| Document type | Operation Guide |
|---|---|
| Document number | 160.00-O1 |
| Equipment | YK Centrifugal Chiller |
| Brand | YORK |
| File size | 1.7 MB |
Fault codes in this document
VSD DISPLAY MESSAGES
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD SHUTDOWN - REQUESTING FAULT DATA | This shutdown is initiated when the #53 to #16 circuit has been interrupted, and the control panel has not yet received the cause of the fault over the serial link. | Whenever the VSD initiates a fault, it first opens the IIS relay in the VSD (between #53 and #16). The VSD then sends a message serially to the ACC, detailing the cause of the fault. | Since the communications link loop is initiated every two seconds, the message should appear for just a few seconds and then be replaced with a VSD Fault message. | 17 |
| INVERTER INITIATED STOP FAULT | Displayed if the #53 to #16 circuit opens without receiving an accompanying cause for the trip over the serial link. | The #53 to #16 circuit opened without receiving an accompanying cause for the trip over the serial link (within 11 communication tries, approximately 22 seconds). Whenever the VSD initiates a fault, it first opens the IIS relay in the VSD (between #53 and #16), then sends a message serially to the ACC detailing the cause of the fault. | 17 | |
| START SEQUENCE INHIBITED BY VSD | Shutdown occurring if a VSD fault takes place during the "Start Sequence Initiated" period; the chiller is inhibited from entering the starting sequence during the time period that a VSD fault occurs. | A VSD fault took place during the "Start Sequence Initiated" period. | When the VSD fault is cleared the start sequence will resume. | 17 |
| PHASE A (OR B,C) OVERCURRENT FAULT | Shutdown generated by the VSD if the motor current exceeds a given limit. Maximum instantaneous permissible currents: 351/292 HP = 771 Amps 503/419 HP = 1200 Amps 790/658 HP = 1890 Amps 1100/900 HP = 3093 Amps | The motor current is sensed by the Current Transformers on the VSD output pole assemblies and the signals are sent to the VSD logic board for processing. If an overcurrent trip occurs but the chiller restarts and runs without a problem, the cause may be attributed to a voltage sag on the utility power feeding the VSD that is in excess of the specified dip voltage for this product — especially if the chiller was running at, or near, full load. With a sudden dip in line voltage the motor current increases (the motor wants to draw constant horsepower), and the vanes cannot close quickly enough to correct for this sudden increase in current. | If the chiller will not restart, but keeps tripping on this same shutdown, an output pole problem is the most likely culprit. The VSD most likely requires service. | 17 |
| PHASE A (B,C) GATE DRIVER FLT | A second level of current protection exists on the VSD driver boards themselves; the entire VSD system is shut down. | The collector-to-emitter saturation voltage of each IGBT is checked continuously while the device is being gated on. If the voltage across the IGBT is greater than a set threshold, the IGBT is gated off and a shutdown pulse is sent to the VSD logic board shutting down the entire VSD system. Be aware that a gate driver fault can be initiated when the VSD is not running. | 17 | |
| SINGLE PHASE POWER SUPPLY | Shutdown generated by the SCR Trigger control and relayed to the VSD logic board to initiate a system shutdown. | The SCR Trigger control uses circuitry to detect the loss of any one of the three input phases; the trigger will detect the loss of a phase within one half line cycle of the phase loss. This message is also displayed every time power to the VSD is removed or if the input power dips to a very low level. Usually it indicates that someone has opened the disconnect switch. | 17 | |
| HIGH PHASE A (B,C) HEATSINK TEMP | This shutdown will occur if the heatsink temperature exceeds 158°F on any of the output pole assemblies. This shutdown will seldom occur, since in most cases where the coolant temperature has risen abnormally, the VSD will trip on "Ambient Temperature" (140°F) before the heatsinks can reach 158°F. | This shutdown requires a manual reset via the Reset push-button on the VSD logic board. Make certain you have an adequate level of coolant, check to be sure the cooling pump is operating when the unit is running, and check the strainer in the primary of the heat exchanger for clogs and silt. | 17 | |
| HIGH CONVERTER HEATSINK TEMP | Converter heatsink overtemperature shutdown — reference "High Phase A (B,C) Heatsink Temp" above. | This shutdown requires a manual reset via the Reset push-button on the VSD logic board. | 18 | |
| 105% MOTOR CURRENT OVERLOAD | Generated by the VSD logic board; indicates that a motor overload has occurred — at least one of the three output phase currents has exceeded 105% of the programmed 100% job full load amps (FLA) value. The 100% job FLA setpoint may be viewed by pressing the "Options" key. | The VSD logic board detected that at least one of the three output phase currents exceeded 105% of the programmed 100% job FLA value. | This shutdown requires a manual reset via the Reset push-button on the VSD logic board. | 18 |
| BUS OVER-VOLTAGE FAULT | The VSD's DC link voltage exceeded 745 VDC, initiating a Bus Over-Voltage shutdown. | The VSD's DC link voltage is continuously monitored; the level exceeded 745 VDC. | If this shutdown occurs, it will be necessary to look at the level of the 460 VAC applied to the drive. The specified voltage range is 414 to 508. If the incoming voltage is in excess of 508, steps should be taken to reduce the voltage within the specified limits. | 18 |
| MAIN BOARD POWER SUPPLY | Indicates that the low voltage power supplies for the logic boards have dropped below their allowable operating limits. | The power supplies for the logic boards are derived from the secondary of the 120 to 24 VAC transformer (Fig. 2) which in turn is derived from the 480 to 120 VAC control transformer (Fig. 1). This message usually means that power to the VSD was removed. | 18 | |
| LOW DC BUS VOLTAGE FLT | The DC link dropped below 500 VDC (or 414 VDC for 50 HZ); the drive initiates a system shutdown. | A common cause for this shutdown is a severe sag in the incoming power to the drive. | Monitor the incoming three phase AC line for severe sags and also monitor the DC link with a digital meter. | 18 |
| BUS VOLTAGE IMBALANCE FAULT | The DC link voltage is not shared equally — the center point should be approximately ½ of the total DC link voltage. | The DC link is filtered by many large, electrolytic capacitors which are rated for 450 VDC; these capacitors are wired in series to achieve a 900 VDC capability for the DC link. It is important that the voltage be shared equally from the junction of the center or series capacitor connection, to the negative bus and to the positive bus. Most actual bus voltage imbalance conditions are caused by a shorted capacitor, or a leaky or shorted IGBT transistor in an output phase bank assembly. | This usually indicates the VSD requires service. | 18 |
| HIGH AMBIENT TEMPERATURE FLT | The ambient temperature monitored is actually the temperature detected by a component mounted on the VSD logic board; the high ambient trip threshold is set for 140°F. | Potential causes for this shutdown are: internal VSD fan failure, VSD water pump failure or an entering condenser water temperature which exceeds the allowable limit for the job. Additional causes: • Plugged Strainer – very dirty condenser water can cause the standard 1.5” Y-Strainer (woven wire mesh element with 20 stainless-steel wires per inch) to plug. • Plugged Heat-Exchanger – in cases where the strainer plugs frequently, the heat-exchanger eventually may plug or become restricted to the point of reduced flow. • Low Condenser Flow – the VSD system requires 8 feet of pressure drop across the heat exchanger to maintain adequate GPM. | Locations with special conditions may want to consider a dual strainer arrangement with quarter turn valves, to permit cleaning of one strainer with the unit still on-line. Back-flush the heat-exchanger by reversing the two rubber hoses which supply condenser water to/from the heat-exchanger; if the rust or sludge cannot be back-flushed, you may need to replace the heat-exchanger. If the pressure drop is less than 8 feet, it will be necessary to correct the flow problem, or add a booster pump as is applied on retrofit chillers. | 18 |
| INVALID CURRENT SCALE FAULT | The logic board found the jumper configuration used to scale the output current to be invalid; the system was shut down. | Since the part number of the logic board is the same on all horsepower sizes, jumpers tell the logic board the size of the VSD being employed in order to properly scale the output current. The jumper configuration was found by the logic to be invalid. | The proper jumper configuration is shown on the wiring label for the VSD. | 18 |
| LOW (CONV, OR PHASE A,B,C) HEATSINK TEMP. | A heatsink temperature sensor indicating a temperature below 37°F will cause the unit to shut down and display this message. | In most cases the problem will actually be an open thermistor or broken wiring to the thermistor. The normal thermistor resistance is 10K ohms at 70°F. | 19 | |
| OUTPUT CURRENT IMBALANCE | An imbalance among the three phases of output current. | Normally the three phases of output current will be closely balanced since the voltage being applied to the motor is derived from the same DC Link voltage and the output transistors all switch in an identical pattern. Thus most imbalances will be due to variations in the motor windings, which may be as high as 8% typically. | 19 | |
| PRECHARGE BUS V IMBALANCE | Bus voltage imbalance occurring during the precharge period, which begins during pre-lube. | This situation is identical to the "Bus Voltage Imbalance Flt" shutdown, except that it has occurred during the precharge period which begins during pre-lube. | 19 | |
| PRECHARGE LOW VOLTAGE FAULT | The precharge DC Link voltage was below the required minimum; the unit is shut down. | During precharge the DC Link must be equal to or greater than 50 VDC (41 VDC for 50 HZ) ½ second after the precharge relay is energized. The unit is shut down and this message is generated if this condition is not met. | 19 | |
| PRE-CHARGE HIGH VOLTAGE FAULT | The precharge DC Link failed to reach the required level; the unit is shut down. | During precharge the DC Link must reach at least 500 VDC (414 VDC for 50 HZ) 15 seconds after the precharge relay is energized. The unit is shut down and this message is generated if this condition is not met. | 19 | |
| PRE-CHARGE FAULT LOCKOUT | The unit failed to make pre-charge on three consecutive tries; the unit shut down and locked out. | If the unit fails to make pre-charge, the pre-charge relay shall drop out for a time period of 10 seconds during which time the unit's fan(s) and water pump(s) shall remain energized in order to permit the pre-charge resistors to cool. Following this 10-second cool down period pre-charge shall again be initiated. The unit shall attempt to make pre-charge three consecutive times; failing on three consecutive tries, the unit will shut down, lockout and display this message. | Lockout — in order to initiate pre-charge again, the Micropanel's rocker switch must first be placed into the STOP/RESET position. | 19 |
| PWM COMMUNICATIONS FAULT | Shutdown generated by a communications problem between the two microprocessors on the VSD logic board. | A communications problem occurred between the two microprocessors on the VSD logic board. | 19 | |
| RUN RELAY FAULT | The missing run command was not asserted within the 5-second window; the unit shut down. | Redundant run signals are generated by the Micropanel, one via wire #24 and the second via the serial communications link. Upon receipt of either of the two run commands by the VSD logic board, a 5-second timer commences timing; if the missing run command is not asserted within the 5-second window the unit will shut down. This shutdown could occur if there is a problem with the wiring between the control panel and the VSD. | 19 | |
| SERIAL RECEIVE FAULT | Communications between the ACC and VSD logic is disrupted. | If all wiring is intact, this problem may also be caused by electrical noise. | Check the shielded cable between J11 on the VSD logic and J8 on the ACC board. | 19 |
| VSD INITIALIZATION FAILED | At power-up, all the boards go through a process called initialization (memory locations are cleared, jumper positions are checked, and serial communications links are established); initialization did not complete successfully. | There are many causes for an unsuccessful initialization. | Check-list: • The Micro-Panel and the VSD must be energized at the same time. The practice of pulling the fuse in the control panel to make wiring changes will create a problem. Power-up must be done by closing the main disconnect on the VSD cabinet with all fuses in place. Be sure you do not have a blown fuse, causing loss of power to the VSD logic board. • The EPROMs must be correct for each board, and they must be correctly installed. There are a total of seven (7) EPROMs in each VSD - Micropanel system. These EPROMs are created as a set, and cannot be intermixed between earlier and later styles of units. Also, the ACC EPROM must be in the ACC board, and the Micropanel EPROM in the Microboard, etc. All pins must be properly inserted into the EPROM sockets. • Serial data communications must be established. See the write ups for the messages, "Serial Receive Fault" and "FLTR Serial Receive Fault". You can check to see that serial communications have been established by pressing the OPTIONS key and noting the %Job FLA value displayed. A zero displayed value for this parameter (and all other VSD parameters) indicates a serial communications link or EPROM problem. • If the IEEE-519 Filter option is included, make sure the '519' Logic board is not in continuous reset — evidenced by the LEDs on the filter logic board alternately blinking. To rule out the '519' filter as the cause of initialization failure, you can disconnect the filter by switching the filter logic board's SW1 switch to the OFF position, and removing the 16 wire ribbon cable between the '519' logic and VSD logic boards. | 19 |
| FLTR HEATSINK OVERTEMP FLT | The temperature on a filter heatsink exceeded 167°F and the unit shut down. The '519' filter power assembly has one heatsink thermistor on the 351 & 503 HP units, and two heatsink thermistors on the 790 HP units. | This message is usually an indication that the level of coolant in the closed loop system on the back of the VSD is low. | Requires a manual reset by pressing the "Overtemp Reset" pushbutton located on the Filter Logic board. | 20 |
| FLTR BUS OVER-VOLTAGE FLT | The harmonic filter's DC link voltage exceeded 860 VDC, initiating a Filter Bus Over-Voltage shutdown. Keep in mind that the harmonic filter has its own DC bus as part of the filter power assembly, and this DC Link is not connected in any way with the drive's DC Link. | The cause of this message will typically be high line voltage, or a surge on the utility supply. | If this shutdown occurs, it will be necessary to look at the level of the 460 VAC applied to the drive. The specified voltage range is 414 to 508. If the incoming voltage is in excess of 508, steps should be taken to reduce the voltage within the specified limits. | 20 |
| FLTR LOW BUS VOLTAGE FLT | The filter's DC link voltage dropped to a level less than 60 VDC below the filter DC link voltage setpoint. The harmonic filter dynamically generates its own filter DC link voltage by switching its IGBT's — a voltage "boost" function necessary to permit current to flow into the power line from the filter when the input line is at its peak level. | The filter DC link voltage setpoint is determined by the filter logic board via the sensing of the three phase input line-to-line voltage; it is set to the peak of the sensed input line-to-line voltage plus 32 volts, not to exceed 760 volts, and varies with the input line-to-line voltage. If this shutdown occurs occasionally, the likely cause is a severe sag in the input line voltage. | A power monitor should be installed to determine if a power problem exists. | 20 |
| FLTR PHASE A (B,C) OVERCURRENT | The maximum instantaneous harmonic filter current exceeded a preset limit; the unit is shut down. Preset limits: 351/292 HP = 378 Amps 503/419 HP = 523 Amps 790/658 HP = 782 Amps 1100/900 HP = 1225 Amps | The filter current is monitored using two DCCTs and these signals are processed by the filter logic board. If you experience this shutdown and the VSD auto-restarts and continues to run properly with the filter operating, it is likely the filter tripped on Overcurrent due to a sag or surge in the voltage feeding the chiller. | If this message re-occurs, preventing the unit from being restarted, the VSD will require service. | 20 |
| FLTR PHASE LOCK LOOP FLT | A circuit called a "phase locked loop" on the filter logic board has lost synchronization with the incoming power line for a period of time. | This is normally an indication that one of the filter's incoming power fuses is blown. | Check filter power fuses 11FU, 12FU and 13FU if this shutdown occurs. | 20 |
| FLTR POWER SUPPLY FLT | The low voltage power supplies on the filter logic board have dropped below their permissible operating voltage range. | The filter logic board receives its power from the VSD logic board via the ribbon cable which connects the two boards. | 20 | |
| FLTR BUS V IMBALANCE FLT | The filter DC link voltage is not shared equally — the center point should be approximately ½ of the total DC link voltage. | The filter DC link is filtered by large, electrolytic capacitors which are rated for 450 VDC; these capacitors are wired in series to achieve a 900 VDC capability for the DC link. It is important that the voltage be shared equally from the junction of the center or series capacitor connection, to the negative bus and to the positive bus. | 20 | |
| FLTR PCHARGE LOW BUS V FLT | During pre-charge the filter's DC link failed to be equal to or greater than 50 VDC (41 VDC for 50 HZ) 1/10 second after the filter pre-charge relay is energized; the unit is shut down. | The required pre-charge condition was not met. | If this shutdown occurs, check the filter pre-charge relay, filter pre-charge resistors, and the wiring between the filter logic board and the filter pre-charge relay. | 21 |
| FLTR PCHARGE HI BUS V FLT | During pre-charge the filter's DC Link failed to reach at least 525 VDC (425 VDC for 50 HZ) 5 seconds after the filter pre-charge relay is energized; the unit is shut down. | The required pre-charge condition was not met. | If this shutdown occurs, check the filter pre-charge relay, filter pre-charge resistors, and the wiring between the filter logic board and the filter pre-charge relay. | 21 |
| FLTR OVERLOAD FLT | One of the three phases of RMS filter current continuously exceeded a given threshold for seven seconds; unit shutdown is initiated. Maximum permissible continuous RMS current ratings for the harmonic filters: 351/292 HP = 128 Amps 503/419 HP = 176 Amps 790/658 HP = 277 Amps 1100/900 HP = 385 Amps | The level of one of the three phases of RMS filter current continuously exceeded the given threshold for seven seconds. | 21 | |
| FLTR HIGH TDD FLT | The filter is not operating correctly and the input current to the VSD/filter system is not sinusoidal. This shutdown will occur if the TDD exceeds 25% continuously for 45 seconds. TDD (Total Demand Distortion) is defined by the IEEE Std 519-1992 standard as "the total root - sum - square harmonic current distortion, in percent of the maximum demand load current (15 or 30 min demand)". In the filter option supplied by York, the displayed TDD is the total RMS value of all the harmonic current supplied by the power mains to the VSD system divided by the job FLA of the VSD, in percent. The harmonic filter option was designed to provide an input current TDD level of 8% or less for the VSD system; a standard VSD less the optional filter typically has an input current TDD level on the order of 28 - 30%. | TDD exceeding 25% continuously for 45 seconds. | 21 | |
| WARNING - FILTER DATA LOSS | The communications link between the VSD logic board and the filter logic board, or the communications link between the filter logic board and the ACC board, has been interrupted. When this message is displayed all filter related parameters are replaced with X's. This message can also occur as a background message when the chiller is running. | Interruption of the communications link. | If communications is re-established, the message will disappear, and normal values will again be displayed. | 21 |
| FILTER DCCT 1 (OR 2) ERROR | The DCCT's are presumed to be bad and this shutdown is generated. | During initialization, with no current flowing through the DCCT's, the DCCT output voltages are measured and compared with a preset limit via the filter logic board. The measured values exceeded the preset limits. | 21 | |
| FLTR RUN RELAY FLT | The redundant run command did not occur on the serial data link before the timer expired; the unit is shut down. | When a digital run command is received at the filter logic board from the VSD logic board via the 16 position ribbon cable, a 1/10 second timer is begun. A redundant run command must also occur on the serial data link from the VSD logic board via the ribbon cable before the timer expires. | 21 |
THE FOLLOWING MESSAGES PERTAIN TO ORIGINAL AND “STYLE A” UNITS ONLY
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| FLTR CO-PROCESSOR FLT | A clock timing problem has occurred on the filter logic board. | Clock timing problem on the filter logic board. | 21 | |
| FLTR SW-BACKGRND FLT (or, FLTR SW-PRECHARGE LOOP FLT on early units) | The software did not complete the program loop in the allotted time — a watchdog timer function on the Filter Logic board. | The software did not complete the program loop in the allotted time. | 21 | |
| FLTR +15 V POWER SUPPLY FLT | A failure of a low voltage DC regulator on the filter logic board. | Failure of a low voltage DC regulator on the filter logic board. | 21 | |
| FLTR –5 V POWER SUPPLY FLT | A failure of a low voltage DC regulator on the filter logic board. | Failure of a low voltage DC regulator on the filter logic board. | 21 | |
| FLTR –15 V POWER SUPPLY FLT | A failure of a low voltage DC regulator on the filter logic board. | Failure of a low voltage DC regulator on the filter logic board. | 21 | |
| FLTR THERMISTOR SUPPLY FLT | A failure of a low voltage DC regulator on the filter logic board. | Failure of a low voltage DC regulator on the filter logic board. | 21 | |
| FLTR LOW HEATSINK TEMP FLT | The temperature as measured by the filter's thermistor (2 thermistors on 790 HP) has dropped below 37°F. | This may be caused by an unplugged thermistor, loose connections, or a wire pinched against the chassis. An open circuit will simulate a temperature of 32°F. | 22 | |
| FLTR A/D CONVERTER FLT | The '519' Filter logic's ground-level check converted to a digital value greater than zero. | The '519' Filter logic does a check where it looks at ground and converts the voltage to a digital value; this level should be zero. However if there is electrical noise present on ground, this value will be greater than zero, and this fault message may appear. | 22 | |
| FLTR INPUT FREQUENCY FLT | The input frequency as measured by the Filter Logic is outside the acceptable range of +/- 1 Hertz. | Input frequency outside the acceptable range of +/- 1 Hertz. | 22 | |
| FLTR HIGH INPUT V FLT | The input voltage as measured phase-to-ground, and in "peak" volts, exceeded 424.6 Volts peak for over 30 seconds. | The normal cause will be a high utility voltage, greater than 500 VAC on a 460 VAC system. | 22 | |
| FLTR TRIANGLE WAVE FLT | A check of the '519' logic board's internal triangle waveform generator. The accuracy of the measuring circuit on the board can have as much error as the generator it is trying to measure, resulting in nuisance shutdowns. | Nuisance shutdowns caused by measuring-circuit error on the board. | If this message occurs repeatedly, it can be corrected by installing a special EPROM. | 22 |
| FLTR SERIAL RECEIVE FAULT | A message which would occur on some early installations with the IEEE-519 Filter option. | Related to the level of electrical noise picked up on the serial communications lines. | 22 | |
| FLTR PHASE ROTATION FLT | The filter determines phase rotation upon receiving a run signal; once determined, the phase rotation must remain constant for 30 line cycles. If not, this message is generated. | The most likely cause of this message would be an interruption in utility power supplying the VSD. | 22 | |
| FILTER DSP FAULT | An error occurred during read-back of DSP memory at initialization. | On initialization, the Filter logic writes all zero's to DSP memory, and then writes all one's to the same memory. If any error occurs during read-back, this message is generated. | 22 | |
| FILTER MEMORY FAULT | An error occurred during read-back of External memory at initialization. | On initialization, the Filter logic writes all zero's to External memory, and then writes all one's to the same memory. If any error occurs during read-back, this message is generated. | 22 |
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