SYSTEM CALIBRATION, SERVICE SETPOINTS AND RESET PRO CE DURES
5. Press the ENTER (✔) key. If the value is within range, it is accepted and the dialog box dis ap pears. The chiller will begin to operate based on the new value. If out of range, the value is not accepted and a message describing why it is not acceptable is displayed momentarily.
Some Safety shutdowns will not permit the chiller to start until a special reset procedure is performed. These reset procedures require SERVICE access level and should not be performed by anyone other than a Ser vice Tech ni cian. Each of these procedures is described below.
ELECTRO-MECHANICAL STARTER AP PLI CA - TIONS
If the Compressor Motor is driven by an Electro- Me chan i cal Starter, the OptiView Control Center is equipped with a CM-2 Current Module along with sup port ing com po nents Diode Bridge (DB) and Cal- i bra tion Resistors (RES), as de scribed in a previous chap ter of this book. The following procedures can be used to verify the cal i bra tion and perform the calibra- tion if necessary. In ad di tion to the calibration, Switch S1 and Potentiometer R16 have to be set appropriately on the CM-2 Module. If the CM-2 and/or RES are fi eld re placed, fi eld cal i bra tion is necessary.
CM-2 Settings:
1. Place Switch S1 in the appropriate position per the Starter type:
UP: Y-Delta or 57% Auto-transformer Start er
Down: All others
2. Calculate LRA/FLA ratio by dividing the Motor Lock Rotor Amps by the chiller Full Load Amps (LRA/FLA = ratio) and then adjust Po ten ti om e ter R16 to the ratio value.
Calibration Verifi cation:
1. At the Keypad, log in at SERVICE access lev el us ing access code 1 3 8 0.
2. Select MOTOR Screen and set Current Lim it and Pulldown Demand Limit Setpoints to 100% FLA. 3. Run chiller. Read compressor motor current in Phase A, B, and C using a clamp-on Am me ter.
4. Select COMPRESSOR Screen.
5. Manually operate the Pre-rotation Vanes by press- ing the OPEN and CLOSE Keypad keys as re quired to achieve a motor current equiv a lent to 100% FLA as indicated by the clamp-on Am me ter. The motor current value on the Display should indicate 100% FLA.
6. Manually operate the Pre-rotation Vanes by press- ing the OPEN and CLOSE keys as required to achieve a motor current equivalent to 105% FLA as indicated by the clamp-on Ammeter. The 105% LED on the CM-2 Module should il lu mi nate. If the calibration verifi cation does not perform as above, the following Calibration procedure will have to be per formed:
Calibration:
1. At the Keypad, log in at SERVICE access level us ing access code 1 3 8 0.
2. Select MOTOR Screen and set Current Lim it and Pulldown Demand Limit Setpoints to 100% FLA. 3. Select COMPRESSOR Screen.
4. Run chiller and read compressor motor cur rent in Phase A, B and C using a clamp-on Ammeter. Ap- ply Ammeter to highest Phase.
5. Manually operate the Pre-rotation Vanes by press ing the OPEN and CLOSE Keypad keys as re quired to achieve a motor current equivalent to 100% FLA as indicated by the clamp-on Am me ter. The voltage across Variable Re sis tors (RES) should be 0.90 to 1.05VDC. Measure this volt age by connecting a Voltmeter at CM-2 Board J1-2 (+) to J1-1(-). If necessary, adjust RES to achieve this value. Figure 38 contains for mu las to cal cu late the resistance of RES required to achieve this volt age. Adjust both re sis tors equally such that the com bined resistance equals the cal cu lat ed val ue.
6. Manually operate the Pre-rotation Vanes by press- ing the OPEN, CLOSE and HOLD Keypad keys, as required, to achieve a motor current equiv a lent to 105% FLA as indicated by the clamp-on Am me ter. Loosen locking nut on Po ten ti om e ter R8 on CM-2 and adjust until the CM-2 Module 105% LED il lu mi nates. Coun ter clock wise increases sig nal lev el; Clock wise
100% FLA as indicated by the clamp-on Am me ter. Loose locking nut on Potentiometer R34 on CM- 2 and adjust until the motor current value on the Display indicates 100% FLA. Clockwise in creas es the signal level; Counterclockwise de creas es the signal level. Tight en locking nut.
SOLID STATE STARTER AP PLI CA TIONS
When the compressor motor is driven by a YORK Solid State Starter, one of three different Starters could be ap- plied. Later production chillers are equipped with either the Style B Liquid Cooled Solid State Starter (LCSSS) or the Medium Voltage Solid State Starter (MVSSS). Earlier production vintage chillers are equipped with the Style “A” Solid State Starter. Refer to Section 11 for details of each of these starters. Use the following procedure to select the appropriate motor drive type, then select the appropriate procedure below for the starter type selected.
Motor Drive Type Selection:
• Microboard 031-1730-000: Position Program Jumpers JP37 and JP39 appropriately per Section 3, Table 1. • Microboard 031-02430-000/001:
1. Chiller must be stopped and RUN switch must be in Stop-Reset position.
2. Select SETUP Screen.
3. Press CHANGE SETTINGS key. 4. A green box will appear around the fi rst changeable setpoint. Use ▲▼ keys to place the box around MOTOR DRIVE TYPE setpoint.
5. Press √ key. A dialog box will appear with the range of settings. Use ◄ ►keys to select “SSS-Mod A”, “SSS-Mod B” or “MV SSS”, as appropriate.
6. Press ENTER (√) key.
MOD “B” LIQ UID COOLED SOLID STATE STARTER 1. At the Keypad, log in at SERVICE Access lev el
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Full Load Amps:
This is the Full Load Amps (FLA) of the chiller as list ed on the Sales Order Screen. The Microboard uses the pro- grammed value to perform Current Limit func tions and display compressor motor current in terms of %FLA. 1. Press FULL LOAD AMPS key.
2. Use numeric keypad keys to enter correct value. 3. Press ENTER (✔) key.
Start Current:
The Logic/Trigger Board will limit compressor motor current to this value during starting. The correct value is (0.45 x Delta Locked Rotor amps), as listed on the SALES ORDER Screen.
1. Press STARTING CURRENT key.
2. Use numeric keypad keys to enter correct value. 3. Press ENTER (✔) key.
Voltage Range:
This is the compressor motor AC power line ap pli ca tion. Selections are 200-208, 220-240, 380, 400, 415, 440- 480, 550-600 and Disabled. The Microboard uses the programmed value to determine the overvoltage and undervoltage shutdown thresholds for “LCSSS – HIGH SUPPLY LINE VOLTAGE” and “LCSSS – LOW SUP- PLY LINE VOLTAGE” cycling shut downs as de scribed in Operation Manual 160.54-O1. If DIS ABLED is se lect ed, the shutdown thresh olds will be ig nored. This check should not be arbitrarily dis abled.
1. Press VOLTAGE RANGE key.
2. Use ◄and►keys to scroll to desired value. 3. Press ENTER (✔) key.
Open SCR Enable/Disable:
This allows the Open SCR safety check, per formed by the Logic/Trigger Board, to be disabled. This must NEV ER be disabled unless advised by the YORK fac to ry.
1. Press OPEN SCR key.
2. Use ◄and►keys to select Enable or Dis able. 3. Press ENTER (✔) key.
Kilowatt Hours (KWH) Reset:
This allows the KWH to be set to a desired starting value in the event the BRAM has to be fi eld replaced. This must never be arbitrarily performed.
1. Press KWH RESET key.
3. Press ENTER (✔) key.
MOD “A” LIQUID COOLED SOLID STATE STARTER The following procedures can be used to ver i fy the cal- i bra tion and perform the calibration if necessary. If the Logic Board is fi eld replaced, fi eld cal i bra tion is neces- sary. Logic Board Program Jumper JP5 (300V/600V) must be placed in the appropriate position per the com- pres sor motor AC power line.
Logic Board Program Jumper:
Place Jumper J5 (300V/600V) in appropriate position per the Compressor Motor AC Power Line application as follows:
600V - Place over pins 1 & 2 for 380/400/415, 440/460/480 or 550/575/600 VAC applica- tions.
300V - Place over pins 2 & 3 for 200/208 or 220/230/240 VAC applications.
Setpoints:
1. At the Keypad, log in at SERVICE access lev el us ing access code 1 3 8 0.
2. Select MOTOR Screen.
3. Enter the following Setpoints using pro ce dures below:
Full Load Amps :
This is the Full Load Amps (FLA) of the chiller as list ed on the Sales Order Screen. The Microboard uses the pro- grammed value to perform Current Limit functions and display compressor motor current in terms of % FLA. 1. Press FULL LOAD AMPS key.
2. Use numeric keypad keys to enter cor rect val ue. 3. Press ENTER (✔) key.
Voltage Range:
This is the AC Power line voltage ap plied to the Com- pres sor Motor. Selections are: 380, 400, 415, 440-480, 550-600 and Supply Voltage Range Disabled. The Microboard uses the programmed selection to de ter mine the overvoltage and undervoltage thresholds for Start er High Supply Line Voltage and Starter Low Sup ply Line Voltage. Cycling shutdowns as de scribed in Op er a tor Manual 160.54-O1. If Supply Voltage Range
Disabled is selected, the thresholds will be ignored and these shutdowns will not occur. This check should not
1. Press VOLTAGE RANGE key.
2. Use ◄and►keys to scroll to desired val ue. 3. Press ENTER (✔) key.
Current Unbalance Check Enable/Disable:
While the chiller is running, if the compressor Motor current in phase A, B and C becomes un bal anced, a Safety shutdown is performed. Refer to Operator Man u al 160.54-O1 for complete de scrip tion of this check. This Setpoint allows the check to be enabled or disabled. If enabled, the check is performed; if dis abled, the check is not performed.
1. Press CURRENT UNBALANCE key.
2. Use ◄ and ► keys to select Enable or Dis- able.
3. Press ENTER (✔) key. Calibration Verifi cation:
At the Keypad, login at SERVICE access level using access code 1 3 8 0.
1. Compressor Motor current display accuracy - a. Run chiller.
b. Select COMPRESSOR Screen.
c. Use the Pre-rotation Vanes HOLD keypad key to sta bi lize the Compressor Motor current. d. Measure phase A, B and C Compressor Motor
cur rent with a clamp-on ammeter. Compare the Ammeter values with displayed mo tor current val ues. If displayed values are not within +5% of Ammeter values, refer to Solid State Starter Ser vice Manual 160.46-OM3.1 to trou ble shoot Start er.
2. Start Current - Proper starting current is (45% x Del ta locked Rotor amps).
a. Select COMPRESSOR Screen.
b. Start chiller and monitor Compressor Motor start ing current in phase A, B and C on the COMPRESSOR Screen.
Highest phase should be equiv a lent to (45% x Del ta Locked rotor amps).
3. Overload -
a. Select COMPRESSOR Screen.
b. Run chiller and monitor Compressor Motor cur- rent on the COMPRESSOR Screen.
The Display should indicate 105% and the 105% LED on the Solid State Starter Logic Board should illuminate when the 105% FLA val ue is reached.
If the calibration verifi cation does not perform as above, one or both of the following Calibration procedures will have to be performed:
Calibration:
At the Keypad, log in at SERVICE access level using access code 1 3 8 0.
1. Start Current -
a. Select COMPRESSOR Screen.
b. Loosen locking nut on Solid State Starter Log ic Board Potentiometer R38.
c. Start chiller and monitor Compressor Motor start ing current in Phase A, B and C on the COM PRES SOR Screen.
d. While chiller is starting, adjust START CUR- RENT potentiometer (R38) on Solid State Start er Logic Board to achieve the proper start ing cur- rent of (0.45 x Delta Locked rotor Amps) on the high est phase. Turning R38 Clock wise in creas es cur rent; Counterclockwise decreases current. Mul ti ple starts could be required to achieve the correct cal i bra tion. Tighten locking nut.
2. Overload -
a. Select COMPRESSOR Screen.
b. Run Chiller and monitor Compressor Motor cur rent on the COMPRESSOR Screen.
c. Manually operate the Pre-rotation Vanes by press ing the OPEN, CLOSE and HOLD key pad keys, as required, until the highest phase indi- cates a current equivalent to 105% FLA. Adjust OVER LOAD potentiometer (R44) on Solid State Starter Logic Board until the 105% FLA LED il lu mi nates. Clockwise increases sig nal level; Coun ter clock wise decreases signal level. Tighten locking nut.
Medium Voltage Solid State Starter
1 At the Keypad, log in at SERVICE Access level using password 1 3 8 0.
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Full Load Amps:
This is the Full Load Amps (FLA) of the chiller as listed on the Sales Order Screen. The Microboard uses the pro- grammed value to perform Current Limit functions and display compressor motor current in terms of %FLA. 1. Press FULL LOAD AMPS key.
2. Use numeric keypad keys to enter the correct value.
3. Press ENTER Key (√) Key. Start Current:
The starter will limit compressor motor current to this value during starting. The correct value is (0.45 x Delta Locked Rotor Amps), as listed on the Sales Order Screen.
1. Press STARTING CURRENT key.
2. Use numeric keypad keys to enter correct value. 3. Press ENTER (√) key.
COMPRESSOR MOTOR VARIABLE SPEED DRIVE APPLICATIONS
When the compressor motor is driven by a YORK Vari- able Speed Drive, there could be a Variable Speed Drive (VSD) or a Medium Voltage Variable Speed Drive (MV VSD) applied. Early vintage VSD’s contain an Adaptive Capacity Control (ACC) Board in the Optiview cabinet that interfaces the microboard using YORK Protocol serial communications. With the later vintage VSD, the ACC functionality resides in the microboard, the ACC Board is not present and the VSD Logic Board directly interfaces the microboard directly using RS-485 Modbus Protocol serial communications. The MV VSD is also interfaced to the microboard with RS-485 Modbus serial communications. Refer to Section 12 for the different possible confi gurations before proceeding.
1. At the Keypad, log in at SERVICE Access level (unless otherwise noted) using password 1 3 8 0. 2. Enter the following Setpoints using procedures
below:
Motor Drive Type:
The Variable Speed Drive type applied must be set as follows. Select the procedure based on the microboard that is present.
• Microboard 031-1730-000: Position Program Jump- ers JP37 and JP39 appropriately per Section 3, Table 1.
• Microboard 031-02430-000/001:
1. Chiller must be stopped and RUN switch must be in Stop-Reset position.
2. Select SETUP Screen.
3. Press CHANGE SETTINGS key.
4. A green box will appear around the fi rst changeable setpoint. Use ▲▼ keys to place box around the MOTOR DRIVE TYPE setpoint.
5. Press √ key. A dialog box will appear with the range of settings. Use ◄ ►keys to select “VSD-60Hz”, “VSD-50Hz” or “MV VSD”, as appropriate. 6. Press ENTER (√) key.
Motor Communications Protocol:
(Software version C.OPT.01.16.xxx and later)
Only displayed when Motor Drive Type setpoint above is selected as “VSD-60Hz” or “VSD-50Hz”. The Service Technician must enable the appropriate serial communi- cations port for communications to the Variable Speed Drive (VSD). Entered as “York” to enable COM5 (J15) or “Modbus” to enable COM2 (J13). Selection required is based on the hardware and interface that is present. Refer to Section 12 (VSD) to determine which hardware/ interface is present before making selection.
• YORK – Enables COM5 (J15) serial port. Used when the Microboard is interfaced to the Variable Speed Drive via the ACC Board.
• MODBUS – Enables COM2 (J13) serial port. Used when the ACC Board is not present and the Microboard is interfaced directly to the Vari- able Speed Drive Logic Board. In order to select MODBUS, microboard 031-02430-001 is required and it must be equipped with the 128K BRAM (031-02565-000). With this microboard, Program Jumpers JP14 (BRAM size) and JP17 (COM 2 serial mode) must be confi gured appropriately per Section
1. Chiller must be stopped and RUN switch must be in Stop-Reset position.
2. Select SETUP Screen.
3. Press CHANGE SETTINGS key.
4. A green box will appear around the fi rst change- able setpoint. Use ▲▼ keys to place box around the MOTOR COMMUNICATIONS PROTOCOL setpoint.
5. Press √ key. A dialog box will appear with the range of settings. Use ◄ ►keys to select “YORK” or “MODBUS”, as appropriate.
6. Press ENTER (√) key. Motor Node ID:
(Software version C.OPT.01.16.xxx and later)
Only displayed when “Modbus” is selected for the Motor Communications Protocol setpoint above. The Motor Node ID must be set to match the setting of the VSD Logic Board Modbus Address Switch SW3. The address assigned to the VSD Logic Board is “1”. This is done by placing the VSD Logic Board Modbus Address Switch SW3 position 1 to ON and setting this setpoint to “1”. 1. Chiller must be stopped and RUN switch must be
in Stop-Reset position. 2. Select SETUP Screen.
3. Press CHANGE SETTINGS key.
4. A green box will appear around the fi rst changeable setpoint. Use ▲▼ keys to place box around the MOTOR NODE ID setpoint.
5. Press √ key. A dialog box will appear with the range of settings. Use numeric keys to set this value to “1”.
6. Press ENTER (√) key. Full Load Amps (VSD):
This is the Full Load Amps (FLA) of the chiller as listed on the Sales Order Screen. The Microboard uses the programmed value to perform Current Limit functions and display compressor motor current in terms of %FLA.
3. Inside the VSD, locate the small trim pot on the VSD Logic Board; (R34) on Logic Board 031- 02506; (R28) on all other Logic Boards.
4. While monitoring the VSD Full Load Amps 000.0 A message on the VSD DETAILS Screen, ad just this trimpot until the correct Full Load Amps val ue is displayed. Clockwise will increase the val ue. Full Load Amps: (MV VSD)
This is the Full Load Amps (FLA) of the chiller as listed on the Sales Order Screen. The Microboard uses the pro- grammed value to perform Current Limit functions and display compressor motor current in terms of %FLA.
1. Select MOTOR Screen
2. Press FULL LOAD AMPS Key.
3. Use NUMERIC Keypad keys to enter the correct value.
4. Press ENTER (√) key.
Pre-rotation Vanes Position Potentiometer:
Refer to the Pre-rotation Vanes Calibration procedure in this section.
Adaptive Capacity Control:
1. Select ACC DETAILS Screen 2. The following keys are available:
a. Surge Map Clear – Clears all previously established surge points that are stored in memory. When this key is pressed, a dialog box appears requesting the special ACC Map Clear Password. Enter 0 3 6 8 and press the ENTER (√) Key. A message is displayed advising the clearing is in progress. If ACC Board is present, press switch SW1 (for at least 1 second) on the ACC Board within 15 seconds of pressing the ENTER key. Another message is displayed when the clearing has completed. IMPORTANT! – This should not be performed unless advised by YORK factory Service.
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c. Auto Map Print – Prints new surge points, as they are established, to a printer connected to COM1 serial port.
d. Manual Surge Point – Captures the instantaneous operating conditions and stores them as a surge point. If ACC Board is present, press switch SW1 (for at least 1 second) on the ACC Board within 15 seconds of pressing this key.
e. Surge Margin Adjust – Refer to Service manual 160.00-M4.
f. Surge Sensitivity – Refer to VSD Service Manual 160.00-M4.
Kilowatt Hours:
1. At the Keypad, log in at ADMIN access level. 2. Select MOTOR Screen.
3. Press KWH RESET key.
4. Use numeric keypad keys to enter desired value. 5. Press ENTER (✔) key.
Frequency Control:
The VSD Frequency can be manually controlled as fol lows:
1. Select VSD TUNING Screen from the COM- PRES SOR Screen.
2. On the VSD Tuning Screen, press the ap pro pri ate key as follows:
a. Set – Places Frequency Control in Manual Mode.