) If the Logic/Trigger
Board is a Rev. C, then the JP1 jumper must be cut for
ELECTRICAL CONDITIONS generator operation. If the Logic/Trigger Board is a Rev.
D or later, the JP1 jumper has been removed, and the
Proper starter operation requires that all phases of the Logic/Trigger Board will function properly regardless
AC power line voltage are present, and in the correct of whether the starter is connected to the utility or gen-
rotation. A “Power Fault” circuit provides protection erator power.
from rapid power line current interruptions and tran-
sient switching. The AC power line voltage also must MOTOR PROTECTION
be relatively free of spikes and noise. If these condi-
tions are not met, safety circuitry on the Logic/Trigger Compressor motor protection circuits are provided on
Board will cause a shutdown of the Liquid Cooled Solid the Logic/Trigger Board. These circuits protect the
State Starter. These shutdowns will protect the chiller motor from continuous or instantaneous high current
from rotating in the wrong direction, or causing tran- levels. Another circuit is used to determine if the cur-
sient torque conditions on the compressor shaft. As well, rent transformers are connected to the Logic/Trigger
the Liquid Cooled Solid State Starter will shut down Board. This ensures that the Liquid Cooled Solid State
and protect itself and the compressor motor if the AC Starter has current feedback before the chiller is started.
power line voltage is too high or too low. Without the current feedback, the inrush current can-
not be regulated. Also, if the output current becomes
If the Liquid Cooled Solid State Starter is intended to imbalanced due to AC power line voltage instability, or
be used on a generator application, then the JP1 jumper faulty SCR, a shutdown will occur. Other circuits are
on the Logic/Trigger Board may need to be cut. Even if employed to sense a signal phase condition to the mo-
the starter will be connected to a generator for emer- tor, or if one of the SCRs is open.
The following Liquid Cooled Solid State Starter components are located in an enclosure mounted to the compressor
motor terminal box. (Refer to Fig. 4 and 5.)
• SCR Assemblies
• Current Transformers
• Logic/Trigger Board
• Control Circuit Fuses
• Oil Pump Motor Fuses
• Circuit Breaker or Disconnect Switch if used
• A control power transformer is attached to the side of the starter enclosure. This supplies 115VAC control
power to the starter and OptiView Control Center. The YK chiller uses a transformer which is different from
that used on YT and YS chillers.
10 YORK INTERNATIONAL
FORM 160.00-O2
INPUT POWER
CONNECTIONS FIBERGLASS
INSULATION
GROUND TERMINAL
POWER CONNECTIONS
TO COMPRESSOR MOTOR
FUSE BLOCK
OPTIONAL
CIRCUIT
BREAKER
LOGIC/TRIGGER
BOARD
00285VIP
BUS BAR
OUTPUT
CURRENT
TRANSFORMERS
SCR
GATE
LEADS
SCR
GATE
LEADS
SCR
HEATSINK
INPUT ASSEMBLIES
BUS
BARS
00286VIP
YORK INTERNATIONAL 11
Logic / Trigger Board
The new Logic/Trigger Board is basically an integra- In order for the motor current to be properly scaled by
tion of the functions in the Logic and Trigger Board in the Micro Board, the Logic/Trigger Board sends a scaling
the style ‘A’ Liquid Cooled Solid State Starter. The new code via the serial communications link to the Micro
board uses a microprocessor, a digital signal processor, Board in the OptiView Control Center. The scaling code
and a programmable logic device to duplicate the func- is determined by how jumpers are arranged on the J1
tions of the older analog boards. This new board is lo- connector on the Logic/Trigger Board. Also, each model
cated in the Liquid Cooled Solid State Starter cabinet. size of starter uses a different CT ratio. (See Table 1.)
The Logic/Trigger Board communicates with the Mi- Since these jumpers are used to determine the size of
cro Board in the OptiView Control Center via a serial the starter, a common Logic/Trigger Board can be used
communications link made up of a three-wire cable for 60Hz applications. This will simplify the replace-
connected to TB1. The serial communications link is ment of the Logic/Trigger Board. Each model has a
used to send all displayed data related to the starter, different current capability, as outlined in Table 2.
fault messages, and history data. This data is transmit-
ted every 2 seconds, and then the data on the display of The motor FLA and the Starting Current are pro-
the OptiView Control Center is updated. grammed on the OptiView Control Center. Refer to
referenced instructions on page 5 for details about which
form is needed to program these values. Also, within
these model classifications, there are various line volt-
age applications.
TABLE 1 – CT RATIO
MODEL SIZE PINS JUMPERED TOGETHER ON J1 CT RATIO
7L J1-7 TO J1-8, J1-8 TO J1-9, J1-9 TO J1-10 700:1
14L J1-8 TO J1-10, J1-9 TO J1-10 1400:1
26L J1-7 TO J1-10, J1-9 TO J1-10 2600:1
33L J1-9 TO J1-10 3300:1
12 YORK INTERNATIONAL
FORM 160.00-O2
LOGIC/TRIGGER BOARD INDICATOR LED’S Relay K2 controls the operation of the closed loop cool-
ant pump. When the Micro Board commands the Liq-
The Logic/Trigger Board contains only two LED’s. uid Cooled Solid State Starter to run, the main system
Since all of the shutdown messages are displayed on microprocessor, via an output driver, causes the K2 re-
the OptiView Control Center, there is no need for LED’s lay contacts to close. As long as the K2 contacts are
to annunciate a shutdown condition. The two LED’s closed, the closed loop coolant pump will run. When the
are used to verify that the serial communications link is Micro Board commands the Liquid Cooled Solid State
working. Starter to stop, the main system microprocessor, via an
output driver, causes the K2 relay contacts to open (pro-
CR6 is the Receive LED. This LED will flash green vided all of the thermistor temperatures are below
every 2 seconds to indicate that the Logic/Trigger Board 110°F). This will stop the closed loop coolant pump.
has received data from the OptiView Control Center. Therefore, the closed loop coolant pump may start and
(Refer to Fig. 6 for location of LED.) stop with the compressor motor. Also, the K2 relay will
be energized by the main system microprocessor when 3
CR7 is the Transmit LED. This LED will flash red ev- any heatsink temperature exceeds 110°F regardless
ery 2 seconds to indicate that the Logic/Trigger Board of whether the chiller is running or not. When the
has sent data to the OptiView Control Center. (Refer temperature falls below 110°F, the main system micro-
to Fig. 6 for location of LED.) processor will de-energize K2 relay causing the pump
to stop.
RELAY FUNCTIONS
LOGIC/TRIGGER BOARD INPUTS AND OUTPUTS
Relay K1 shall provide a hardware shutdown signal to (Refer to Fig. 6 and 7.)
the OptiView Control Center via wires 16 and 53. The
relay will provide a normally open set of contacts that All measurements made to GND (J3-1)
are driven closed when the Liquid Cooled Solid State unless otherwise noted.
Starter is operating satisfactorily, and the contacts will
open when the Liquid Cooled Solid State Starter ini-
tiates a Cycling or Safety shutdown. These contacts
will remain open until the cause of the shutdown has
been rectified.
J11 J10 J9 J8 J7 J6
J5
J1
J12
00287VIP
TB2 TB4 J4 J3 J2 JP1 CR7 CR6 U15 RAM CHIP U16 EPROM
YORK INTERNATIONAL 13
Logic / Trigger Board
J1 PINS J5-PINS
• J5-1: 115VAC neutral input.
• J1-1&2: Phase “A” motor current input from cur- • J5-2: 115VAC from the secondary of the 1T.
rent transformer (2T). AC voltage is read with digi-
tal voltmeter across resistor R76 (top of R76 is J6-PINS
GND). Voltage read should be:
• J6-l: Phase “A” Positive SCR gate output. .55-
RMS Motor Current = 2VDC as measured to J6-2 when the starter is run-
(AC Voltage Measured/3.01) x CT RATIO ning.
• J6-2: Phase “A” Positive SCR cathode. See J6-1.
CT ratio = 700(7L), 1400(14L), 2600(26L), 3300(33L)
J7-PINS
• J1-3&4: Phase “B” motor current input from cur- • J7-1: Phase “A” Negative SCR gate output. .55-
rent transformer (3T). AC voltage is read across 2VDC as measured to J7-2 when the starter is run-
resistor R77 (top of R77 is GND). Refer to Jl-1&2 ning.
to calculate current.
• J7-2: Phase “A” Negative SCR cathode. See
• J1-5&6: Phase “C” motor current input from cur- J7-1.
rent transformer (4T). AC voltage is read across
resistor R78 (top of R78 is GND). Refer to J1-1&2
J8-PINS
to calculate current.
• J8-l: Phase “B” Positive SCR gate output. .55-
• J1-7: Part of current scaling feedback, and deter-
2VDC as measured to J8-2 when the starter is run-
mining the HP of the starter.
ning.
• J1-8: Part of current scaling feedback, and deter-
• J8-2: Phase “B” Positive SCR cathode. See J8-1.
mining the HP of the starter.
• J1-9: Part of current scaling feedback, and deter- J9-PINS
mining the HP of the starter.
• J9-1: Phase “B” Negative SCR gate output.
• J1-10: Ground, used as part of the current scaling .55-2VDC as measured to J9-2 when the starter is
feedback. running.
• J1-11: Part of current transformer connector in- • J9-2: Phase “B” Negative SCR cathode. See
terlock circuit. J9-1.
• J1-12: Part of current transformer connector in-
terlock circuit. J10-PINS
• J10-L: Phase “C” Positive SCR gate output. .55-
J2 PINS 2VDC as measured to J10-2 when the starter is
• J2-1: Phase “A” SCR assembly thermistor input. running.
Refer to Table 6 for voltages and temperatures. • J10-2: Phase “C” Positive SCR cathode. See
(Utilize 10K ohm @ 25°C thermistors.) J10-1.
• J2-2: See J2-1.
J11-PINS
J3-PINS • J11-1: Phase “C” Negative SCR gate output. .55-
• J3-1: Phase “B” SCR assembly thermistor input. 2VDC as measured to J11-2 when the starter is
See J2-1 voltage. running.
• J3-2: See J3-1. • J11-2: Phase “C” Negative SCR cathode. See
J11-1.
J4-PINS
• J4-1: Phase “C” SCR assembly thermistor input.
See J2-1 for voltage.
• J4-2: See J4-1.
14 YORK INTERNATIONAL
FORM 160.00-O2
2 1 2 1 2 1 2 1 2 1 2 1
J11 J10 J9 J8 J7 J6
1
J5
2
J1
12 8 4 J12
11 7 3
2
10 6 2
9 5 1 1
TB2 TB1 J4 J3 J2
1 2 3 4 5 1 2 3 2 1 2 1 2 1
LD05282
YORK INTERNATIONAL 15
Safety Shutdowns
16 YORK INTERNATIONAL
FORM 160.00-O2
The shutdown message displayed will be “LCSSS - one phase of motor current exceeds 30% of the aver-
HIGH INSTANTANEOUS CURRENT”. age current for 45 seconds, a Safety shutdown will oc-
cur. Review the following example.
Possible Problems:
• Check for a shorted SCR. If:
current in the A phase = 200A
• Disconnect the motor and test for shorts phase to
current in the B phase = 200A
ground, and phase to phase.
current in the C phase = 118A
• If the shutdown occurs during the ramp up of the
motor, an open SCR maybe the problem. Then:
• Verify that the gate of the SCR is not open. IAVE = 200 + 200 + 118
• Verify that the programmed starting current is cor- 3
rect on the OptiView Control Center.
IAVE = 173A
• Verify that the output CT’s are reading current cor-
rectly. IACCEPTABLE = 173 x + 30% = 121A, 225A
• Check for an open input fuse.
Therefore,
OPEN SCR Since phase “C” current = 118A which is less than the
acceptable 121A, the chiller would shut down if this 4
This shutdown becomes active after the first 40 sec- imbalance exists for 45 seconds.
onds of starter operation. The main system micropro-
cessor looks at the voltage across each SCR via an The shutdown message displayed will be “LCSSS –
opto-coupler. When the SCR is turned on, the output of MOTOR OR STARTER-CURRENT IMBAL-
the opto-coupler is high, and when the SCR is turned ANCE”.
off, the output of the opto-coupler is low. If this signal is
low for 5 consecutive seconds, a Safety shutdown will Possible Problems:
occur. • Verify the input voltage to the starter.
• Verify that the output CT’s are reading current cor-
To help eliminate nuisance trips, this shutdown can be rectly.
disabled from the OptiView Control Center. Refer to
• Verify the gate drive on the Logic/Trigger Board.
the OptiView Control Center Service form for your style
of chiller (refer to Reference Instruction in this form,
page 5, for the proper form number). PHASE ROTATION
The shutdown message displayed will be “LCSSS - The Logic/Trigger Board contains circuitry that gener-
OPEN SCR”. ates a waveform for each of the input phase voltages.
These waveforms are compared to each other by the
Possible Problems: main system microprocessor. When the “A” phase volt-
age transitions positive, the “C” phase voltage must be
• Verify operation of the gate drivers. positive. Also, when the “A” phase voltage transitions
• Verify that the motor is connected. negative, the “B” phase voltage must be positive. This
• Verify that the gate of the SCR is not open. shutdown is only active during the first 30 line cycles
• Check for an open input fuse. after power is applied to the starter. After the first 30
line cycles, the shutdown is no longer active.
YORK INTERNATIONAL 17
Cycling Shutdowns
VOLTAGE RANGE HIGH SUPPLY LIMIT – STOPPED HIGH SUPPLY LIMIT – RUNNING
Disabled None None
200 - 208 226 227
220 - 240 261 262
380 414 415
400 435 436
415 453 454
440 - 480 523 524
550 - 600 654 655
18 YORK INTERNATIONAL
FORM 160.00-O2
The shutdown message displayed will be “LCSSS - down will occur. The presence of the P1/J1 connector
HIGH SUPPLY LINE VOLTAGE”. is verified when power is applied to the starter. During
the period that the connector is not connected to J1, the
Possible Problems: three phase currents and the KW values will be dis-
• Verify that the proper voltage range is selected on played as zero on the display of the OptiView Control
the OptiView Control Center. Center.
• Verify proper line voltage is being applied to the
Generally, this shutdown will occur during the start-up
starter.
of the chiller.
INITIALIZATION FAILED The shutdown message displayed will be “LCSSS -
INVALID CURRENT SCALE SELECTION”.
After power has been applied to the OptiView Control
Center, the Micro Board attempts to communicate with Possible Problems:
the Logic/Trigger Board via the serial communication
link. If the Micro Board has tried to communicate with • Verify that the J1 connector is installed on the Logic/
the Logic/Trigger Board ten times, and the Logic/Trig- Trigger Board.
ger Board has not responded, a Cycling shutdown will • Verify the wiring of the J1 connector.
occur. Even though the shutdown was recorded, the
Micro Board will continue to try to communicate with LOGIC BOARD POWER SUPPLY
the Logic/Trigger Board. Since the Micro Board at-
tempts to communicate with the Logic/Trigger Board Whenever power is applied to the LCSSS this shut-
every two seconds, the shutdown will occur approxi- down is indicated.
mately 20 seconds after power was applied.
The shutdown message displayed will be “LCSSS -
The shutdown message displayed will be “LCSSS INI- LOGIC BOARD POWER SUPPLY”.
TIALIZATION FAILED”.
Possible Problems: 5
Possible Problems: • Check for possible input power problems.
• Verify the communication cable between the
OptiView Control Center and the Logic/Trigger LOGIC BOARD PROCESSOR
Board.
• If CR6 is blinking, but CR7 is not blinking, the Logic/ A watchdog type of system is used to determine if the
Trigger Board has failed. If both CR6 and CR7 are main system microprocessor and the DSP are still com-
blinking every two seconds continue to the next step municating. Normally, the main system microprocessor
• If problem is still not detected, then perform the and the DSP communicate every 3 mSec. A watchdog
communication loop back test (Ref. Forms listed counter is set-up in the main system microprocessor to
on page 5 for OptiView Control Center Service). a count of 80. If after 80 attempts to communicate be-
tween the main system microprocessor and the DSP,
INVALID CURRENT SCALE and the DSP still does not respond, a Cycling shutdown
will occur. At the same point in time the DSP will be
To protect the motor and starter from high current con- rebooted. The watchdog timer will only reset if com-
ditions, and the chiller from Power Fault conditions, the munications have been established.
current transformers must be properly connected to the
Logic/Trigger Board. The current transformers are con- The shutdown message displayed will be “LCSSS -
nected to the Logic/Trigger Board via the P1/J1 con- LOGIC BOARD PROCESSOR”.
nector. This connection also determines starter HP size,
and allows the use of only one Logic/Trigger Board. If Possible Problems:
P1 is not connected to J1, the three inputs to determine • If the problem continues replace the Logic/Trigger
the starter size will be pulled high and a Cycling shut- Board.
YORK INTERNATIONAL 19
Cycling Shutdowns
LOW PHASE TEMPERATURE downs from heavily loaded transformers. The voltage
range is programmed on the OptiView Control Center.
The value of each thermistor mounted on the SCR as- If no voltage range is programmed, then this shutdown
semblies is constantly compared to a shutdown thresh- will be disabled (Ref. Forms listed on Page 5).
old value of 37°F in the main system microprocessor. If
any one of the three thermistors has a value that corre- The shutdown message displayed will be “LCSSS -
sponds to 37°F or lower, a Cycling shutdown will occur. LOW SUPPLY LINE VOLTAGE”.
The thermistors are connected to the Logic/Trigger
Board at plugs P2, P3, P4. Possible Problems:
• Verify that the proper voltage range is selected on
The shutdown message displayed will be “LCSSS - the OptiView Control Center.
LOW PHASE X TEMPERATURE SENSOR”,
• Verify proper line voltage is being applied to the
where X is either A, B or C corresponding to SCR
starter.
phase assemblies A, B or C respectively.
• If the problem occurs during generator operation,
Possible Problems: add some standby load to the generator so that the
generator can respond more quickly to load changes.
• This problem is normally associated with a open
thermistor.
PHASE LOCKED LOOP
• Verify that P2, P3, and P4 are connected to the
Logic/Trigger Board.
The cathode connection of the negative SCRs is con-
• Verify the interconnection between the thermistor nected to the 3-phase AC power line. This information
and the P2, P3, and P4 connectors. is sent to the Logic/Trigger Board, where a circuit gen-
erates a waveform that is synchronized to the ‘A’ phase
LOW SUPPLY LINE VOLTAGE voltage. This waveform and the ‘A’ phase voltage are
compared, and the deviation is used to generate an er-
The Logic/Trigger Board monitors the three phases of ror signal. The error signal is then used to correct the
input voltage via the negative SCR cathode connection. waveform and maintain synchronization with the ‘A’
The DSP determines the phase to phase RMS voltage phase voltage. The synchronized waveform is used for
and sends this information to the main system micro- the firing control of all the SCRs. If the error signal
processor. The main system microprocessor will com- becomes too large then the synchronization with the
pare these voltages to shutdown thresholds in Table 4. ‘A’ phase voltage will be lost. If synchronization is not
If the input voltage falls below the shutdown threshold maintained, the SCRs will misfire and damage the chiller.
for 20 continuous seconds, then a Cycling shutdown
will occur. This shutdown is disabled for the first 20 The shutdown message displayed will be “LCSSS -
seconds of the starter run, to prevent nuisance shut- PHASE LOCKED LOOP”.
VOLTAGE RANGE HIGH SUPPLY LIMIT – STOPPED HIGH SUPPLY LIMIT – RUNNING
Disabled None None
200 - 208 174 160
220 - 240 200 185
380 331 305
400 349 320
415 362 335
440 - 480 400 370
550 - 600 502 460
20 YORK INTERNATIONAL
FORM 160.00-O2
The shutdown message displayed will be “LCSSS - The shutdown message displayed will be “LCSSS -
PHASE LOSS”. RUN RELAY”.
YORK INTERNATIONAL 21
Start Inhibit
This shutdown becomes active after a successful Whenever a shutdown occurs, the K1 relay de-ener-
completion of initialization. If the Micro Board has tried gizes and the contacts open on the Logic/Trigger Board.
to communicate with the Logic/Trigger Board ten times, If the K1 contacts open, and no fault is detected in the
or if the Logic/Trigger Board does not receive a trans- serial communications link, then a Cycling shutdown
mission from the Micro Board within 20 seconds, then will occur.
a Cycling shutdown will occur. Since the Micro Board
attempts to communicate with the Logic/Trigger Board The shutdown message displayed will be “LCSSS -
every two seconds, the shutdown will occur in approxi- STOP CONTACTS OPEN”.
mately 20 seconds. Under this condition, all information
Possible Problems:
about the starter displayed on the OptiView Control
Center will be zero. • Verify that the J1 connector is installed on the Logic/
Trigger Board, and that there is a wire installed
The shutdown message displayed will be “LCSSS - between J1-11 and J1-12.
SERIAL COMMUNICATIONS”. • Verify that TB1-1 and TB1-2 are properly wired.
• Verify the communication cable between the
Possible Problems: OptiView Control Center and the Logic/Trigger
• Verify the communication cable between the Board.
OptiView Control Center and the Logic/Trigger • Verify operation of the K1 relay. If the function of
Board. K1 is not working properly, replace the Logic/Trig-
• If CR6 is blinking, but CR7 is not blinking, the Logic/ ger Board.
Trigger Board has failed. If both CR6 and CR7 are • If CR6 is blinking, but CR7 is not blinking, the Logic/
blinking every 2 seconds, continue to the next step. Trigger Board has failed. If both CR6 and CR7 are
• If problem is still not detected, then perform the blinking every two seconds, continue to the next
communication loop back test (Ref. Forms listed step.
on page 5 for OptiView Control Center Service). • If problem is still not detected, then perform the
communication loop back test (Ref. Forms listed
on page 5 for OptiView Control Center Service).
105°F, and if it has been less than one hour since the has been less than one hour since the chiller was last
chiller was last stopped. The condenser water pump stopped or shutdown due to a safety or cycling shut-
will also turn on, when power is restored after a power down. Once the temperature of all three thermistors is
fault, if any one of the three SCR assemblies thermistors below 105°F, the condenser water pump will turn off,
indicates a temperature of greater than 105°F, and it and will not turn on until the next compressor start.
YORK INTERNATIONAL 23
Start-Up Instructions
YORK INTERNATIONAL 25
Troubleshooting Procedures
• Use this section to determine if the current imbal- • A typical motor of today may induce a current im-
ance is real or a reporting problem. balance of up to 6%, but factory specifications al-
• Start the chiller. low for up to 8% before rejecting a motor. So, if the
• Connect another current measuring device around measured current imbalance is 13.5% or less, this
the output wire to the motor. is normal for the above example, and no more in-
• Compare the measured three phase currents to vestigation is required. If this is not the source of
each other. the problem, continue.
• If the currents are imbalanced, then continue. If
Typical input voltage imbalance is 1 to 1½%. Ex-
they are not imbalanced, continue to section titled
cessive input voltage imbalance is 2% or greater.
“Verify False Phase Current Imbalance”.
Most often imbalances are due to unequal distri-
• While the starter is running, record the three phases bution of single phase loads within the building.
of input voltage.
• Add the 3 values of voltage together, and divide by • Connect an AC voltage meter from L-1 to T-1.
3 to get the average voltage. Then take each mea-
• After the chiller has been running for one minute,
sured value, subtract the average value, and divide
measure the voltage across the SCR. The voltage
this difference by the average value, and multiply
should measure between .70 – 2.0VAC. The volt-
by 100. The result is the percentage phase imbal-
age should remain stable. If the voltage is not stable,
ance for that phase. Depending on the load of the
or is higher than 9.0VAC, there could be a problem
motor a value of 1.5% can cause a current imbal-
with the gate driver on the Logic/Trigger Board, or
ance of 15%. If this is not the source of the prob-
the SCR is not latching on. In the case of the SCR
lem continue.
NO LOAD
30
20% LOAD
40% LOAD
25 60% LOAD
80% LOAD
% CURRENT IMBALANCE
FULL LOAD
20
15
10
LD05247
0
0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
% VOLTAGE IMBALANCE
26 YORK INTERNATIONAL
FORM 160.00-O2
not latching on, this is typical of older starters. Verify • If this is not the source of the problem, continue.
each SCR pole by moving the meter to L-2 and • Measure resistance across J1 pin 1-2. A resistance
T-2, and L-3 and T-3. This test verifies the opera- value of 3.0 ohms should be displayed on your
tion of the starter. If these voltages are correct, meter. This resistor is a 0.1% tolerance compo-
then the problem is most likely other than the starter. nent. If it is out of tolerance, replace the Logic/
Trigger Board. Repeat this step with J1 pin 3-4,
VERIFY FALSE PHASE CURRENT IMBALANCE and J1 pin 5-6.
• Reconnect the J1 connector.
Use this section if the current imbalance is not real, but • If this is not the source of the problem, continue.
is a reporting problem.
• Start the chiller.
• Verify that the OptiView Control Center has the
• Connect another current measuring device around
correct model of starter selected. If not, verify wir-
the output wire to the motor.
ing of the J1 connector. Refer to the current scal-
ing section in this form. • Compare the three phase current from the OptiView
Control Center to the three measured currents.
• If this is not the source of the problem, continue.
• Replace the CT in the phase in which the current
• Remove main input power to the starter.
does not measure correctly.
• Set ohm meter to Rx1 range. If the ohm meter is a
digital model, and has a diode test scale, place the
REMOVING SCR ASSEMBLIES
meter in the diode test mode.
• Remove the J1 connector, and measure the resis- Refer to the Replacement Parts List Form 160.00-RP3
tance of the three output CT’s. The resistance value for replacement SCR assembly kit part numbers.
will vary depending on the model of the starter.
• Remove AC power from system. If the starter has
MODEL STARTER CT RESISTANCE RANGE a circuit breaker, place it in the off position.
7L 2.4 – 4.3 OHMS
• Drain coolant as directed in the Fill Cooling Loop
14L 5.0 – 7.3 OHMS
Section.
26L 8.0 – 16.8 OHMS
33L 10.7 – 22.0 OHMS
• Loosen the hose clamps and remove the hoses from
the defective heatsink assembly.
COOLANT
PUMP
CONDUIT
OIL
PUMP
CONDUIT
SCR
ASSEMBLY
(1 OF 3)
8
RESISTOR
AND
CAPACITOR
INPUT
ASSEMBLY
BUS BAR
00286VIP
YORK INTERNATIONAL 27
• Place tape over the hose barbs, so that the coolant • Install SCR assembly into the starter and tighten
does not leak into the cabinet of the starter. the 4 mounting bolts.
• Remove all electrical connections from the Logic/ • Install the coolant hose over the hose barbs, and
Trigger Board. Remove Logic/Trigger Board as- tighten the hose clamps (tubing must not contain
sembly by removing 4 panel mounting screws and any kinks).
the 6 screws holding the gate wire clamps. • On 7L and 14L models, it is necessary to clean the
• Disconnect the thermistor wire connector for the mating surfaces of the SCR assembly and input
failed SCR (J/P16, J/P17, J/P18). bus bar with fine emery cloth or ScotchbriteTM pad
• Mark and then remove the output wires to the mo- and coat with a thin film of thermal joint compound
tor. Fold out of the way if possible. (013-02880-000) before attaching the input bus bar.
Torque the two bolts to 13-17 ft.-lbs.
• Remove the current transformer mounting bracket
by removing the four screws on the back of the On 26L and 33L models, clean the mating surfaces
starter. Move CT assembly out of the way. of the SCR assembly and input bus bar with fine
emery cloth or ScotchbriteTM pad. Torque the two
• Remove the two bolts connecting the SCR assem-
bolts to 13-17 ft.-lbs.
bly to the bus bar.
• Install the current transformer mounting bracket by
• Remove the four SCR/heatsink assembly mount-
inserting the four screws on the back of the starter.
ing nuts from the mounting studs and remove the
entire SCR/Heatsink assembly. • Install the output wires from the motor.
• Remove resistor and capacitor assembly from de- • Connect the thermistor wire connector for the new
fective SCR assembly. Save these parts; they will SCR (J/P16, J/P17, J/P18).
be needed for the new SCR assembly. (Refer to • Install Logic/Trigger Board assembly by installing
Fig. 9.) 4 panel mounting screws and the 6 screws holding
the gate wire clamps. Install all electrical connec-
INSTALLING SCR ASSEMBLIES tions to the Logic/Trigger Board.
• Fill the coolant loop as directed in the Fill Cooling
• Install new plastic hose barbs into the new SCR Loop Section in this form.
assembly. Use Teflon tape on threads of the hose • The starter is now ready to be restarted.
barbs.
• Install resistor and capacitor assembly onto the SCR
assembly.
P.O. Box 1592, York, Pennsylvania USA 17405-1592 (717) 771-7890 Subject to change without notice. Printed in USA
Copyright © by York International Corporation 2000 www.york.com ALL RIGHTS RESERVED
Form 160.00-O2 (200)
New Release