Fault, warning and safety-shutdown messages documented by Johnson Controls for the YORK YK. Each row cites the page of the manual it was taken from — nothing here is summarised or reworded.
From SC-EQ Communication Card Installation Instructions 450.50-N1
Original: docs.johnsoncontrols.com
Section 2 - Installation
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Print functions enabled (03478 microboard note) | Enabling any part of Print functions disrupts BAS/SC-EQ communications. | Any part of the Print functions enabled. | Refer to YORK Equipment form 201.21-NMx in the Installation, Operation and Maintenance (IOM) air-cooled screw liquid chillers manual for more information. | 33 |
| MS/TP Bus conflict | Conflict on the MS/TP Bus resulting in no communication between the chiller IPU I board and the E-Link Gateway. | The Chiller address and the SC-EQ address are set to the same value. | Do not set the Chiller address and the SC-EQ address to the same value. | 34 |
Section 3 - Troubleshooting
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Power LED OFF | If the power source is present at the SC-EQ power terminals (J9 +12 VDC [Red wire + Black wire -] or J10 24 V AC as applicable) and the Power LED is not illuminated, then the SC-EQ is faulty. | Power source present at the SC-EQ power terminals but Power LED not illuminated. | Use a digital multimeter to verify the power source to the SC-EQ is present. | 37 |
| BRX LED illuminates solid | BAS Port receive LED stays on continuously instead of blinking with data packets sent on the BAS network. | The + and - RS-485 wires are probably swapped. | The + and - RS-485 wires must be corrected. | 37 |
| ETX illuminated, microboard Receive LED illuminated, no response transmitted from the microboard | No response transmitted from the microboard to the SC-EQ request for data. | Chiller address not set to 1. | Check that the chiller address is set to 1. For microboards with a rotary switch, set the switch to 0 (interpreted as 1). If the address is set in the software, then it should be set to 1. | 38 |
| BS BUS LED off continuously | The SC-EQ board is not likely seeing any valid communications occurring on the BAS bus. | Make simple voltage measurements with a DC voltmeter on the SC-EQ board and the BAS communication bus to help diagnose the problem. | 38 | |
| Fault LED blinks at a 500 ms cycle Unable to Load Firmware | The SC-EQ could not load a firmware update. | Try loading the firmware update on to another USB thumb drive and perform the update again. | 39 | |
| Fault LED blinks at a 1 second cycle Firmware Validation Failure | The SC-EQ fails to validate the firmware at intial power up or after a firmware upgrade. | Try cycling power to the SC-EQ and updating the firmware again. | 39 | |
| Fault LED ON solid Firmware Programming Required | No firmware is present. | Complete a firmware update to remedy this. | 39 |
Section 4 - SC-AP gateway
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Offline | Status displayed on the SC-EQ Data tab (viewed via the SC-AP) for the BAS or EQ port. | Either the BAS or the EQ port are not active for a short period of time. | The SC-EQ continually tries to connect to the absent ports (automatic retry). | 43 |
| No Protocol | Status displayed on the SC-EQ Data tab (viewed via the SC-AP) for the BAS or EQ port. | Communications is not present for a few minutes. | The SC-EQ continually tries to connect to the absent ports (automatic retry). | 43 |
| Invalid points offline | If an E-Link is replaced by an SC-EQ, the BAS shows the points that were previously nonrelevant as offline. | The E-Link transfers a list of all possible chiller parameters to the BAS, even ones that do not apply; the SC-EQ discovers the chiller type and features and exposes only the relevant points to the BAS. | Either delete the E-Link and re-discover the SC-EQ or delete each of the inappropriate offline points. | 45 |
| Unreliable remote setpoints | Points that are commandable show as unreliable. | The BAS has not sent the setpoints. | Condition lasts until the BAS sends the setpoints. | 45 |
| Auto Detected Chiller Model: NONE (No chiller model type detected) | Auto Detected Chiller Protocol is displayed as YorkTalk2 but the Auto Detected Chiller Model is NONE. Some Modbus chillers do not identify their model type over the Modbus protocol. | Some of the older YorkTalk2 chillers do not have programming in place to communicate their chiller model to the SC-EQ. | Use the MANUALLY SELECTED CHILLER MODEL selection to load the appropriate chiller model into the SC-EQ. A few seconds after the selection is applied, the SC-EQ begins to reprogram the Currently Loaded Equipment Model; this may take up to 8 minutes to complete. Upon completion, the SC-EQ reboots and then begins to run using the selected chiller model. | 46 |
| SC-EQ fails to retrieve point data | The SC-EQ continues to use the old or invalid Modbus address. The SC-EQ never times out and then attempts to rediscover the new Modbus address of the previously connected chiller. | The Modbus address of the chiller was modified. | After changing the address of the BAS or SC-EQ connected devices, it is recommended to reboot the SC-EQ. | 46 |
Section 6 - LON ProtoNode
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| SPL | The SPL LED lights up if the unit is not getting a response from one or more of the configured devices. For LonWorks units, LED lights up until the unit is commissioned on the LonWorks network. | No response from one or more of the configured devices; for LonWorks units, the unit is not yet commissioned on the LonWorks network. | Commission the unit on the LonWorks network (LonWorks units). | 56 |
| ERR (SYS ERR LED) | A steady red light indicates a system error on the unit. (The LED normally lights up 15 seconds after powering up and turns off after 5 seconds.) | If a steady red light occurs, immediately report the related system error shown in the error screen of the GUI to support for evaluation. | 56 |
From Model YK Style G, with R-134a, R-513A, or R-1234ze for Europe, Operation Guide 160.75-O1.EN.CE
Original: docs.johnsoncontrols.com
Troubleshooting
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 1. Symptom: Abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Air in condenser. | 37 | |
| 1. Symptom: Abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Condenser tubes dirty or scaled. | Clean the condenser tubes. Check water conditioning. | 37 |
| 1. Symptom: Abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | High discharge pressure. High condenser water temperature. | Reduce the condenser water inlet temperature. Check the cooling tower and water circulation. | 37 |
| 2. Symptom: Abnormally low suction pressure | Insufficient charge of refrigerant. | Check for leaks and charge refrigerant into the system. | 37 | |
| 2. Symptom: Abnormally low suction pressure | The temperature difference between the leaving chilled water and refrigerant in evaporator is greater than normal, with high discharge temperature. | Variable orifice problem. | Remove the obstruction. | 37 |
| 2. Symptom: Abnormally low suction pressure | The temperature difference between the leaving chilled water and refrigerant in the evaporator is greater than normal, with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean the evaporator tubes. | 37 |
| 2. Symptom: Abnormally low suction pressure | The temperature of chilled water is too low with low motor amperes. | Insufficient load for system capacity. | Check the pre-rotation vane motor operation and setting of the low water temperature cutout. | 37 |
| 3. Symptom: High evaporator pressure | Pre-rotation vanes fail to open. | Check the pre-rotation vane motor positioning circuit. | 37 | |
| 3. Symptom: High evaporator pressure | High chilled water temperature. System overload. | Make sure that the vanes are wide open, without overloading the motor, until the load decreases. | 37 | |
| 4. Symptom: No oil pressure when SYSTEM START button pressed | Low oil pressure displayed on control center; compressor does not start. | Oil pump is running in the incorrect direction. | Check the rotation of oil pump (Electrical Connections). | 37 |
| 4. Symptom: No oil pressure when SYSTEM START button pressed | Low oil pressure displayed on control center; compressor does not start. | Oil pump is not running. | Troubleshoot electrical problem with oil pump VSD. | 37 |
| 5. Symptom: Unusually high oil pressure develops when oil pump runs | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure. Transducer defective. | Replace the low or high oil pressure transducer. | 37 |
| 6. Symptom: Oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. Note: When the oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Oil not reaching pump suction inlet in sufficient quantity. | Check the oil level. | 37 |
| 6. Symptom: Oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. | Worn or failed oil pump. | Repair or replace the oil pump. | 37 |
| 7. Symptom: Reduced oil pump capacity | Oil pump pumping capacity. | Excessive end clearance pump. Other worn pump parts. | Inspect and replace all worn parts. | 37 |
| 7. Symptom: Reduced oil pump capacity | Oil pump pumping capacity. | Partially blocked oil supply inlet. | Check the oil inlet for a blockage. | 37 |
| 8. Symptom: Oil pressure gradually decreases (Noted by Observation of Daily Log Sheets) | When oil pump VSD frequency increases to 55 + Hz to maintain target oil pressure. | Oil filter is dirty. | Change the oil filter. | 37 |
| 9. Symptom: Oil pressure system ceases to return an oil or refrigerant sample | Filter-drier in oil return system dirty. | Replace the old filter-drier with a new filter-drier. | 38 | |
| 9. Symptom: Oil pressure system ceases to return an oil or refrigerant sample | Oil refrigerant return not functioning. | Jet or orifice of oil return jet clogged. | Remove the jet, and inspect for dirt. Remove all dirt using solvent and replace. | 38 |
| 10. Symptom: Oil pump fails to deliver oil pressure | No oil pressure registers when pressing OIL PRESSURE display key when oil pump runs. | Faulty oil pressure transducer. Faulty wiring or connectors. | Replace the oil pressure transducer. | 38 |
Safety controls
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Airflow reduced below minimum required flow or failure of the permanent mechanical extraction | The unit shuts down, safe mode, within 10 s. | The unit is not allowed to be powered on, safe mode must be maintained, until the airflow is restored. The ventilation system must be interlocked with the chiller to stop the operation of the chiller as well as initiate the alarm systems in the event of ventilation system failure. | 8 | |
| Refrigerant detector — first threshold reached (10% of the LFL) | Triggers an alarm which alerts authorized persons to take the appropriate action. | Take the appropriate action, such as checking potential leakage points, and checking detector and fan functionality. | 9 | |
| Refrigerant detector — second threshold reached (25% of the LFL) | Triggers the emergency stop for the facility and its safety measures are implemented. | All equipment must be shut down unless rated as suitable for use in a hazardous area. Emergency mechanical ventilation must be activated. | 9 | |
| Failure of the ventilation system, refrigerant detector, or alarm system | Any failure must be indicated. | The unit must be shut down, and the machine room ventilator running until the fault has been resolved. | 8 | |
| Leaving Chilled Liquid – Low Temperature Control | The chiller is shut down by this control. | If the load continues to decrease, after the pre-rotation vanes are entirely closed. | 25 | |
| Oil pressure safety cutout | Actuates and stops the system. | If the quantity of refrigerant in the oil becomes excessive, violent oil foaming results as the pressure within the system is lowered on starting. If this foam reaches the oil pump suction, the bearing oil pressure fluctuates with a possible temporary loss of lubrication. | Refer to OptiView™ control center operation manual (Form 160.54-O1). | 31 |
| High oil temperature (HOT) | Unit shutting down on high oil temperature. | Incorrect lubrication, brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. However, if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed, notify the nearest Johnson Controls office to request the presence of a Johnson Controls Service Technician. | 57 |
| Low oil pressure (OP) | Unit shutting down on low oil pressure. | Incorrect lubrication, brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. However, if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed, notify the nearest Johnson Controls office to request the presence of a Johnson Controls Service Technician. | 57 |
From Model YK Style H, Centrifugal Liquid Chillers for Europe, Operation Guide 160.76-O1-EN.CE
Original: docs.johnsoncontrols.com
A2L refrigerant application
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Ventilation airflow failure / failure of the permanent mechanical extraction | The unit shuts down, into safe mode, within 10 s in the event that airflow is reduced below the minimum required flow or in case of any failure of the permanent mechanical extraction. | Airflow reduced below the minimum required flow or failure of the permanent mechanical extraction. | Do not powered on the unit, and maintain safe mode, until the airflow is restored. | 8 |
| Refrigerant concentration reaches 10% of the LFL (first detection threshold) | First refrigerant detection threshold. | Refrigerant concentration reaching the first threshold (10% of the LFL). | Triggers an alarm which alerts authorized persons to take the appropriate action, such as checking potential leakage points, and checking detector and fan functionality. | 9 |
| Refrigerant concentration reaches 25% of the LFL (second detection threshold) | Second refrigerant detection threshold. | Refrigerant concentration reaching the second threshold (25% of the LFL). | Triggers the emergency stop for the facility and its safety measures are implemented. | 9 |
| Failure of the ventilation system, refrigerant detector, or alarm system | Any failure must be indicated. | The unit must be shut down, and the machine room ventilator running until the fault has been resolved. | 8 |
Oil heater
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Oil pressure safety cutout | The oil pressure safety cutout actuates and stops the system. | Violent oil foaming results as the pressure within the system is lowered on starting, caused by refrigerant boiling out of the oil; if this foam reaches the oil pump suction, the bearing oil pressure will fluctuate with possible temporary loss of lubrication. | Refer to OptiView Control Center – Operation Manual (160.76-O2). | 25 |
Troubleshooting — Table 5: Operation analysis chart
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Air is in the condenser. | 31 | |
| abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Condenser tubes dirty or scaled. | Clean condenser tubes. Check water conditioning. | 31 |
| abnormally high discharge pressure | High discharge pressure. | High condenser water temperature. | Reduce condenser water inlet temperature. Check cooling tower and water circulation. | 31 |
| abnormally high discharge pressure | Temperature difference between condenser water on and water off higher than normal, with normal evaporator pressure. | Insufficient condensing water flow. | Increase the quantity of water through the condenser to proper value. | 31 |
| abnormally low suction pressure | Insufficient charge of refrigerant. | Check for leaks and charge refrigerant into system. | 31 | |
| abnormally low suction pressure | Temperature difference between leaving chilled water and refrigerant in evaporator greater than normal with high discharge temperature. | Variable orifice problem. | Remove obstruction. | 31 |
| abnormally low suction pressure | Temperature difference between leaving chilled water and refrigerant in the evaporator greater than normal with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean evaporator tubes. | 31 |
| abnormally low suction pressure | Temperature of chilled water too low with low motor amperes. | Insufficient load for system capacity. | Check pre-rotation vane motor operation and setting of low water temperature cutout. | 31 |
| high evaporator pressure | Pre-rotation vanes fail to open. | Check the pre-rotation vane motor positioning circuit. | 31 | |
| high evaporator pressure | High chilled water temperature. | System overload. | Be sure the vanes are wide open (without overloading the motor) until the load decreases. | 31 |
| no oil pressure when system start button pushed | Low oil pressure displayed on control center; compressor does not start. | Oil pump running in the incorrect direction. | Check rotation of oil pump (Electrical Connections). | 31 |
| no oil pressure when system start button pushed | Low oil pressure displayed on control center; compressor does not start. | Oil pump not running. | Troubleshoot electrical problem with oil pump VSD. | 31 |
| unusually high oil pressure develops when oil pump runs | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure. Transducer defective. | Replace low or high oil pressure transducer. | 31 |
| oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. Note: When oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Oil not reaching pump suction inlet in sufficient quantity. | Check oil level. | 31 |
| oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. Note: When oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Worn or failed oil pump. | Repair or replace oil pump. | 31 |
| reduced oil pump capacity | Oil pump pumping capacity. | Excessive end clearance pump. Other worn pump parts. | Inspect and replace worn parts. | 31 |
| reduced oil pump capacity | Oil pump pumping capacity. | Partially blocked oil supply inlet. | Check oil inlet for blockage. | 31 |
| oil pressure gradually decreases, noted by observing the daily log sheets | When the oil pump VSD frequency increases to 55 + Hz to maintain target oil pressure. | Oil filter is dirty. | Change oil filter. | 31 |
| oil pressure system ceases to return an oil/refrigerant sample | Oil refrigerant return not functioning. | Filter-drier in oil return system dirty. | Replace old filter-drier with a new filter-drier. | 32 |
| oil pressure system ceases to return an oil/refrigerant sample | Oil refrigerant return not functioning. | Jet or orifice of oil return jet clogged. | Remove jet, inspect for dirt. Remove dirt using solvent and replace the jet. | 32 |
| oil pump fails to deliver oil pressure | No oil pressure registers when pressing OIL PRESSURE display key when oil pump runs. | Faulty oil pressure transducer. Faulty wiring/connectors. | Replace oil pressure transducer. | 32 |
Compressor maintenance
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| HOT | Unit shutting down on high oil temperature. | Improper lubrication brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. However, if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed, notify the nearest Johnson Controls office to request the presence of a Johnson Controls Service Technician. | 49 |
| OP | Unit shutting down on low oil pressure. | Improper lubrication brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. However, if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed, notify the nearest Johnson Controls office to request the presence of a Johnson Controls Service Technician. | 49 |
Motor relubrication instruction
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Re-lubrication warning message | Current YORK OptiView panels provide a warning message to re-lubricate beginning at a programmed number of operating hours (the default value is 1000 h). At the programmed value plus 400 h this feature shuts down the chiller if re-lubrication is not addressed. In plants where chillers run 24/7, there is more than 16 days of advance warning before shutting down the chiller. | Programmed number of operating hours reached without re-lubrication. | Address re-lubrication; if re-lubrication is not addressed, the chiller is shut down at the programmed value plus 400 h. | 52 |
| Bearing temperature warning (above 65°C) | Normal operating temperature for grease lubricated bearings on YORK chillers is 40°C to 65°C. If the temperature exceeds 65°C, at which point a warning is issued, it is an indication that either the bearings are in need of lubrication or that something is incorrect. If temperature reaches 70°C, it generally indicates some type of problem. | Bearings in need of lubrication or something is incorrect. | Operation should be checked. | 56 |
| Bearing RTD motor shutdown (90°C) | Bearing RTDs are normally set to shut down the motors at 90°C, although once this temperature is reached, the bearings most likely have already been compromised. | 54 |
From Model YK Style J, with R-515B, R-513A, R-1234ze, or R134a Refrigerant with OptiView Control Center for Electromechanical Starter, Solid State Starter, and Variable Speed Drive Operation Guide 160.95-O1
Original: docs.johnsoncontrols.com
Troubleshooting — Table 4: Operation analysis chart
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 1. Issue: abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Air is in the condenser. | 34 | |
| 1. Issue: abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Condenser tubes dirty or scaled. | Clean condenser tubes. Check water conditioning. | 34 |
| 1. Issue: abnormally high discharge pressure | High discharge pressure. | High condenser water temperature. | Reduce condenser water inlet temperature. Check cooling tower and water circulation. | 34 |
| 1. Issue: abnormally high discharge pressure | The temperature difference between condenser water on and water off is higher than normal, with normal evaporator pressure. | Insufficient condensing water flow. | Increase the quantity of water through the condenser to proper value. | 34 |
| 2. Issue: abnormally low suction pressure | Insufficient charge of refrigerant. | Check for leaks and charge refrigerant into system. | 34 | |
| 2. Issue: abnormally low suction pressure | The temperature difference between the leaving chilled water and the refrigerant in the evaporator is greater than normal with high discharge temperature. | Variable orifice problem. | Remove obstruction. | 34 |
| 2. Issue: abnormally low suction pressure | The temperature difference between the leaving chilled water and the refrigerant in the evaporator is greater than normal with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean evaporator tubes. | 34 |
| 2. Issue: abnormally low suction pressure | The temperature of chilled water is too low with low motor amperes. | Insufficient load for system capacity. | Check the motor operation of the PRV and check the setting of the low water temperature cutout. | 34 |
| 3. Issue: high evaporator pressure | PRVs fail to open. | Check the PRV motor positioning circuit. | 34 | |
| 3. Issue: high evaporator pressure | High chilled water temperature. | System overload. | Ensure the vanes are wide open (without overloading the motor) until the load decreases. | 34 |
| 4. Issue: no oil pressure when system start button pushed | Low oil pressure is displayed on the control center; the compressor does not start. | Oil pump running in wrong direction. | Check rotation of oil pump (Electrical Connections). | 34 |
| 4. Issue: no oil pressure when system start button pushed | Low oil pressure is displayed on the control center; the compressor does not start. | Oil pump not running. | Troubleshoot electrical problem with oil pump VSD. | 34 |
| 5. Issue: unusually high oil pressure develops when oil pump runs | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure. The transducer is defective. | Replace low or high oil pressure transducer. | 34 |
| 6. Issue: oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing the Oil Pressure display key. Note: When the oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Oil not reaching pump suction inlet in sufficient quantity. | Check oil level. | 34 |
| 6. Issue: oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing the Oil Pressure display key. | Worn or failed oil pump. | Repair or, if necessary, replace the oil pump. | 34 |
| 7. Issue: reduced oil pump capacity | Oil pump pumping capacity. | Excessive end clearance pump. Other worn pump parts. | Inspect and replace worn parts. | 34 |
| 7. Issue: reduced oil pump capacity | Oil pump pumping capacity. | The oil supply inlet is partially blocked. | Check the oil inlet for blockage. | 34 |
| 8. Issue: oil pressure gradually decreases as noted by observation of daily log sheets | When the oil pump VSD frequency increases to 55 + Hz to maintain target oil pressure. | Oil filter is dirty. | Change oil filter. | 34 |
| 9. Issue: oil pressure system ceases to return an oil/refrigerant sample | Oil refrigerant return not functioning. | Filter-drier in oil return system dirty. | Replace old filter-drier with new. | 34 |
| 9. Issue: oil pressure system ceases to return an oil/refrigerant sample | Oil refrigerant return not functioning. | Jet or orifice of oil return jet clogged. | Remove jet, inspect for dirt. Remove dirt using solvent and replace. | 34 |
| 10. Issue: oil pump fails to deliver oil pressure | No oil pressure registers when pressing the Oil Pressure display key when the oil pump runs. | Faulty oil pressure transducer. | Replace oil pressure transducer. | 35 |
| 10. Issue: oil pump fails to deliver oil pressure | No oil pressure registers when pressing the Oil Pressure display key when the oil pump runs. | Faulty wiring or connectors. | Replace oil pressure transducer. | 35 |
Safety shutdowns and warnings
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Leaving Chilled Liquid – Low Temperature Control | Safety control that shuts down the chiller. | The load continues to decrease, after the PRVs are entirely closed. | 15 | |
| oil pressure safety cutout | Actuates and stops the system. | Refrigerant boiling out of the oil as the pressure is lowered on starting causes violent oil foaming; if this foam reaches the oil pump suction, the bearing oil pressure fluctuates with possible temporary loss of lubrication. | Refer to OptiView Control Center – Operation Manual (160.76-O2). | 27 |
| high oil temperature (HOT) | The unit is shutting down on high oil temperature. | Incorrect lubrication, brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles; if aluminum particles continue to accumulate, contact Johnson Controls Service. | 40 |
| low oil pressure (OP) | The unit is shutting down on low oil pressure. | Incorrect lubrication, brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles; if aluminum particles continue to accumulate, contact Johnson Controls Service. | 40 |
| warning message to re-lubricate | OptiView panels provide a warning message to re-lubricate beginning at a programmed number of operating hours (the default value is 1000 hours). At the programmed value plus 400 hours this feature shuts down the chiller if re-lubrication is not addressed. | Programmed number of operating hours reached. | Re-lubricate the motor bearings; if re-lubrication is not addressed, the chiller shuts down at the programmed value plus 400 hours. | 43 |
| bearing temperature warning — 149°F (65°C) | If the temperature exceeds 149°F (65°C), a warning is issued. | Either the bearings are in need of lubrication or that something is wrong. | Operation should be checked. | 47 |
| bearing RTD shutdown — 194°F (90°C) | Bearing RTDs are normally set to shut down the motors at 194°F (90°C), although when this temperature is reached, the bearings most likely have already been compromised. | Motors shut down by bearing RTDs at 194°F (90°C). | 44 | |
| quarterly maintenance warning item | Monthly items appear on OptiView as a quarterly maintenance warning item. | Monthly items are still required. | Perform the monthly maintenance procedures. | 20 |
From OptiView Touch Screen Control Center for YK Style H and Style J Operation Guide 160.95-O2
Original: docs.johnsoncontrols.com
Start inhibit messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Anti-recycle XX/sec | Anti-recycle setting enabled on the setup screen and the anti-recycle time has not yet elapsed; time remaining is displayed next to the message. Timer set active: LCSSS, MVSSS, and EM starters = 30 minutes from entering a run state or motor current >15% FLA; all variable speed compressor motor starters = 10 minutes from entering a run state, motor current >15% FLA, or VSD frequency >0 Hz. | For variable speed compressor motor drives, the start inhibit is set when any of the listed events occur five times before the 10 min timer expires. For all other starters, the start inhibit is set while the timer is active. | 185 | |
| LCSSS - High phase A, B, or C heatsink temperature - Stopped | Chiller stopped and the LCSSS trigger board detected the temperature of the phase A, B, or C (X in message) SCR module greater than 110°F (43.3°C). | The starter cooling pump runs and the chiller is inhibited from starting until the temperature decreases to less than 109°F (42.8°C). | 185 | |
| Setup - Line Frequency Not Set | The line frequency programmed on the setup screen is Invalid. | 185 | ||
| Setup – Line voltage not set | HYP model drives: the line voltage programmed on the setup screen is Invalid. | 186 | ||
| MVSSS - High heatsink 1, 2, or 3 temperature - Stopped | Temperature sensed on the stated phase stack has exceeded 194°F (90°C) while not running. | 186 | ||
| Motor controller – Initialization in progress | For Y.OPT.01.07.308 and later. OptiView is waiting for a response from the starter to initialize or re-initialize, based on certain events. Applies to all starters except EM. | While this fault is active, all motor controller data displayed on the screens must be replaced with XXX. | 186 | |
| Oil - High sump pressure - Stopped | Heat pump enabled and the oil sump pressure is greater than 133.0 psig. | Released when the oil sump pressure drops below 130.0 psig. | 186 | |
| Oil - Low temperature differential | Instantly set when the oil sump temperature minus the condenser saturation temperature is less than 40.0°F (4.4°C) when the oil pump is not running. | Released when the set criteria is no longer true. | 186 | |
| Oil - High dilution inhibit | Only applies when oil quality protection is enabled. Oil dilution is greater than the JCI Service programmable high dilution inhibit trip threshold (default 20.0%). | The chiller can start when the oil dilution is less than the high dilution start inhibit dilution trip threshold minus 0.2%. | 186 | |
| Oil - Low viscosity inhibit | Only applies when oil quality protection and oil cooling control are enabled. Oil viscosity is less than the JCI Service programmable low viscosity inhibit trip threshold (default 5.0 cSt) after 48 s of pre-lube. | The chiller can be restarted after the oil viscosity is greater than the low viscosity inhibit trip threshold plus 0.2 cSt. | 186 | |
| Compressor – PRV not calibrated | The PRVs have not been calibrated. | The message clears when the PRV calibration has successfully passed. | 187 | |
| Compressor – PRV motor switch open | The PRVs are not fully closed. | Inhibit is disabled when the PRV start position is greater than 0%. | 187 |
Warning messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Warning – Auto lube grease level low | Auto lube type is P203; the motor auto lube cycle has been in progress for 30 s and OptiView receives three low level inputs from the auto lube device in a 15 s window. The low level indicator is a magnetic switch that closes as the wiper arm in the luber passes over it. | Manual reset warning. | 188 | |
| Warning – Auto lube req’d on next shutdown | Auto lube type is P203; operating hours since last motor lube is greater than or equal to the lube required period. | Auto-reset. Clear at Standard access or higher by entering initials, name, or user ID using the Motor Lube Acknowledge key on the Motor Lubrication Screen; date/time logged as date/time of last motor lubrication and operating hours since last lubrication reset to zero. Not displayed if the auto lube setpoint on the motor lubrication screen is enabled. | 189 | |
| Warning - Check oil system | Oil pump frequency command is greater than 50 Hz for 30 min consecutively. | Manual reset: reset when the frequency command is less than or equal to 50 Hz and the Clear button on the System Details Screen is pressed. | 189 | |
| Warning – Compressor – Low discharge superheat limit | Compressor discharge superheat has decreased to the capacity control discharge superheat override of less than 8°F (4.4°C) for 30 s. | Auto-reset: releases when the discharge superheat increases above 10°F (5.6°C). | 189 | |
| Warning – Condenser – Freeze threat from low pressure | Chiller not running, condenser saturation temperature less than 34°F (1.1°C) and drop leg temperature less than 35°F (1.7°C). | Auto-reset: resets if the chiller is started, the condenser saturation temperature is greater than 36°F (2.2°C), or the drop leg temperature is greater than 38°F (3.3°C). | 189 | |
| Warning – Condenser – High pressure limit | Condenser pressure exceeds the high pressure warning setpoint threshold. | While in effect, the PRVs are inhibited from further opening. Automatically clears and the PRVs are permitted to open when the condenser pressure decreases to 5 psig below the setpoint. | 189 | |
| Warning - Condenser - High small temperature difference | Condenser small temperature difference is greater than the condenser small temperature difference warning threshold (service programmable, default 8.0°F, on the maintenance screen). | Manual reset: reset when the difference is less than or equal to the threshold, the Maintenance Acknowledge key is pressed, Cond High Small Temp Diff is selected, and the code 0726 is entered. | 190 | |
| Warning – Condenser – Liquid level stability | After 30 min of running, a 10 min condenser liquid level minimum/maximum window starts; the difference between minimum and maximum level is compared to the liquid level stability threshold (JCI Service programmable 20%–80%, default 20%). Difference greater than the threshold for three consecutive 10 min windows sets this warning. | Manual reset: reset when the difference is less than the threshold for 10 min and the Clear button on the System Details Screen is pressed. | 190 | |
| Warning – Condenser or evaporator XDCR error | After 10 min of running, the evaporator pressure transducer indicates a higher pressure than the condenser pressure transducer — indicative of a condenser or evaporator transducer failure. Not checked in brine mode. | Displayed until the condition clears and the Clear button on the System Details Screen is pressed. | 190 | |
| Warning - Condenser or VGD sensor failure | Difference between the discharge/stall pressure transducer and the condenser pressure transducer is greater than 21 psid or less than -21 psid for 3 min continuously (both transducers measure essentially the same pressure). | Displayed until the condition clears and the Clear button on the System Details Screen is pressed. While displayed, the VGD is driven to the full open position and held until the warning is cleared; when cleared, the VGD returns to normal operation. | 190 | |
| Warning – Conditions override VGD | An extreme stall condition detected while running: stall detector voltage exceeds twice the high limit setpoint for the duration programmed in the extreme stall duration setpoint (10 min to 20 min). Protects the VGD ring from damage. Not checked while the VGD is in manual control, fully closed (limit switch closed), or the PRV position is greater than the PRV VGD inhibit setpoint. | While displayed, the compressor VGD is driven to the full open position and held until the message is cleared. Cleared after the stall detector voltage returns to less than two times the high limit setpoint and the Clear button on the System Details Screen is pressed. | 191 | |
| Warning – Control panel – Internal error | Software detects an error in the timing of the internal processing. Does not impact any functions; indicates there may be an issue slowing down the process (hardware, software, or external influence). | Auto reset warning. | 191 | |
| Warning – Excess surge detected | Applies only if the surge protection shutdown is disabled and any of: hot gas disabled (SSS/EM), hot gas enabled with HGBP valve command 100% (SSS/EM), hot gas disabled with VSD at maximum frequency, hot gas enabled with HGBP 100% and VSD at maximum frequency — and the surge window count has exceeded the count limit. | Manually cleared after the surge window count is less than or equal to the count limit, or the event has been set for more than 10 min, or the chiller is not running; press the Clear button on the System Details Screen. | 192 | |
| Warning – External I/O – Serial communication | Microboard has not received valid communication from the optional LTC I/O board for 12 consecutive attempts with a 2 s timeout between attempts (approximately 24 s). Required for: heat recovery, oil sump condenser (high temperature heat pump), hot gas liquid injection, isolation valves, variable water outlet control, and oil cooling control when the oil cooling control source is LTCIO. | Automatically resets when a valid response is received. | 192 | |
| Warning – High auxiliary condenser pressure | High temperature heat pump oil sump condenser enabled and the auxiliary condenser pressure >140.0 psig while running. | Auto-reset: resets when the pressure drops below 120.0 psig. | 192 | |
| Warning – Harmonic filter – Data loss | Communications between the harmonic filter logic board and the compressor motor VSD logic board is not occurring. | All filter related parameters display as X. Automatically clears when communications are restored. | 192 | |
| Warning – Harmonic filter – Input frequency range | Power line frequency detected by the VSD harmonic filter is outside 58 Hz to 62 Hz (default 60 Hz) or 49 Hz to 51 Hz (default 50 Hz). | All filter related parameters display as X. Automatically clears when the line frequency is within range. | 193 | |
| Warning – Harmonic filter – Invalid model | On power up the VSD checks that the filter model reported by the filter is correct; the reported model is not correct. | While displayed, the VSD runs with the filter disabled. Clears when the filter is inhibited on the VSD Screen or the VSD receives the correct model from the filter on the next power up. | 193 | |
| Warning – Harmonic filter – Not running | All of the following true for 20 s continuously: chiller running, filter enabled, filter present status true, Run Time greater than 20 seconds, filter operating mode is stopped. | Released when the condition clears, or the chiller is stopped, but is displayed until manually cleared using the Clear button on the System Details Screen. | 193 | |
| Warning – Harmonic filter – Operation inhibited | A harmonic filter is present and has been inhibited on the VSD Screen. All harmonic filter data is still displayed. Harmonic filter operation must only be altered by a qualified service technician. | Auto-reset warning. | 193 | |
| Warning – Liquid level setpoint not achieved | Refrigerant level is not within ±15% of the refrigerant level setpoint for 10 continuous min after the chiller has been running for 30 min. | Auto-reset: clears when the refrigerant level is within the 15% range or the chiller is stopped. | 193 | |
| Warning – Loss of subcooler liquid seal | Chiller running greater than 30 min and the subcooler effectiveness is less than the subcooler effectiveness low threshold with input FLA greater than 40%; or the subcooler effectiveness is more than the subcooler effectiveness high threshold, the drop leg temperature is less than the ECLT minus 0.5°F, and the input FLA is greater than 40%. | Manual reset: press the Clear button on the System Details Screen. | 193 | |
| Warning – MMB – Serial communications | Microboard has not received valid communication from the optional motor monitoring board for 12 consecutive attempts with a 2 s timeout between attempts (approximately 24 s). | Automatically resets when a valid response is received. | 194 | |
| Warning – Motor – Auto lube failed | Auto lube type is P203; the Warning – Auto lube grease low warning is set in the first half of the motor auto lube duration after the lube cycle is complete, or the Cancel Auto Lube key is pressed during the cycle. | Manual reset warning. | 194 | |
| Warning – Motor – Bearing vibration baseline not set | Shaft end and opposite shaft end motor bearing vibration baseline values have not been entered on the motor details screen. | Displayed until both baselines are entered, either manually with the manual baseline setpoint or automatically with the Auto Baseline key. While displayed, the vibration baseline values are set to X.X. | 194 | |
| Warning – Motor – High bearing temperature | Either of the enabled motor bearing temperatures exceeds the programmed High Bearing Temperature Warning for 3 s continuously. Does not occur when bearing temperature protection is set to disabled; does not act on RTD inputs registering as open. | Automatically clears when all bearing temperatures decrease below the warning threshold. | 194 | |
| Warning – Motor – High bearing vibration | Either the shaft end or opposite shaft end motor bearing vibration has exceeded the value programmed for the high vibration warning setpoint for the programmed number of delay seconds. Does not occur when motor vibration protection is disabled or while the Baseline Not Set warning is displayed. | Automatically clears when both vibration values decrease below the warning threshold. | 194 | |
| Warning – Motor – High winding temperature | Any of the enabled motor winding temperatures exceed the high winding temperature shutdown threshold minus 18°F (-7.8°C) for 3 s continuously. Does not occur when winding temperature protection is disabled; does not act on open RTDs or individually disabled winding sensors. | Automatically clears when all winding temperatures decrease below the warning threshold. | 195 | |
| Warning – Motor - Bearing lube required | Operating hours since last motor lubrication exceeds the set hours. Replaces Warning – Motor bearing lube suggested. Not displayed if the auto lube type is none. | Displayed until manually cleared by the operator, or until the operating hours exceed the set hours plus 200, when it is replaced by the fault Motor – Lack of bearing lubrication. Clear by entering initials, name, or user ID using the Motor Lube Acknowledge key on the Motor Lubrication Screen; date/time logged and operating hours since last lubrication reset to zero. | 195 | |
| Warning – Motor - Bearing lube suggested | Operating hours since last motor lubrication exceeds the set hours. Not displayed if the auto lube type is none. | Displayed until manually cleared by the operator, or until the operating hours exceed the set hours plus 200, when it is replaced by Warning - Motor bearing lube required. Clear at Standard access or higher by entering initials, name, or user ID using the MOTOR LUBE ACKNOWLEDGE key on the Motor Lubrication Screen; date/time logged and operating hours since last lubrication reset to zero. | 195 | |
| Warning – Motor – Bearing lube not done | Auto lube type is none or P203 and the motor lube shutdown is disabled; operating hours since last motor lubrication is greater than the lube required period plus 200 hours. | Clear by entering initials, name, or user ID using the Motor Lube Acknowledge key on the Motor Lubrication Screen; date/time logged and operating hours since last lubrication reset to zero. | 196 | |
| Warning – Motor – Oil change suggested | Auto lube type is sleeve and the operating hours since last motor lubrication is greater than or equal to 4,000 hours. | Displayed until manually cleared, or until the operating hours exceed the set hours, when it is replaced by Warning – Motor – Oil change required. Clear by entering initials, name, or user ID using the Motor Lube Acknowledge key; date/time logged and operating hours since last lubrication reset to zero. | 196 | |
| Warning – Motor – Oil change required | Auto lube type is sleeve and the operating hours since last motor lubrication is greater than or equal to 5,000 hours. Replaces Warning – Motor – Oil change suggested. | Displayed until manually cleared, or until the operating hours exceed the set hours plus 1,000, when it is replaced by the safety fault Motor – Lack of bearing oil change. Clear by entering initials, name, or user ID using the Motor Lube Acknowledge key; date/time logged and operating hours since last lubrication reset to zero. | 196 | |
| Warning – Motor – Oil change not done | Auto lube type is sleeve and the motor lube shutdown is disabled; operating hours since last motor lubrication is greater than or equal to 6,000 hours. | Clear by entering initials, name, or user ID using the Motor Lube Acknowledge key on the Motor Lubrication Screen; date/time logged and operating hours since last lubrication reset to zero. | 197 | |
| Warning – Oil – High supply temperature | Oil cooling control enabled; after 30 min of running, the oil supply temperature is 10°F (5.6°C) higher than the oil supply temperature setpoint for 1 min continuously. | Auto reset: resets when the oil supply temperature is lower than the oil supply temperature plus 5.0°F (2.8°C). | 197 | |
| Warning – Oil – Low supply temperature | Oil cooling control enabled; after 30 min of running, the oil supply temperature is 15°F (8.3°C) lower than the oil supply temperature setpoint for 1 min continuously. | Auto reset: reset when the oil supply temperature is higher than the trip threshold. | 197 | |
| Warning – Oil – High sump pressure | Heat pump mode enabled. Displayed when the chiller has been running less than 10 min and the oil sump pressure is greater than 132.0 psig for 10 s; also when running 10 min and the oil sump pressure is greater than 103.0 psig for 10 s; or instantly when the oil sump pressure is greater than 200 psig at any time. | Auto reset: clears if the chiller is stopped, the chiller has been running less than 10 min and the oil sump pressure is less than 130.0 psig, or the chiller has been running 10 min and the oil sump pressure is less than 100.0 psig. | 197 | |
| Warning – Quarterly service required – Contact JCI | Days since last quarterly service is equal to or greater than 90 days. | Manual reset: reset when the Maintenance Acknowledge key is pressed, Quarterly Service is selected, and the code 0726 is entered; also resets the quarterly service timer to 0. | 197 | |
| Warning - Yearly service required - Contact JCI | Days since last yearly service is equal to or greater than 365 days, or operating hours since last yearly service is greater than 2,890 hours (33% of a full year’s run hours). | Manual reset: reset when the Maintenance Acknowledge key is pressed, Yearly Service is selected, and the code 0726 is entered; also resets both the yearly service days and hours timers to 0. | 198 | |
| Warning - 3 year service required - Contact JCI | Days since last 3 year service is equal to or greater than 1,095 days. | Manual reset: reset when the Maintenance Acknowledge key is pressed, 3 Year Service is selected, and the code 0726 is entered; also resets the 3 Year Service timer to 0. | 198 | |
| Warning – Sales order – Invalid serial number | The unit serial number is blank on the Sales Order Screen. | Auto-reset: clear by entering a serial number. | 198 | |
| Warning – Standby lube – Low oil pressure | A minimum of 15 psid of oil pressure was not achieved in the first 30 s of a standby lubrication cycle, or the pressure decreased below this value during the remainder of the cycle. Also set when either the pump oil pressure transducer or the sump oil pressure transducer is less than 2 psig when a standby lube is requested by automatic control (inhibits the standby lube cycle when the chiller is open to atmosphere). | Message is displayed and no further standby lubrications are performed until the Clear button is pressed on the System Details Screen. | 198 | |
| Warning – Standby lube – Inhibited | The oil pump pressure is less than 2 psig, the oil sump pressure is less than 2 psig, the Oil – Pump pressure transducer out of range safety fault is set, or the Oil – Sump pressure transducer out of range safety fault is set. | Auto-reset: reset when the set criteria are not true. | 198 | |
| Warning – Surge protection – Excess surge limit | Applies only if the surge protection extended run feature is enabled and any of: hot gas disabled (SSS/EM), hot gas enabled with HGBP valve command 100% (SSS/EM), hot gas disabled with VSD at maximum frequency, hot gas enabled with HGBP 100% and VSD at maximum frequency. Begins when the surge window count exceeds the count limit; during the 10 min period the PRVs are driven closed. | When 10 min have elapsed, the message and the PRV load inhibit are automatically cleared; also cleared when the chiller is shutdown. | 199 | |
| Warning – VSD – Input voltage imbalance | Variable speed compressor motor drive is a HYP model and the input voltage imbalance is greater than or equal to 5%. | Auto-reset warning. | 199 |
Cycling faults
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Condenser – Flow switch open | The condenser flow switch (and the heating condenser flow switch for heat recovery chillers) has remained open for 5 s continuously while the chiller was running. | The chiller automatically restarts when the flow switch closes. While active, the condenser pump relay contacts (TB2-150/151) remain closed until the chiller is given a stop command or has another fault. | 200 | |
| Condenser – Freeze threat – Flow switch open | The condenser flow switch has remained open for more than 1 min while the chiller is stopped, and the condenser saturation temperature is less than 34.0°F (1.1°C) and the drop leg temperature is less than 35.0°F (1.7°C). | Released if the condenser flow switch is closed, the condenser saturation temperature is greater than 36.0°F (2.2°C), or the drop leg temperature has been greater than 36.0°F (2.2°C) for 5 min consecutively. | 200 | |
| Control panel – Power failure | When the power failure restart is auto, this is a cycling fault: a control power failure has occurred. | If the power failure occurred while running, the chiller automatically restarts when power is restored. If the failure duration was less than the applicable coastdown period when power is restored, the remainder of the coastdown is performed before starting. | 200 | |
| Control panel – Loss of control voltage | When the power failure restart is auto, this is a cycling fault: the line power input signal at I/O board TB3-30 was low for 1 s continuously. This signal determines when digital inputs are affected by a line power loss as opposed to an actual condition. | 201 | ||
| Control panel – Schedule | Schedule feature enabled; the chiller has been shut down in accordance with the schedule entered. | The unit restarts at the next scheduled start time. | 201 | |
| Evaporator – Low pressure - Smart freeze | Evaporator pressure has decreased to the capacity control low pressure override with the Warning - Evaporator - Low press limit active, and capacity control is not able to increase the evaporator pressure within 2 min. | If the chiller was running, it automatically shuts down and then restarts. If this cycling fault happens three times within 90 min a safety fault is set. | 201 | |
| Isolation valves – Not closed | Isolation valves enabled on the setup screen; the isolation close output relay on LTC I/O TB16 has been energized for more than 40 s and the isolation valve closed digital input on LTC I/O board TB18-1,2 is low. | Released when the closed digital input is high. | 201 | |
| Leaving chilled liquid – Flow switch open | The chilled liquid flow switch has remained open for 5 s continuously while the chiller was running, or failed to close during the last 5 s of the system prelube period. | The chiller automatically restarts when the flow switch closes. While active, the evaporator pump relay contacts (TB2-44/45) remain closed until the chiller is given a stop command or has another fault. | 202 | |
| Chilled liquid – Flow switch open | The chilled liquid flow switch has remained open for 5 s continuously while the chiller was running, or failed to close during the last 5 s of the system prelube period. | The chiller automatically restarts when the flow switch closes. While active, the evaporator pump relay contacts (TB2-44/45) remain closed until the chiller is given a stop command or has another fault. | 202 | |
| Leaving chilled liquid – Low temperature | The leaving chilled liquid temperature has decreased to the programmed shutdown temperature setpoint. In heat pump heating mode, additional logic causes this shutdown when the LCHLT decreases below the programmed heating LCHLT shutdown temperature setpoint. | If running, the PRVs are driven fully closed before shutting down the chiller. The chiller automatically restarts when the temperature increases to the programmed restart temperature setpoint. | 202 | |
| Leaving condenser liquid – High temperature | The leaving condenser liquid temperature has increased to the programmed heating shutdown temperature setpoint. Only applicable when heat pump duty is enabled and operating in heating mode. When the heating setpoint is decreased, the shutdown threshold becomes 125°F (51.7°C) for the next 10 min, then becomes the programmed setpoint value. | The heat pump automatically restarts when the temperature decreases to the programmed heating restart temperature setpoint. | 202 | |
| Motor controller - Initialization failure | When AC power is restored after a power failure, the control center attempts to establish serial communications with the starter; communications are not established in 10 consecutive attempts. Applies to all starters that communicate through Modbus or fiber optic comms. | A cycling shutdown is performed; the control center continues attempting to establish communications until successful. | 202 | |
| Motor controller – Fault contacts open | The motor controller fault contacts connected to TB6-16 and TB6-53 in the OptiView Control Panel have opened. Applies to all starters. | The chiller automatically restarts if it was running when the fault occurred. | 203 | |
| Motor controller – Loss of current | Compressor motor current decreased to 10% FLA for 25 s continuously while running — possibly caused by the starter de-energizing during run or a defect in the motor current feedback circuitry. Applies to all starters. | The chiller automatically restarts at the completion of system coastdown. | 203 | |
| Motor controller – Serial communications | Communications between the control center microboard and the starter cause no response over three consecutive attempts (approximately 6 sec). Applies to all starters that communicate through Modbus or fiber optic comms. | Released when a valid response is received; the chiller automatically restarts if it was running. | 203 | |
| Motor – Auto lube in progress | Auto lube type is P203 and the lubrication cycle is in progress, either automatically or manually initiated when the Start Auto Lube key is pressed. | This cycling shutdown remains in effect until the P203 auto luber has completed a lubrication cycle or is manually canceled. | 203 | |
| Motor – Lack of bearing lubrication | Auto lube type is P203 and the operating hours since last motor lubrication has exceeded the setpoint hours plus 200. Replaces Warning - Motor bearing lube required. | This cycling shutdown remains in effect until the P203 auto luber has completed a lubrication cycle. | 203 | |
| Multiunit cycling – Contacts open | The multiunit cycling contacts on the I/O board TB4-9 have opened to initiate a cycling shutdown. | If running, the PRVs are driven fully closed before shutting down the chiller. The chiller automatically restarts when the contacts close. | 203 | |
| Oil – Low sump temperature | The oil temperature has decreased to less than or equal to 55°F (12.8°C). | The chiller automatically restarts when the temperature increases above 56°F (13.3°C). | 203 | |
| Oil – Variable speed pump – Drive contacts open | The oil pump VSD has shut down the chiller by opening its status contacts connected to the I/O board TB3-70. The drive initiates a shutdown anytime its internal protection circuits do not permit the drive to run; the red LED on the drive board blinks. Refer to the label inside the VSOP cabinet. | The contacts remain open until the internal protection circuits are satisfied it is safe to operate; some drive-initiated shutdowns require AC power to be cycled to clear the fault. The chiller automatically restarts when the contacts close. | 204 | |
| Power fault | EM starter applications only. After the chiller has been running for 75 s, the CM-2 board has shut down the chiller to protect the motor from a transient torque condition; the CM contacts in the CM-2 board momentarily opened for less than 3 s (connected between TB6-16 and TB6-53). The power fault LED on the CM-2 illuminates. | The chiller automatically restarts when the contacts close. | 204 | |
| Proximity probe – Low supply voltage | The +24 VDC power supply voltage to the proximity probe has decreased to +19.0 VDC, below the minimum level required for reliable operation. Only applies to compressors that use proximity thrust bearing protection. | The chiller automatically restarts when the voltage increases to greater than or equal to 19.7 VDC. | 204 | |
| Setup - Refrigerant type not set | The refrigerant type is set to invalid on the Setup Screen. | The fault clears when a refrigerant type has been selected. | 204 | |
| System cycling – Contacts open | The system cycling contacts on the I/O board TB4-13 have opened to initiate a cycling shutdown. | If running, the PRVs are driven fully closed before shutting down the chiller. The chiller automatically restarts when the contacts close. | 204 |
Liquid cooled solid state starter
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| LCSSS – Serial receive | After communications were successfully established in the initialization process, the LCSSS does not receive a response from the control center after 10 consecutive attempts (approximately 20 sec) to communicate with the control center. | 205 | ||
| LCSSS – Power fault | The LCSSS logic/trigger board detected that the compressor motor current in one or more phases has decreased to less than 10% of the FLA for a minimum of one line cycle. Check is inhibited during the first 4 s of system run and until the motor current is greater than 25% of the job FLA. | The chiller automatically restarts upon completion of system coastdown. | 205 | |
| LCSSS – Low phase A, B, or C temperature sensor | The LCSSS logic/trigger board detected that the temperature of the phase A, B, or C (X in message) SCR module has decreased to less than 37°F (2.8°C) — generally a disconnected or defective sensor. If all three SCR modules indicate less than 37°F (2.8°C), the SCR module cooling pump turns on (accomplished by disconnecting all three sensors). | This feature allows service technicians to run the cooling pump while filling the cooling system by disconnecting plugs P2, P3, and P4 in the LCSSS. | 205 | |
| LCSSS - Run signal | The LCSSS receives two start signals from the control center simultaneously — one through the serial communications link and one through the start relay on the I/O board to TB6-24 — and they are not received within 5 s of one another. | A cycling shutdown is performed. | 205 | |
| LCSSS – Invalid current scale selection | An invalid compressor motor current scale jumper combination is installed in the LCSSS logic/trigger board J1. Allowable 100% FLA setpoint ranges: 7L – 35 to 260 A; 14L – 65 to 510 A; 26L – 125 to 850 A; 33L – 215 to 1050 A. | The chiller is permitted to start when the jumpers are configured correctly. Refer to Solid State Starter (Mod B) – Operation and Maintenance (Form 160.00-O2) for valid jumper configurations. | 206 | |
| LCSSS – Phase locked loop | The LCSSS logic/trigger board phase locked loop circuit was unable to maintain lock with phase A of the power line; a power line anomaly can cause such a sag or jitter. A power line frequency jitter of up to 3 Hz/s can be tolerated. | The chiller automatically restarts when lock has resumed. | 206 | |
| LCSSS – Low supply line voltage | The LCSSS logic/trigger board detected that the compressor motor AC power line voltage, in any phase, decreased below the low line voltage threshold continuously for 20 s. Shutdown/restart thresholds: 200–208 V: 160/174; 220–240 V: 185/200; 380 V: 305/331; 400 V: 320/349; 415 V: 335/362; 440–480 V: 370/400; 550–600 V: 460/502; Disabled: none. | The chiller automatically restarts when the voltage in all phases returns to the restart level. | 206 | |
| LCSSS – High supply line voltage | The LCSSS logic/trigger board detected that the compressor motor AC power line voltage, in any phase, exceeded the high line voltage threshold continuously for 20 s. Shutdown/restart thresholds: 200–208 V: 227/226; 220–240 V: 262/261; 380 V: 415/414; 400 V: 436/435; 415 V: 454/453; 440–480 V: 524/523; 550–600 V: 655/654; Disabled: none. | The chiller automatically restarts when the voltage in all phases returns to the restart level. | 207 | |
| LCSSS – Logic board processor | Communication between the microprocessor and digital signal processor (DSP) on the LCSSS logic/trigger board has been interrupted. | The chiller automatically restarts when communications are restored. | 207 | |
| LCSSS – Logic board power supply | Following the application of power. | The message is displayed and a snapshot of the LCSSS parameters and time of power failure are sent to the control center. | 207 | |
| LCSSS – Phase loss | The LCSSS logic/trigger board detected the line-to-line RMS voltage in any phase has decreased to less than or equal to 30% of the lowest value of the programmed voltage range. If the programmed voltage range is disabled, a value of 60 VAC is used as the threshold. | The chiller automatically restarts when the line voltage is greater than the shutdown threshold. | 207 |
Medium voltage solid state starter cycling fault messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| MVSSS – Low supply line voltage | The starter controller board has detected that the power line voltage (L1 to L2, L2 to L3, or L3 to L1) is less than 19% below the rated voltage for 20 s. | Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 208 | |
| MVSSS – High supply line voltage | The starter controller board has detected that the power line voltage (L1 to L2, L2 to L3, or L3 to L1) is greater than 13.2% above the rated voltage for 20 s. | Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 208 | |
| MVSSS – Run signal | The starter controller board receives two start signals from the control center simultaneously — one through the serial communications link and one through the start relay on the I/O board to TB6-24. | Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 208 | |
| MVSSS – Power fault | One or more phases of motor current has dropped below 10% of FLA for two line cycles. This fault is inhibited for the first 4 s of starting, and until all phase currents have reached 25% FLA. | Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 208 | |
| MVSSS – Phase loss | The drive controller board has detected a single phase has dropped more than 30% below the rated value. | Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 209 | |
| MVSSS – Logic board power supply | Generated by the starter controller board when it detects that the control power has dropped below the operational limit. | Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 209 | |
| MVSSS – Serial receive | Set if the starter controller board has lost Modbus communications from OptiView for more than 60 s. | Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 209 |
Medium voltage variable speed drive cycling fault messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD - High instantaneous current | Two of the three output lines (T1 and T3) to the motor are continuously monitored by two DC current transformers; the third phase (T2) is derived. The three phases of instantaneous output current are compared to an instantaneous limit of 233% of the drive’s 100% FLA rating (see Table 177 for per-model trip values). The peak instantaneous current trip limit was exceeded. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 210 | |
| VSD - Initialization failed | When a run signal is received from the control panel, the drive performs an operational check of the DC current transformers monitoring the current flow to the motor; the drive determines that the transformers are not operational. | The system cannot start and a cycling shutdown is initiated. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 211 | |
| VSD - DC bus voltage imbalance – XY | X denotes the power cell phase location (A, B, or C) and Y the location of the cell within that phase (U upper or L lower). The absolute value of the difference between the positive and negative bus voltages on all phases must remain within 413 VDC (25% of 1,650 VDC); it exceeded this range continuously for 3 ms. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 211 | |
| VSD - Precharge - DC bus voltage imbalance – XY | X denotes the power cell phase location (A, B, or C) and Y the location of the cell within that phase (U upper or L lower). During precharge, the absolute value of the difference between the positive and negative bus voltages on all phases must remain within 0 VDC to 248 VDC (15% of 1,650 VDC); it exceeded this range continuously for 3 ms. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 211 | |
| VSD - Precharge - Low DC bus voltage | During precharge, all DC bus voltages are compared to a threshold of 330 VDC (20% of 1,650 VDC) 0.5 s after initiation of precharge; all DC bus voltages did not meet or exceed the 330 VDC threshold. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 211 | |
| VSD - Gate driver - XYZ | X denotes the power cell phase location (A, B, or C), Y the location of the IGBT in the pole in relation to its connection (N neutral or M motor), and Z the location relative to the internal neutral connection (U upper or L lower). The voltage across the IGBT is too high; the gate driver board determines this shutdown and provides feedback to the MVVSD controller board. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 212 | |
| VSD - Run signal | Redundant run signals are generated by the OptiView Control Center — one through the start relay on the I/O board to TB6-24 and one through the serial communications link. When the MVVSD receives either run command a 5 s timer starts; it did not receive both run commands within 5 s. | The MVVSD initiates this shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 212 | |
| VSD - Input power supply | The 120 VAC control supply feeding the various DC power supplies powering the MVVSD controls circuitry dropped to a nominal trip threshold of 84 VAC; additionally, the RMS value of the transformer input voltage dropped to 70% of the nameplate voltage rating of the drive. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 212 | |
| VSD - High DC bus voltage - XY | X denotes the power cell phase location (A, B, or C) and Y the location of the cell within that phase (U upper or L lower). All DC bus voltages are continuously monitored and compared to an over-voltage trip level of 2,063 VDC (125% of 1,650 VDC); a DC bus voltage exceeded this level. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 212 | |
| VSD - Low DC bus voltage | All DC bus voltages are continuously monitored; one of the voltages dropped below a threshold level of 1,238 VDC (75% of 1,650 VDC) continuously for 30 ms. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 212 | |
| VSD - Loss of cooling fan | Any of the fan motor supply voltage is below the minimum threshold, or the manual fan motor starter is in the off mode, or the thermal overload is tripped. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 212 | |
| VSD - Single phase input power | The drive monitors each of the three phase line-to-line voltages; the RMS voltage of any of the three inputs dropped below 75% of the drive’s nameplate voltage rating. | The drive initiates a cycling shutdown. Messages automatically clear when the fault condition no longer exists; if the chiller was running when the fault occurred, it automatically restarts. | 213 |
Variable speed compressor drive cycling fault messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD – 105% motor current overload | HYP model drives only. The VSD logic board detects that at least one of the three output phase currents has exceeded 105% of the chiller’s FLA value for greater than 40 s. | Cycling shutdown. If three 105% motor current overload cycling faults occur on any phase within 90 min, the third fault in the 90 min period causes a safety shutdown. | 214 | |
| VSD – High Phase A, B, or C input current | HYP model drives. The stated phase input current exceeds 2,796 A. | Cycling shutdown. If three high input current cycling faults occur on any phase within 90 min, the third fault in the 90 min period causes a safety shutdown. | 214 | |
| VSD – High Phase A, B, or C motor current | HYP model drives. The stated phase motor current exceeds 2,164 A. | Cycling shutdown. If three high motor current cycling faults occur on any phase within 90 min, the third fault in the 90 min period causes a safety shutdown. | 215 | |
| VSD – High phase A, B, C instantaneous current | TM, VSD, and LVSD model drives. The motor current on that phase exceeds the given limit, sensed by current transformers on the VSD output pole assemblies. Maximum instantaneous currents: 351/292 – 771 A; 503/419 – 1,200 A; 790/658 – 1,890 A; 1055/914 – 2,749 A; 1300/1100 – 3,265 A. If the chiller restarts and runs fine, the cause is a voltage sag on the utility power feeding the VSD beyond the specified voltage range (especially at or near full load). If the chiller keeps tripping on this shutdown, an output pole problem is the most likely cause. | If the restart succeeds after a voltage sag, no further action indicated. If the chiller does not restart and keeps tripping, the VSD requires service. If this cycling shutdown occurs three times in 90 min, the third shutdown becomes a safety shutdown. | 215 | |
| VSD – Phase A, B, C gate driver | TM, VSD, and LVSD model drives. Second level of current protection on the VSD driver boards: the collector-to-emitter saturation voltage of each IGBT is checked continuously while gated on; the voltage across the IGBT exceeded the set threshold, so the IGBT is gated off and a shutdown pulse is sent to the VSD logic board shutting down the entire VSD system. Can be initiated when the VSD is not running. | 215 | ||
| VSD – Phase A, B, C motor gate driver | HYP model drives. One of the motor gate driver power supplies is operating outside of tolerance, or the voltage across the motor IGBT is too high; the gate driver board determines this shutdown and provides feedback to the VSD logic board. | 216 | ||
| VSD – Phase A, B, C input gate driver | HYP model drives. One of the input gate driver power supplies is operating outside of tolerance, or the voltage across the input IGBT is too high; the gate driver board determines this shutdown and provides feedback to the VSD logic board. | 216 | ||
| VSD – Single phase input power | All model drives. Generated by the SCR trigger control and relayed to the VSD logic board when the RMS value of any one of the three line-to-line voltages falls below the low limit in any half cycle. For HYP model drives the voltage and fault detection are all done by the VSD logic board. Low limits: 400–460 VAC TM/VSD – 230 VAC; 575 VAC TM/VSD – 300 VAC; 380 VAC or 415 VAC HYP – 264 VAC; 460 VAC HYP – 295 VAC. | 216 | ||
| VSD – High DC bus voltage | All model drives. The VSD DC bus voltage is continuously monitored and exceeded the limit. Thresholds: 380–440 VAC TM/VSD/LVSD – 745 VDC; 440–460 VAC TM/VSD/LVSD – 745 VDC; 575 VAC TM/VSD/LVSD – 909 VDC; all HYP – 985 VDC. | If this shutdown occurs, look at the level of the 460 VAC applied to the drive; the specified voltage range is 414 VAC to 508 VAC. If the incoming voltage exceeds 508 VAC, take steps to reduce the voltage to within the specified limits. | 216 | |
| VSD – Logic board power supply | All model drives. The low voltage power supplies for the logic boards have dropped below their allowable operating limits; they are derived from the secondary of the 120 VAC to 24 VAC transformer, which is derived from the 480 VAC to 120 VAC control power transformer. Usually means the power to the VSD has been removed. | 217 | ||
| VSD – Low DC Bus Voltage | All model drives. The DC bus voltage dropped below the limit; a common cause is a severe sag in the incoming power to the drive. Thresholds: 400 VAC TM/VSD/LVSD – 414 VDC; 460 VAC – 500 VDC; 575 VAC – 600 VDC; all HYP – 735 VDC. | The drive initiates a system shutdown. | 217 | |
| VSD – DC bus voltage imbalance | TM, VSD, and LVSD models. The 1/2 bus voltage is not within ±88 VDC for 400–460 VAC line or ±106 VDC for 575 VAC line of 1/2 of the total bus voltage. | 217 | ||
| VSD – DC bus pre-regulation | All model drives. The DC bus voltage has not increased to a value of ±50 V of the DC bus voltage setpoint within 2 s after entering the pre-regulation state; the setpoint depends on the rated input voltage of the VSD and the rated motor voltage (HYP thresholds: 380–415 in / 380–460 motor – 680; 460 / 380–460 – 750; 380–460 / 575 – 820). | After a delay of 10 s, the VSD attempts another pre-charge and pre-regulation cycle. If this shutdown occurs three consecutive times, the chiller locks out on a VSD – DC bus pre-regulation lockout. | 217 | |
| VSD – Precharge – DC bus voltage imbalance | All model drives. Same condition as the VSD DC bus voltage imbalance message, except the condition occurred during the pre-charge period. | 218 | ||
| VSD – High internal ambient temperature | All model drives. The drive ambient temperature, monitored by a sensor on the drive logic board, exceeded the high ambient trip threshold: 122°F (50°C) for TM, VSD, and LVSD models, or 158°F (70°C) for HYP model drives. | The fans and coolant pumps remain on until the internal ambient temperature has fallen to 115°F (46°C) for TM, VSD, and LVSD models, or 148°F (64°C) for HYP model drives. | 218 | |
| VSD – Invalid current scale selection | The part number of the VSD logic board is the same on all horsepower sizes; the position of the program jumpers tells the logic board the size of the VSD used so it can scale the output current. The jumper configuration is invalid. | A shutdown is performed. | 218 | |
| VSD – Invalid setpoints | HYP model drives. The VSD logic board determines which model of drive can run which model of motor; the control center provided a model of motor that is not compatible with this model of VSD. | When this condition clears, the chiller can be started after the Clear Faults key is pressed. | 218 | |
| VSD – Phase A, B, or C input DCCT offset | HYP model drives. Before the VSD enters the precharge state, the DCCT output is measured to verify it reads zero current correctly; the output of the DCCT is above a threshold determined by the drive logic board. The test is performed on all three input/rectifier DCCTs at the same time. | If this cycling shutdown occurs three times in a row on the same phase, a VSD – Phase A, B, or C input DCCT offset safety shutdown occurs. | 218 | |
| VSD – Line voltage phase rotation | HYP model drives. Internally to the drive the rotation must remain the same; the output of the line voltage isolation board cannot show CBA rotation when the input voltage is really ABC rotation. Two methods in the VSD logic board determine the line voltage phase rotation; they do not report the same phase rotation. | 219 | ||
| VSD – Low phase A, B, C inverter heatsink temperature | TM model drives. A heatsink temperature sensor indicates a temperature less than 37°F (2.8°C); in most cases the issue is an open thermistor or broken wiring to the thermistor. | The chiller shuts down. | 219 | |
| VSD – Low converter heatsink temperature | TM, VSD, and LVSD model drives. A thermistor sensor located on the SCR/diode block side of the copper chill plate on the drive power unit detects a temperature of 37°F (2.8°C) or lower. | A shutdown occurs. | 219 | |
| VSD – Low phase A, B, C input baseplate temperature | HYP model drives. The input/rectifier modules temperature drops below 37°F (2.8°C). | This shutdown cannot be reset until the temperature of all modules exceeds 42°F (5.6°C). The fans and pumps for the VSD continue to run until the temperature exceeds the reset level. | 219 | |
| VSD – Low inverter baseplate temperature | Single pole VSD and LVSD model drives. A thermistor sensor located inside the transistor modules on the drive power unit detects a temperature of 37°F (2.8°C) or lower. | A shutdown occurs. | 219 | |
| VSD – Low phase A, B, or C inverter baseplate temperature | 3-pole VSD and LVSD model drives. A thermistor sensor located inside the transistor modules on the drive power unit detects a temperature of 37°F (2.8°C) or lower. | A shutdown occurs. | 219 | |
| VSD – Low phase A, B, or C motor baseplate temperature | HYP model drives. The motor or inverter modules temperature drops below 37°F (2.8°C). | This shutdown cannot be reset until the temperature of all modules exceeds 42°F (5.6°C). The fans and pumps for the VSD continue to run until the temperature exceeds the reset level. | 220 | |
| VSD – Phase locked loop | HYP model drives. The drive automatically determines the input voltage frequency via the line voltage isolation board; the drive logic board cannot determine that the input voltage frequency is 50 Hz or 60 Hz. | 220 | ||
| VSD – Precharge – Low DC bus voltage 1 | All model drives. During precharge, the DC bus voltage must reach at least the low threshold determined by the line voltage setpoint within 4 s after the precharge signal is commanded; it did not. Thresholds: 380–415 VAC – 41 VDC; 460 VAC – 50 VDC; 575 VAC – 60 VDC. | The VSD logic board waits 10 s before clearing the fault and allowing another precharge to start; fans and water pumps remain energized. Up to three consecutive precharge-related faults are allowed; after the third, the safety shutdown message VSD – Precharge lockout is generated. | 220 | |
| VSD - Precharge - Low DC bus voltage 2 | All model drives. Near the end of precharge, the DC link voltage must reach at least the high threshold determined by the line voltage setpoint within 20 s after the precharge signal is commanded; it did not. Thresholds: 380–415 VAC – 414 VDC; 460 VAC – 500 VDC; 575 VAC – 600 VDC. | The VSD logic board waits 10 s before clearing the fault and allowing another precharge to start; fans and water pumps remain energized. Up to three consecutive precharge-related faults are allowed; after the third, the safety shutdown message VSD – Precharge lockout is generated. | 220 | |
| VSD – Logic board processor | All model drives. A communication problem occurs between the two microprocessors on the drive logic board. | 221 | ||
| VSD – Not running | All model drives. OptiView-generated: the VSD logic board communicates that it has received the run command but is not reporting that it is running for 8 s consecutively. | 221 | ||
| VSD – Run signal | All model drives. Redundant run signals are generated by the OptiView control center — one through TB6-24 and one through the serial communications link. When the VSD receives either run command a 5 s timer starts; the VSD logic board does not receive both run commands within 5 s. | A shutdown is performed by the VSD. | 221 | |
| VSD – Serial receive | Generated by the VSD logic board when communications between the microboard and the drive logic board are disrupted for at least 10 s. With the optional harmonic filter installed, the fault can also be generated when communications between the drive logic board and the harmonic filter logic board are disrupted. | 221 | ||
| Harmonic filter – High DC bus voltage | TM and VSD model drives. The harmonic filter logic board continuously monitors the filter DC link voltage (the filter has its own DC bus, not connected to the drive DC Link); the level exceeded the range: 400–460 VAC – 822 to 900 VDC; 575 VAC – 999 to 1,099 VDC. | This shutdown is initiated. | 221 | |
| Harmonic filter – High phase A, B, or C current | TM and VSD model drives. The maximum instantaneous harmonic filter current, monitored using two DCCTs and processed by the filter logic board, exceeded the preset limit: 292/351/424 hp – 378 ±59 A; 385/419/503/608 hp – 523 ±84 A; 658/704/790 hp – 782 ±118 A; 914/1,055 hp – 1,225 ±176 A; 1,100/1,300 hp – 1,700 ±154 A. | If the VSD automatically restarts and continues to operate correctly with the filter operating, the filter likely tripped due to a sag or surge in the voltage feeding the VSD. If this message reoccurs and prevents the chiller from starting, the VSD requires service. | 222 | |
| Harmonic filter – Phase locked loop | TM and VSD model drives. The phase locked loop circuit on the filter logic board has lost synchronization with the incoming power line; usually indicates an open fuse in one of the filter’s incoming power lines. | 222 | ||
| Harmonic filter – Precharge – Low DC bus voltage 1 | During filter precharge, the filter DC bus voltage must reach at least the high threshold determined by the line voltage setpoint within 0.1 s after the precharge signal is commanded; it did not. Thresholds: 400–460 VAC – 41 VDC; 575 VAC – 60 VDC. | This shutdown is generated by the harmonic filter logic board. | 222 | |
| Harmonic filter – Precharge – Low DC bus voltage 2 | Near the end of filter precharge, the filter DC bus voltage must reach at least the high threshold determined by the line voltage setpoint within 5 s after the precharge signal is commanded; it did not. Thresholds: 400–460 VAC – 425 VDC; 575 VAC – 630 VDC. | This shutdown is generated by the harmonic filter logic board. | 223 | |
| Harmonic filter – Low DC bus voltage | TM and VSD model drives. The filter generates its own boosted DC bus voltage (higher than obtainable by rectifying the input line) to permit current to flow into the power line at the input peak; the filter’s DC bus voltage decreased to a level less than 80 VDC (400–460 VAC line) or 100 VDC (575 VAC line) below the filter DC link voltage setpoint, which is set to the peak of the sensed input line-to-line voltage. | 223 | ||
| Harmonic filter – DC bus voltage imbalance | TM and VSD model drives. The DC bus uses series-connected capacitor sets that must share approximately half the total DC bus voltage each; while the filter is running, the difference in voltage between the two sets of capacitors is greater than 50 VDC (400–460 VAC line) or 65 VDC (575 VAC line). | A shutdown occurs. | 223 | |
| Harmonic filter – Input current overload | TM and VSD model drives. One of the three phases of RMS filter current continuously exceeds the given threshold for 40 s. Maximum continuous RMS ratings: 351/292 hp – 128 A; 503/419 hp – 176 A; 790/658 hp – 277 A; 1,055/914 hp – 385 A; 1,100/1,300 hp – 506 A. | A chiller shutdown is performed. | 223 | |
| Harmonic filter – Logic board power supply | TM and VSD model drives. The low voltage power supplies on the filter logic board have decreased below their permissible operating range; the filter logic board receives its power from the VSD logic board through the ribbon cable connecting the two boards. | 224 | ||
| Harmonic filter – Run signal | TM and VSD model drives. When a digital run command is received at the filter logic board from the VSD logic board through the 16-position ribbon cable, a 1/10 s timer starts; a redundant run command does not occur on the serial data link from the VSD logic board before the timer expires. | A shutdown is performed. | 224 | |
| Harmonic filter – DC current transformer 1 or 2 | TM and VSD model drives. During initialization, with no current flowing through the DCCTs, the DCCT output voltages are measured and compared with preset limits from the filter logic board; the measured values exceed the preset limits, so the DCCTs are presumed defective. | This shutdown is generated. | 224 |
Safety fault messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Auxiliary safety – Contacts closed | The auxiliary safety shutdown contacts, connected to I/O board TB4-31, have closed, initiating a safety shutdown. General-purpose, user-defined safety shutdown input. | The chiller can be started after the contacts open and the Clear button is pressed next to the listed event on the Systems Details Screen. | 225 | |
| Evaporator - Low pressure - Smart Freeze | Occurs when the Evaporator - Low pressure - Smart Freeze cycling fault has been set three times in 90 min. | The chiller can be restarted after the evaporator pressure has increased above the override threshold and the Clear button is pressed next to the listed event on the Systems Details Screen. | 226 | |
| Evaporator – Transducer or leaving liquid probe | Possible defective evaporator pressure transducer or LCHLT thermistor: the converted evaporator saturated temperature differs from the LCHLT by more than +25.0°F colder or 2.5°F warmer (acceptable range -2.5°F to +25.0°F) continuously for 10 min. Bypassed if the head pressure is less than 5 psid. | The chiller can be started after the Clear Fault key is pressed on the display. | 226 | |
| Evaporator – Transducer or temperature sensor | Possible defective evaporator pressure transducer or refrigerant temperature sensor: the difference between the converted evaporator saturation temperature and the optional evaporator refrigerant temperature sensor is greater than 3.0°F continuously for 1 min. Checked when: chiller running at least 10 min; evaporator refrigerant temperature (RT7) enabled; not in brine cooling mode; Smart Freeze enabled; RT7 or evaporator saturation temperature below 32.0°F (0°C). | The chiller can be started after the temperatures are within 3.0°F of one another and the Clear button is pressed next to the listed event on the Systems Details Screen. | 227 | |
| Compressor – Low discharge superheat | The discharge superheat has decreased to less than 1.0°F (0.5°C) for 5 min after the chiller has been running for 30 min, for all compressor and evaporator combinations. | This fault clears when the chiller is not running, and the Clear button is pressed next to the listed event on the Systems Details Screen. | 227 | |
| Control panel – Loss of control voltage | When the power failure reset is manual, this is a safety fault: the line power input signal at I/O board TB3-30 was low for 1 s continuously. This signal determines when digital inputs are affected by a line power loss rather than an actual device condition. | 227 | ||
| Control panel – Power failure | When the power failure restart is set to manual, this is a safety fault: a control power failure has occurred. | If the power failure duration was less than the applicable coastdown period when power is restored, the remainder of the coastdown is performed after power is restored. The chiller can be restarted after the Clear button is pressed next to the listed event on the Systems Details Screen. | 227 | |
| Condenser – High pressure contacts open | The contacts of the electromechanical high pressure safety switch have opened, causing the input to I/O board TB3-32 to cease while the control voltage signal at I/O board TB3-30 is high. | The chiller can be started after the contacts close and the Clear button is pressed next to the listed event on the Systems Details Screen. | 227 | |
| Condenser – High pressure | The condenser pressure, as sensed by the condenser transducer, has increased to more than 180.0 psig. Extended condenser temperature applications: trip/reset 200.0 psig/140 psig. High temperature heat pump applications: trip/reset 364.0 psig/340.0 psig. | The chiller can be started after the pressure decreases to less than 120.0 psig (extended range: 140 psig; high temperature heat pump: 340.0 psig) and the Clear button is pressed next to the listed event on the Systems Details Screen. | 228 | |
| Condenser – High pressure – Stopped | The condenser pressure exceeded 160.0 psig while the chiller was stopped. High temperature condenser water flowing through the condenser while shutdown can cause a high pressure condition resulting in loss of refrigerant; this fault anticipates that problem. Extended condenser temperature applications: trip/reset 170/170 psig. High temperature heat pump applications: trip/reset 358.0 psig/358.0 psig. | The chiller can be restarted after a service technician performs a special reset procedure. | 228 | |
| Condenser – Pressure transducer out of range | The condenser pressure transducer indicates a pressure less than 0.0 psig or more than 300.0 psig — outside the normal operating range; generally indicates a defective transducer. | The chiller can be started after the transducer indicates a pressure within range and the Clear button is pressed next to the listed event on the Systems Details Screen. | 228 | |
| Discharge – High temperature | The discharge temperature, as sensed by the discharge temperature thermistor, has increased to greater than 220.0°F (104.4°C). | The chiller can be started after the temperature decreases to less than 219.0°F (103.9°C) and the Clear button is pressed next to the listed event on the Systems Details Screen. | 228 | |
| Discharge - Low temperature | The discharge temperature, as sensed by the discharge temperature thermistor, has decreased to less than or equal to 30.0°F (-1.1°C). | The chiller can be started after the temperature increases to greater than 31.0°F (-0.6°C) and the Clear button is pressed next to the listed event on the Systems Details Screen. | 228 | |
| Internal error – No timer handles available | Set in the unlikely event that the operating system reports an error in providing a requested timer handle. | This message clears when the power to the panel is turned off and then back on. | 228 | |
| Isolation valves – Not opened | Isolation valves enabled on the setup screen; the isolation open output relay on LTC I/O TB17 has been energized for more than 40 s and the isolation valve opened digital input on LTC I/O board TB19-3,4 is low. | The fault is released when the chiller is not running and the Clear button is pressed next to the listed event on the Systems Details Screen. | 229 | |
| Oil - High viscosity | Only applies when oil quality protection and oil cooling control are enabled. After 30 min of running, the oil kinematic viscosity has been greater than the JCI Service programmable high viscosity trip threshold (default 30.0 cSt) for 5 min. | The fault can be cleared after the chiller has stopped and the Clear button is pressed next to the listed event on the Systems Details Screen. | 229 | |
| Oil - Low viscosity | Only applies when oil quality protection and oil cooling control are enabled. Either: after 10 min of running, the oil kinematic viscosity has been less than the JCI Service programmable low viscosity long trip threshold (default 8.0 cSt) for 5 min; or after 1 min of running, the viscosity has been less than the short trip threshold (default 6.0 cSt) for 10 s. | The fault can be cleared after the chiller has stopped and the Clear button is pressed next to the listed event on the Systems Details Screen. | 229 | |
| Oil - High dilution | Only applies when oil quality protection is enabled. After 10 min of running, the oil dilution is greater than the JCI Service programmable high dilution safety trip threshold (default 15.0%). | The fault can be cleared when the chiller has stopped and the Clear button is pressed next to the listed event on the Systems Details Screen. | 229 | |
| Oil - High sump temperature | The oil temperature, as sensed by the oil temperature thermistor, has increased to greater than 180.0°F (82.2°C). | The chiller can be started after the temperature decreases to less than or equal to 180.0°F (82.2°C) and the Clear button is pressed next to the listed event on the Systems Details Screen. | 229 | |
| Oil – High sump pressure | Heat pump mode enabled. Displayed when the chiller has been running less than 10 min and the oil sump pressure is greater than 140.0 psig for 10 s; also when running 10 min and the oil sump pressure is greater than 110.0 psig for 10 s, or instantly if the oil sump pressure is greater than 220 psig at any time. | The fault clears when the chiller is in a stopped state and the Clear button is pressed next to the listed event on the Systems Details Screen. | 230 | |
| Oil – High supply temperature | Oil cooling control enabled; after 5 min of running, the oil supply temperature, as sensed by the oil supply temperature thermistor, has increased 15°F (8.3°C) above the service-programmable oil supply temperature setpoint (default 120°F [48.9°C]) for 1 min. | The chiller can be started after the temperature decreases below the trip threshold and the Clear button is pressed next to the listed event on the Systems Details Screen. | 230 | |
| Oil – Low supply temperature | Oil cooling control enabled; after 5 min of running, the oil supply temperature, as sensed by the oil supply temperature thermistor, has decreased 15°F below the oil supply temperature setpoint for 1 min. | The chiller can be started after the temperature rises above the trip threshold or the chiller is in a stopped state, and the Clear button is pressed next to the listed event on the Systems Details Screen. | 230 | |
| Oil – Low differential pressure | The differential oil pressure (sump oil pressure transducer output minus pump oil pressure transducer output) decreased to less than 15.0 psid while running, or failed to achieve 25.0 psid by the last 5 s of the system prelube period. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details Screen while in a stopped state. | 230 | |
| Oil – High differential pressure | The differential oil pressure (sump oil pressure transducer output minus pump oil pressure transducer output) increased to greater than 120.0 psid while the oil pump was running. | The chiller can be started after the differential oil pressure decreases to less than 120.0 psid and the Clear button is pressed next to the listed event on the Systems Details Screen. | 230 | |
| Oil – Pump pressure transducer out of range | The pump oil pressure transducer (system high pressure) indicates a pressure less than 0.0 psig or greater than 300 psig — outside the normal operating range; generally indicates a defective transducer. | The chiller can be started after the transducer indicates a pressure within range and the Clear button is pressed next to the listed event on the Systems Details Screen. | 231 | |
| Oil – Sump pressure transducer out of range | The sump oil pressure transducer (system low pressure) indicates a pressure outside the normal operating range — less than 0.0 psig or more than 300 psig; generally indicates a defective transducer. | The chiller can be started after the transducer indicates a pressure within range and the Clear button is pressed next to the listed event on the Systems Details Screen. | 231 | |
| Oil – Differential pressure calibration | The sump and pump oil pressure transducers indicated a differential oil pressure of greater than 15.0 psid during the auto-zeroing period that begins 10 s into system prelube and lasts 3 s. Indicates a defective sump or pump transducer, since the oil pump is not running during this period and the actual differential is 0 psid. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details Screen. | 231 | |
| Oil – Variable speed pump – Setpoint not achieved | Occurred while in system prelube, system run, or system coastdown: the differential oil pressure is less than 35.0 psid for 5 s continuously during the last 10 s of the system prelube period or during the first 15 s of system run; or anytime after the first 30 s of system run, the differential oil pressure is less than the active oil pressure setpoint minus 5.0 psid with the speed command from the microboard at 60 Hz for 5 s continuously. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details Screen. | 231 | |
| Oil – Variable speed pump - High rate of change | After the chiller has been running for 90 s, the current oil pump frequency compared with previous frequencies in a set period of time (oil pump frequency difference) is greater than 1.5 Hz (default). Bypassed for 60 s if the oil pressure setpoint is changed during operation. | This safety fault immediately shuts down the chiller. The message is released when the Clear button is pressed next to the listed event on the Systems Details Screen. | 231 | |
| Motor or starter – Current imbalance | The 3-phase compressor motor current imbalance was greater than 30% continuously for 45 s. Not checked until the chiller has been running at least 45 s and the average of the three phases of motor current is greater than 80% of the programmed 100% chiller FLA. The LVSSS and VSD detect the condition and advise the OptiView microboard through serial communications. Not performed on electromechanical starter applications. | The fault is released when the chiller is in a stopped state and the Clear button is pressed next to the listed event on the Systems Details Screen. | 232 | |
| Motor – Current >15% FLA | Instantly set when the chiller is not running and a motor current of greater than 15% FLA is detected. | The oil pump is started as soon as this fault is detected (variable speed oil pump starting frequency 45.0 Hz). The start inhibit is released when the motor current decreases to less than 15%; a full system coastdown is performed when this fault is released. | 232 | |
| Motor – Lack of bearing lubrication | Auto lube type is none and the operating hours since last motor lubrication has exceeded the setpoint hours plus 200. Replaces Warning - Motor beaing lube required. | This safety shutdown remains in effect until the operator presses the Clear button next to the listed event on the Systems Details Screen and enters their initials, name, or user ID using the Motor Lube Acknowledge key on the motor lubrication screen; the date/time is logged and the operating hours since last lubrication reset to zero. | 232 | |
| Motor – Lack of bearing oil change | Auto lube type is sleeve and the operating hours since last motor lubrication is greater than or equal to 6,000 hours. Replaces Warning - Motor – Oil change required. | This safety shutdown remains in effect until the operator presses the Clear button next to the listed event on the Systems Details Screen and enters their initials, name, or user ID using the Motor Lube Acknowledge key on the motor lubrication screen; the date/time is logged and the operating hours since last lubrication reset to zero. | 233 | |
| Motor – High winding temperature | Either any of the enabled motor winding temperatures exceeded the programmed high winding temperature shutdown threshold plus the programmed winding hotspot allowance threshold for 3 s continuously, or the average winding temperature exceeded the programmed high winding temperature shutdown threshold for 3 s continuously. Does not occur when winding temperature protection is set to Disabled; does not act on open RTDs or disabled sensors. | The chiller can be started after all winding temperatures decrease to at least 18°F (10°C) below the shutdown threshold and the Clear button is pressed next to the listed event on the Systems Details Screen. | 233 | |
| Motor – High bearing temperature | Either of the enabled motor bearing temperatures exceeds the programmed high bearing temperature shutdown threshold for 3 s continuously. Does not occur when bearing temperature protection is set to disabled; does not act on open RTDs. | The chiller can be started after both bearing temperatures decrease to at least 9°F below the shutdown threshold and the Clear button is pressed next to the listed event on the Systems Details Screen. | 233 | |
| Motor – High bearing vibration | Either the shaft end or opposite shaft end motor bearing vibration has exceeded the value programmed for the high vibration shutdown setpoint for the programmed number of delay seconds. Does not occur when motor vibration protection is set to disabled or while the Warning – Motor – Bearing vibration baseline set warning is displayed. | The chiller can be started after both vibration values decrease below the shutdown threshold and the Clear button is pressed next to the listed event on the Systems Details Screen. | 233 | |
| Motor - Cooling coil leak | The motor cooling coil leak detector has registered a fault condition for at least 3 s continuously. With an optical sensor the input to the motor monitoring board goes high to indicate a leak; with a float switch the input goes low. Does not occur when the motor cooling coil leak protection setpoint is set to disabled. | The chiller can be started after the leak sensor no longer indicates a leak and the Clear button is pressed next to the listed event on the Systems Details Screen. | 234 | |
| Motor controller – Fault contacts open | MVVSD applications: the motor controller fault contacts connected to TB6-16 and TB6-53 in the OptiView Control Panel have opened three times in 15 min. | The chiller automatically restarts if it was running when the fault occurred. | 234 | |
| Safety stop | The panel safety stop hardware push button was pressed, removing input from the I/O board terminal TB3-28 for >500 ms continuous; also sets the local command to stop. | The chiller can be started when the push button is released, and the Clear button is pressed next to the listed event on the Systems Details Screen. | 234 | |
| Sales order – Invalid compressor model | The compressor code in positions 7 and 8 of the model number on the Sales Order Screen is invalid. | The fault clears when a valid code is entered, and the Clear button is pressed next to the listed event on the Systems Details Screen. | 234 | |
| Sales order – Invalid gear code | The gear code entered on the Sales Order Screen does not match the particular compressor code from the model number. | The fault clears when the gear code and compressor code are a valid combination, and the Clear button is pressed next to the listed event on the Systems Details Screen. | 234 | |
| Surge protection – Excess surge | Applies only if the surge protection shutdown feature is enabled and any of: hot gas disabled (SSS/EM), hot gas enabled with HGBP valve command 100% (SSS/EM), hot gas disabled with VSD at maximum frequency, hot gas enabled with HGBP 100% and VSD at maximum frequency. The surge window count exceeded the count limit setpoint. | If the extended run feature is disabled, the chiller shuts down as soon as the count exceeds the limit; if enabled, the shutdown occurs only if the count exceeds the limit at completion of the 10 min extended run period. The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details Screen. | 235 | |
| Thrust bearing – Proximity probe uncalibrated | The high speed thrust bearing proximity reference position has not been calibrated. Only applies to compressors that use proximity thrust bearing protection. | This fault can only be released when the compressor switch is placed in the stop position and the high speed thrust bearing proximity reference position is successfully calibrated. For MVVSD applications, a password is required to acknowledge the fault on the Proximity Probe Calibration Screen before the Clear button is pressed next to the listed event on the Systems Details Screen. | 235 | |
| Thrust bearing – Proximity probe clearance | The clearance between the compressor high speed thrust collar and the tip of the proximity probe has increased more than 10 ml or decreased to less than -25 ml for 0.2 s from the reference position (minimum allowed clearance 23 ml). Checked only during the last 20 s of system prelube, during system run and during coastdown. Only applies to compressors that use proximity thrust bearing protection. | The fault is released when the proximity position is less than +10 ml or greater than -25 ml from the reference position, or the proximity position is greater than 22 ml. The message is released when the compressor switch is placed in the stop position and the Clear button is pressed next to the listed event on the Systems Details Screen; a password is required to acknowledge the fault on the Proximity Probe Calibration Screen first. CAUTION: a qualified service technician must evaluate this shutdown before starting; restart is inhibited until the clearance is within acceptable limits and a special reset procedure is performed by the service technician. | 235 | |
| Thrust bearing – Proximity probe out of range | The clearance between the compressor high speed thrust collar and the tip of the proximity probe has decreased to less than 18 ml. Checked/detected only during the last 20 s of system prelube, during system run and during coastdown. Only applies to compressors that use proximity thrust bearing protection. | The fault is released when the proximity position is at least 18 ml. The message is released when the compressor switch is placed in the stop position and the Clear button is pressed next to the listed event on the Systems Details Screen; a special password is required to acknowledge the fault on the Proximity Probe Calibration Screen first. CAUTION: a qualified service technician must evaluate this shutdown before starting; restart is inhibited until the clearance is within +10 ml to -25 ml of the reference position and a special reset procedure is performed by the service technician. | 236 | |
| Thrust bearing – Limit switch open | The high speed thrust bearing limit switch contacts, connected to TB3-81, have opened — the bearing position has decreased to less than the allowed position. Only applies to compressors that use a sacrificial limit switch for thrust bearing protection. | The message is released when the chiller is in a stopped state and the Clear button is pressed next to the listed event on the Systems Details Screen; a special password is required to acknowledge the fault on the Proximity Probe Calibration Screen first. CAUTION: a qualified service technician must evaluate this shutdown before starting; restart is inhibited until the switch contacts have closed and a special reset procedure is performed by the service technician. | 236 | |
| Watchdog – Software reboot | The microboard software watchdog initiated a microprocessor reset because it detected that a portion of the chiller operating program was not being executed; generally indicates a severe electrical power disturbance or impending microboard failure. | The result is a safety shutdown and re-initialization of the program. The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details Screen. | 237 |
Liquid cooled solid states starter safety fault messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| LCSSS – 105% motor current overload | The highest phase of the compressor motor current increased to greater than 105% of the programmed 100% chiller FLA continuously for 40 s. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 238 | |
| LCSSS – High instantaneous current | The LCSSS logic/trigger board detected that the compressor motor current in any phase exceeded 1.15 (1.414 x RMS value of the programmed start current) for a minimum of 1 s. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 238 | |
| LCSSS – High phase A, B, or C heatsink temperature | The LCSSS logic/trigger board detected that the temperature of the phase A, B, or C SCR modules has exceeded 212°F (100°C) while the chiller was running. | The safety can be reset after all SCR temperatures are less than 210°F (98.9°C) and the Clear button is pressed next to the listed event on the Systems Details screen; however, the chiller cannot be started until all SCR temperatures are less than 109°F (42.8°C). During the shutdown, the starter cooling pump runs until the temperature is less than 109°F (42.8°C). | 238 | |
| LCSSS – Motor or starter – Current imbalance | Set by the LCSSS trigger/logic board; the calculation is the same as the OptiView uses. | 238 | ||
| LCSSS – Phase A, B, or C shorted SCR | A shorted SCR in phase A, B, or C has been detected by the LCSS logic/trigger board; the voltage across each SCR is monitored. The shorted condition must exist continuously for 5 s to annunciate the fault. This check is disabled while the chiller is running. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 238 | |
| LCSSS – Open SCR | An open SCR in phase A, B, or C has been detected by the LCSSS logic/trigger board; the open condition must exist continuously for 5 s to annunciate the fault. This check is disabled when the chiller is shut down. In certain applications, local power line conditions could interfere with the open SCR detection technique. | The chiller can be started after the condition has been corrected and the chiller is in a stopped state. Interference from local power line conditions requires a qualified service technician to disable this check. | 239 | |
| LCSSS – Phase rotation | The LCSSS logic/trigger board has detected the three phase compressor motor power line voltage phase rotation is not correct. | The chiller can be started after the phase rotation is correct and the Clear button is pressed next to the listed event on the Systems Details screen. | 239 |
Medium voltage solid state starter safety fault messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| MVSSS - Failed SCR | The starter has detected an open or shorted SCR. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 240 | |
| MVSSS – High instantaneous current | The starter controller board detected that the motor current in any phase exceeded the maximum rated amps for a minimum of 1 s. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 240 | |
| MVSSS – 105% motor current overload | The highest phase of the compressor motor current increased to greater than 105% of the programmed 100% chiller FLA continuously for 40 s. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 240 | |
| MVSSS – Motor or starter current imbalance | A current imbalance greater than 30% difference between phases has been detected for 45 s consecutively by the starter controller board. Bypassed for the first 45 s of runtime, and when motor current is below 80% FLA. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 241 | |
| MVSSS – Disconnect fault | The disconnect feedback indicates the switch has opened while running. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 241 | |
| MVSSS – Control board fault | The control board in the medium voltage solid state starter has detected a hardware or software problem. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 241 | |
| MVSSS – Ground fault | The ground fault current as detected by the starter has exceeded 50% FLA for 3 s. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 241 | |
| MVSSS – Contactor fault | The auxiliary hardwired contacts do not match the contactor status. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 241 | |
| MVSSS – Phase rotation | The starter controller board has sensed the three phase power line voltage phase rotation is not correct. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 241 | |
| MVSSS – High Heatsink 1, 2, or 3 temperature | The temperature sensed on the stated phase stack has exceeded 194°F (90°C) while running. | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 241 |
Medium voltage variable speed drive safety fault messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD - High instantaneous current | Becomes a safety fault when the cycling fault has occurred three times in 90 min. See Cycling faults. | The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 242 | |
| VSD - High phase A, B, or C inverter baseplate temperature | The stated phase heatsink temperature exceeds 175°F (79.4°C). | The drive releases the fault when all the heatsink temperatures fall below 145°F (62.8°C). The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 242 | |
| VSD - Main control board fault | The drive controller board has detected a hardware or software problem. | The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 242 | |
| VSD - Power transformer high temperature | Any one of the three input power transformer temperature sensors exceeds 392°F (200°C) (Hammond transformer) or 374°F (190°C) (Hitran transformer). | The drive releases the fault when the temperatures drop below the trip values. The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 243 | |
| VSD - High output frequency | The drive detects the output voltage frequency has exceeded 65 Hz for 60 Hz units or 55 Hz for 50 Hz units. | The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 243 | |
| MVVSD - Interlock fault | The drive has detected that one of the cabinet door interlocks or microswitches is open, indicating a door is not closed or secured. | The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 243 | |
| MVVSD - Ground fault | During startup and while running, the drive monitors the peak value of the current conducted through the neutral connection of the three inverter power assemblies and the earth (ground) lug; the ground current continuously exceeds 6 mA for 200 ms. | The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 243 | |
| VSD - 105% Motor overload current | The average of the three phase currents exceeds 1.05 times the 100% job FLA limit. | The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 243 | |
| MVVSD - Contactor fault | The auxiliary contact for the input contactor is not in the correct state (precharge contactor open fault), or the auxiliary contact for the input disconnect switch is in an incorrect state (input contactor open fault). | The chiller can be started after the fault is cleared on the starter, and the Clear button is pressed next to the listed event on the Systems Details screen. | 243 |
Variable speed compressor drive safety fault messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD – 105% motor current overload | All model drives. Generated by the VSD logic board when at least one of the three output phase currents has exceeded 105% of the chiller FLA value for greater than 7 s for TM model drives, and 40 s for VSD, LVSD, and HYP model drives. The chiller FLA value is set by the FLA potentiometer on the VSD logic board. | In a stopped state, the chiller can be started after the Reset push-button on the VSD logic board is pressed and the Clear button is pressed next to the listed event on the Systems Details screen. | 244 | |
| VSD - DC bus lockout - Do not cycle power | HYP model drives. When the unit is stopped in a mode where no command exists to energize the DC bus, the DC bus voltage is monitored and checked against a threshold of 100 VDC every 5 min; the DC bus voltage is higher than the threshold value. | When the condition clears and the VSD rectifier modules are tested, the chiller can be started. If power is removed and reapplied without correcting this problem, more damage occurs to the drive and the repair is more costly. | 245 | |
| VSD – DC bus pre-regulation lockout | HYP model drives. The unit fails to complete pre-regulation due to the VSD – DC bus pre-regulation fault; up to three consecutive pre-regulation related faults are allowed, and this shutdown is generated after the third consecutive fault. | The VSD waits 10 s before clearing the fault and allowing another precharge to start; unit fans and water pumps remain energized during the wait time. | 245 | |
| VSD – Frequency > 0 Hz | Set when the chiller is shutdown and a compressor motor VSD output frequency greater than 0 Hz is detected. | The oil pump is started (starting frequency 45 Hz) as soon as this fault is detected. The fault is released and the chiller can be started after the operator presses the Clear button next to the listed event on the Systems Details screen; a system coastdown is performed whenever this fault is released. | 245 | |
| VSD – Ground fault | HYP model drives. The sum of the three phases of instantaneous input current values is greater than 200 A for a period of 1 s. | 245 | ||
| VSD – High phase A, B, or C inverter heatsink temperature | TM model drives. The heatsink temperature exceeds 158°F (70°C) on any of the output pole assemblies. | Ensure the coolant level is adequate, verify the pump is operating when the chiller is running, and check the strainer in the primary of the heat exchanger for clogs and silt. The fans and water pump remain energized until all inverter heatsink temperatures fall below 155°F (68.3°C). The chiller can be started after the fault condition clears and the Clear button is pressed next to the listed event on the Systems Details screen. | 246 | |
| VSD – High converter heatsink temperature | TM, VSD, and LVSD model drives. The heatsink temperature exceeds 170°F (76.7°C), or 150°F (65.6°C) for VSD 1300/1100 hp. | The fans and water pump remain energized until all converter heatsink temperatures fall below 160°F (71.1°C), or 140°F (60.0°C) for VSD 1300/1100 hp. The chiller can be started after the fault condition clears and the Clear button is pressed next to the listed event on the Systems Details screen. | 246 | |
| VSD – High input current TDD | HYP model drives. The 3-phase input current TDD is monitored while the chiller is running; the highest phase of TDD is greater than or equal to 25% for 40 s continuously. | The chiller can be started when the Clear button is pressed next to the listed event on the Systems Details screen. | 246 | |
| VSD – High phase A, B, or C input baseplate temperature | HYP model drives. The input/rectifier IGBT module temperatures are continuously monitored by the gate driver board; the highest temperature per phase is compared against a threshold by the VSD logic board and an IGBT module exceeds it. Shutdown threshold: 1100 model – 170°F (76.6°C); 1300 model – 150°F (65.5°C). | The cooling fans and pumps for the VSD continue to run for 2 min after the fault occurred. The chiller can be started after the fault condition clears and the Clear button is pressed next to the listed event on the Systems Details screen. | 247 | |
| VSD – High phase A, B, or C input current | HYP model drives. Three high input current cycling shutdown faults have occurred on any phase within 90 min; the third fault in the 90 min period causes a safety shutdown. See Cycling faults. | The chiller can be started after the fault condition clears, and the Clear button is pressed next to the listed event on the Systems Details screen. | 247 | |
| VSD – High total demand distortion | HYP model drives. OptiView-generated shutdown when the highest phase of TDD is greater than or equal to 25%. | The chiller can be started when the highest phase TDD is less than 25%, and the Clear button is pressed next to the listed event on the Systems Details screen. | 248 | |
| VSD – High phase A, B, or C instantaneous current | TM, VSD, and LVSD model drives. Becomes a safety fault when the cycling fault has occurred three times in 90 min. See Cycling faults. | The chiller can be started after the fault condition clears, and the Clear button is pressed next to the listed event on the Systems Details screen. | 248 | |
| VSD – High phase A, B, or C motor current | HYP model drives. Three high motor current cycling shutdown faults have occurred on any phase within 90 min; the third fault in the 90 min period causes a safety shutdown. See Cycling faults. | The chiller can be started after the fault condition clears, and the Clear button is pressed next to the listed event on the Systems Details screen. | 248 | |
| VSD – Inverter program fault | HYP model drives. The drive is used on two different motor designs; the inverter software must be verified as correct for the motor design used. Three pieces of data must state that the correct inverter software is installed in the VSD logic board to prevent this shutdown. | 248 | ||
| VSD – Input DCCT offset lockout | HYP model drives. The drive contains three DCCTs to measure the input current; the Input DCCT offset cycling shutdown has occurred three times in a row on the same phase. | This safety shutdown is generated to require investigation and manual reset. See the Input DCCT Offset cycling shutdown for more details. | 248 | |
| VSD – Input current overload | HYP model drives. The input current overload value is 1.16 times the input job FLA value (not to exceed 1,305 A), accounting for installations where the input line voltage could be up to 10% below nominal, plus an additional 5% to reduce nuisance shutdowns; the value must be exceeded for 10 s continuously for this shutdown to occur. | To unload, the chiller can be started after the fault condition clears, and the Clear button is pressed next to the listed event on the Systems Details screen. | 249 | |
| VSD – Logic board plug | HYP model drives. A jumper is connected across the connector where the input and output currents connect to the drive logic board so the board can prove the connector is installed; the proof failed. | The chiller can be started after the fault condition clears, and the Clear button is pressed next to the listed event on the Systems Details screen. | 249 | |
| VSD – Logic board hardware | HYP model drives. After power is applied, the VSD logic board performs several internal tests to ensure correct operation of the input power device; the tests fail. | 249 | ||
| VSD – Low frequency detected | All model drives. After a 20 s bypass after entering system run, the VSD frequency decreases 1 Hz less than the minimum allowed frequency (25 Hz for 50 Hz units, 30 Hz for 60 Hz units) for 25 s continuously. | The message is released when the chiller is in a stopped state and the Clear button is pressed next to the listed event on the Systems Details screen. | 249 | |
| VSD - Motor current imbalance | All model drives. Generated by the drive logic board; becomes active when the highest of the three motor currents exceeds 80% of the programmed FLA and any one phase of motor current exceeds 30% of the average current for 45 s. | The chiller can be started after the fault condition clears, and the Clear button is pressed next to the listed event on the Systems Details screen. | 250 | |
| VSD – Motor current THD fault | HYP model drives. Protects the compressor motor from overheating due to current harmonics produced by the VSD; output voltage isolation board data determines the output frequency and output DCCT data determines the current harmonics presented to the motor, which are above the preset value determined by the drive logic board. | The chiller can be started after the fault condition clears, and the Clear button is pressed next to the listed event on the Systems Details screen. | 250 | |
| VSD – Phase A, B, or C motor DCCT | HYP model drives. Determines if the cable at the motor DCCT is connected; generated 1.5 s after the motor is commanded to run if the motor current does not exceed 25 A. | 250 | ||
| VSD – Phase A, B, or C input DCCT | HYP model drives. Determines if the cable at the input DCCT is connected; the input current in each phase to the VSD is measured during the precharge time and does not exceed 5 A in each phase. | 250 | ||
| VSD – Precharge lockout | All model drives. The VSD fails to make precharge; the precharge relay drops out for 10 s (fans and water pumps remain energized to cool the precharge resistors), precharge is retried, and fails on three consecutive tries. | The unit shuts down, locks out and displays this message. The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 250 | |
| VSD – Rectifier program fault | HYP model drives. After power is applied, the drive logic board verifies that the two software programs on the drive logic board are compatible with each other and that the application of the software matches the application of the VSD; they are not compatible. | 251 | ||
| Harmonic filter – High heatsink temperature | TM model drives. The temperature on any filter heatsink exceeds 167°F (75°C). | The chiller can be started after the fault condition clears, the OVERTEMP RESET button on the filter logic board is pressed, and the Clear button is pressed next to the listed event on the Systems Details screen. | 251 | |
| Harmonic filter – High baseplate temperature | VSD and LVSD model drives. The baseplate temperature exceeds the trip temperature. | The chiller can be started after the fault condition clears, the OVERTEMP RESET button on the filter logic board is pressed, and the Clear button is pressed next to the listed event on the Systems Details screen. | 251 | |
| Harmonic filter – High total demand distortion | TM, VSD, and LVSD model drives. OptiView shutdown indicating the filter is not operating correctly and the input current to the VSD/filter is not sinusoidal; the TDD exceeds 25% continuously for 45 s. In the YORK-supplied filter option, displayed TDD is the total RMS harmonic current supplied by the main power to the VSD divided by the chiller FLA, in percent (a standard VSD without the filter typically has an input current TDD of about 28% to 30%). | The chiller can be started after the Clear button is pressed next to the listed event on the Systems Details screen. | 251 |
From SSS 7L-B, 14L-B, 26L-B, 33L-B, 7LK-B, 14LK-B, 26LK-B, 33LK-B Style B Liquid Cooled Solid State Starter, Drives and Starters 160.00-O2
Original: docs.johnsoncontrols.com
Safety shutdowns
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| LCSSS - 105% MOTOR CURRENT OVERLOAD | The highest of the three phase RMS currents exceeds 100% FLA × 1.05 continuously for 40 seconds. | Programmed FLA incorrect on the OptiView™ control center; output CT's not reading current correctly; output current unbalanced; pre-rotation vanes or slide valve not working properly. | Safety shutdown: SCR gate outputs turn off, coastdown starts (150 seconds centrifugal / 2 minute lockout screw chillers), K1 relay de-energizes. After coastdown times out, place the Compressor Switch in Stop/Reset, then Start and release; the chiller will start if no faults are active. | 21 |
| LCSSS – HIGH PHASE X HEATSINK TEMPERATURE - RUNNING (X = A, B or C) |
Any one of the three SCR heatsink temperature sensors exceeds the 212°F shutdown threshold during a running condition. | Coolant level improper; coolant not pink or clear; coolant pump not working; heat exchanger dirty or no condenser water flow; heatsink assembly clogged. | Safety shutdown. The coolant pump continues to run until all temperatures are below 109°F. After the coastdown period, restart via Compressor Switch Stop/Reset then Start if the shutdown is no longer active. | 21 |
| LCSSS - HIGH INSTANTANEOUS CURRENT | Motor current in any phase reaches the shutdown threshold (programmed RMS starting current of 20–45% × Delta LRA, normal value 45%, converted to peak × 115%) and is maintained for one second. Current at threshold for less than one second does not trip. | Shorted SCR; motor shorted phase-to-ground or phase-to-phase; open SCR (if shutdown occurs during ramp up of the motor); open SCR gate; programmed starting current incorrect on the OptiView™ control center; output CT's not reading current correctly; open input fuse. | Safety shutdown. After the coastdown period, restart via Compressor Switch Stop/Reset then Start if the shutdown is no longer active. | 21 |
| LCSSS - OPEN SCR | Becomes active after the first 40 seconds of starter operation. Voltage across each SCR is monitored through an opto-coupler; if the signal is low for 5 consecutive seconds. | Gate drivers not operating; starting current value incorrect; motor overloaded on start (has been a problem on screw compressors); motor not connected; SCR gate open; open input fuse. | Safety shutdown. To help eliminate nuisance trips this shutdown can be disabled from the OptiView™ control center (refer to the service form for your style of chiller). After the coastdown period, restart via Compressor Switch Stop/Reset then Start if the shutdown is no longer active. | 22 |
| LCSSS – MOTOR OR STARTER-CURRENT IMBALANCE | Active after the starter has been running 45 seconds and the highest of the three motor currents exceeds 80% of programmed FLA; then any one phase of motor current exceeding 30% of the average current for 45 seconds. (Example: A=200A, B=200A, C=118A gives IAVE=173A, acceptable band 121A–225A; C at 118A shuts down.) | Input voltage to the starter abnormal; output CT's not reading current correctly; gate drive on the Logic/Trigger Board faulty. | Safety shutdown. After the coastdown period, restart via Compressor Switch Stop/Reset then Start if the shutdown is no longer active. | 22 |
| LCSSS - PHASE ROTATION | Input phase sequence wrong: when the "A" phase voltage transitions positive the "C" phase must be positive; when the "A" phase transitions negative the "B" phase must be positive. Only active during the first 30 line cycles after power is applied to the starter. | Phasing of the input power wiring incorrect. | Verify the phasing of the input power wiring. After the coastdown period, restart via Compressor Switch Stop/Reset then Start if the shutdown is no longer active. | 23 |
| LCSSS - PHASE X SHORTED SCR (X = A, B or C) |
Active any time the starter is not running. Opto-coupler output low (SCR turned on or shorted) for 5 continuous seconds, and the RMS phase voltage for that phase is approximately 90% of the selected input voltage range. If no voltage range has been selected on the OptiView™ control center, the voltage check is not performed. | One of the SCRs shorted. | Safety shutdown. To help eliminate nuisance trips this shutdown can be disabled from the OptiView™ control center (refer to the service form for your style of chiller). After the coastdown period, restart via Compressor Switch Stop/Reset then Start if the shutdown is no longer active. | 23 |
| MOTOR – PHASE ROTATION | YR chiller fault — this is not a fault of the LCSSS. The motor is turning in the wrong direction. | Motor wiring between the LCSSS and the chiller motor being reversed. | 23 |
Cycling shutdowns
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| LCSSS - HIGH SUPPLY LINE VOLTAGE | Phase-to-phase RMS input voltage exceeds the high supply limit for the programmed voltage range (e.g., 440–480 V: 523 V stopped / 524 V running) for 20 continuous seconds. Disabled for the first 20 seconds of the starter run; disabled entirely if no voltage range is programmed. | Improper voltage range selected on the OptiView™ control center; improper line voltage applied to the starter. | Cycling shutdown: after the coastdown period (150 seconds centrifugal / 2 minute lockout screw chillers) the chiller automatically restarts if the shutdown is no longer active and the compressor switch is still in the run position. | 25 |
| LCSSS INITIALIZATION FAILED | After power is applied to the OptiView™ control center, the Micro Board fails to get a response from the Logic/Trigger Board after ten communication attempts (approximately 20 seconds after power was applied). The Micro Board continues trying to communicate even after recording the shutdown. | Communication cable between the OptiView™ control center and the Logic/Trigger Board faulty; Logic/Trigger Board failed (CR6 blinking but CR7 not blinking); if both CR6 and CR7 blink every two seconds, perform the communication loop back test. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 25 |
| LCSSS - INVALID CURRENT SCALE SELECTION | P1 is not connected to J1, pulling the three starter-size determination inputs high. The presence of the P1/J1 connector is verified when power is applied; while disconnected, the three phase currents and kW values display as zero. Generally occurs during start-up of the chiller. | J1 connector not installed on the Logic/Trigger Board; J1 connector wiring faulty. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 26 |
| LCSSS - Logic Board Power Supply | Indicated whenever power is applied to the LCSSS. | Possible input power problems. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 26 |
| LCSSS - LOGIC BOARD PROCESSOR | Watchdog between the main system microprocessor and the DSP (normally communicating every 3 mSec): if the DSP does not respond after 80 attempts, a cycling shutdown occurs and the DSP is rebooted. The watchdog timer only resets if communications have been established. | If the problem continues, replace the Logic/Trigger Board. Automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 26 | |
| LCSSS - LOW PHASE X TEMPERATURE SENSOR (X = A, B or C) |
Any one of the three thermistors mounted on the SCR assemblies reads a value corresponding to 37°F or lower. Thermistors are connected to the Logic/Trigger Board at plugs P2, P3, P4. | Normally associated with an open thermistor; P2, P3, and P4 not connected to the Logic/Trigger Board; interconnection between the thermistor and the P2, P3, and P4 connectors faulty. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 26 |
| LCSSS - LOW SUPPLY LINE VOLTAGE | Phase-to-phase RMS input voltage falls below the low supply limit for the programmed voltage range (e.g., 440–480 V: 400 V stopped / 370 V running) for 20 continuous seconds. Disabled for the first 20 seconds of the starter run; disabled if no voltage range is programmed. | Improper voltage range selected on the OptiView™ control center; improper line voltage applied to the starter; during generator operation, the generator responding slowly to load changes. | If the problem occurs during generator operation, add some standby load to the generator so that it can respond more quickly to load changes. Automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 27 |
| LCSSS - PHASE LOCKED LOOP | The error signal of the synchronization circuit becomes too large and synchronization with the 'A' phase voltage is lost; if synchronization is not maintained the SCRs will misfire and damage the chiller. | Storms or power problems causing the frequency of the 'A' phase voltage to change too rapidly; during generator operation, JP1 jumper not cut (on Rev. C or earlier Logic/Trigger Boards); during generator operation, the generator responding slowly to load changes. | If the problem occurs during generator operation, ensure the JP1 jumper has been cut (Rev. C or earlier boards) and/or add standby load to the generator. Automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 27 |
| LCSSS - PHASE LOSS | Any one of the three phases of input line voltage drops below the threshold value (30% of the programmed input voltage range; e.g., 60 VAC if the range is disabled, 132 VAC for 440–480 VAC). | Many times a normal fault related to a storm or lightning; one of the three phases of input voltage absent (an input fuse may be open); improper voltage range selected on the OptiView™ control center. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 27 |
| LCSSS - POWER FAULT | Active after the first four seconds of a chiller start and after all three phases of motor current have exceeded 25% of FLA for one second; then any one phase of motor current dropping below a threshold of 10% FLA for three line cycles. Disabled just before the chiller is placed into coastdown to prevent nuisance shutdowns. | Many times a normal fault related to a storm or lightning; output CT's not reading current correctly. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 28 |
| LCSSS - RUN SIGNAL | The hardware 115 VAC start signal (between J5-2 wire #2 and TB1-3 wire #24) and the software run signal sent through the serial communications link are not both received by the main system microprocessor within 5 seconds of each other. | 115 VAC not applied between J5-2 wire #2 and TB1-3 wire #24; solder cracks around J5 and TB-1; serial communication link cable faulty. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 28 |
| LCSSS - SERIAL COMMUNICATIONS | Becomes active after successful completion of initialization: the Micro Board has tried to communicate ten times, or the Logic/Trigger Board has not received a transmission from the Micro Board within 20 seconds (shutdown occurs in approximately 20 seconds). Under this condition all starter information displayed on the OptiView™ control center will be zero. | Communication cable between the OptiView™ control center and the Logic/Trigger Board faulty; Logic/Trigger Board failed (CR6 blinking but CR7 not blinking); if both CR6 and CR7 blink every two seconds, perform the communication loop back test. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 28 |
| LCSSS - STOP CONTACTS OPEN | The K1 relay contacts open and no fault is detected in the serial communications link. | J1 connector not installed on the Logic/Trigger Board or no wire installed between J1-11 and J1-12; TB1-1 and TB1-2 improperly wired; communication cable between the OptiView™ control center and the Logic/Trigger Board faulty; K1 relay not working properly (replace the Logic/Trigger Board); Logic/Trigger Board failed (CR6 blinking but CR7 not blinking); if both CR6 and CR7 blink every two seconds, perform the communication loop back test. | Cycling shutdown: automatic restart after coastdown if the shutdown is no longer active and the compressor switch is still in the run position. | 29 |
Start inhibit
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| LCSSS - HIGH PHASE X HEATSINK TEMPERATURE – STOPPED (X = A, B or C) |
Any SCR heatsink temperature above the 110°F Start Inhibit threshold while the starter is not running prevents the chiller from starting. Not a fault condition — no events are logged into the History Log. The coolant pump continues to run as long as the Start Inhibit is active and the Remote Ready Relay contacts are open. | Normal after chiller coastdown: under normal running conditions the SCR temperature is typically greater than 110°F, so the SCRs must cool before each start or they will fail. | When the temperature of all three phases has fallen below 109°F, the coolant pump stops and the LCSSS is able to start (anti-recycle timer permitting). To shorten cool-down, the condenser water pump control (OptiView™ software C.MLM.01.04 or later on YK, C.MLM.02.01 or later on YT, C.MLM.03.01 or later on YS) keeps the condenser water pump running after coastdown while any thermistor reads above 105°F and less than one hour since the chiller was last stopped; it also turns the pump on after power restoration following a power fault under the same conditions, and turns off once all three thermistors are below 105°F. | 21 |
From YK Style D Millennium with MicroComputer Control Center 371-01200-010, 371-01200-011, 371-01200-015, for Electromechanical Starter, Solid State Starter and Variable Speed Drive 160.52-O1
Original: docs.johnsoncontrols.com
Warning Messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| WARNING: COND OR EVAP TRANSDUCER ERROR | Probable condenser or evaporator pressure transducer problem — transducer output unreasonable. | The microprocessor subtracts the evaporator transducer output from the condenser transducer output; the result must be zero or some positive number. If the result is a negative number, a probable condenser or evaporator transducer problem is concluded. This function is inhibited for the first 10 minutes of chiller run-time and is checked every 10 minutes thereafter. | Message is reset by pressing the WARNING RESET key in the Service mode. | 24 |
| WARNING - REFRIGERANT LEVEL OUT OF RANGE | Condenser refrigerant level has gone out of range (level 100%, sensor output greater than 4.4 VDC). | Refrigerant level is 100% (level sensor output greater than 4.4 VDC, indicating a level greater than 100%). While displayed, the variable orifice (level control actuator) is driven open until the level is within range. | Message is automatically cleared when the output is back within range; normal control is then resumed. No manual reset required. | 24 |
System Shutdown Messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| MON 10:00 AM - LOW WATER TEMP - AUTOSTART | Cycling shutdown — leaving chilled water temperature fell 4°F (2.2°C) below the chilled liquid temperature setpoint. | LCWT decreased to a value 4°F (2.2°C) below the operator-programmed chilled liquid temperature setpoint. If the setpoint is less than 40°F (4.4°C), the chiller always shuts down at 36°F (2.2°C). If the chiller is running and the setpoint is changed, the LWT cutout is a fixed 36°F (2.2°C) for 10 minutes to eliminate nuisance trips. For brine chilling applications the LWT cutout is always 4°F (2.2°C) below the setpoint (water jumper on Micro Board removed). Probable cause: system load is less than minimum capacity. | Automatic restart when water reaches setpoint; if the setpoint is increased 4°F (2.2°C) the system will continue to run, as the LWT cutout shifts to a fixed 36°F (2.2°C) for 10 minutes. | 25 |
| MON XX:XX AM - FLOW SWITCH - AUTOSTART | Cycling shutdown — chilled liquid flow switch open. | A chilled-liquid flow switch has opened; it must open for a minimum of 2 seconds to cause a shutdown. The flow switch is checked 25 seconds into "Start Sequence Initiated" and continuously thereafter. Probable cause: lack of water flow. | Automatic restart when water flow is restored (flow switch closes). Check operation of chilled water pump. | 25 |
| MON XX:XX AM - SYSTEM CYCLING - AUTOSTART | Cycling shutdown — remote cycling command received. | A remote command (computer relay contact or manual switch) connected to the Remote/Local cycling input of the digital input board has shut down the chiller. | Automatic restart upon remote command. | 25 |
| MON XX:XX AM - MULTI UNIT CYCLING - AUTOSTART | Cycling shutdown — lead/lag sequence control. | Lead/Lag sequence control accessory has shut down the chiller (contact connected to the Multi-Unit cycling input of the Digital Input Board). | Automatic restart upon remote command. | 25 |
| MON XX:XX AM - POWER FAILURE - AUTOSTART | Cycling shutdown — utility power interruption, auto-restart configuration. | There has been a power interruption or failure. Displayed when the Micro Board is configured for AUTO-RESTART AFTER POWER FAILURE (two-pin program jumper installed on the terminals labeled "Auto R" (J60); factory setting is manual restart). | Chiller will automatically restart when power is restored. | 25 |
| MON XX:XX AM - POWER FAILURE | Cycling shutdown — utility power interruption, manual-restart configuration. | There has been a power interruption or failure. Displayed when the Micro Board is configured for MANUAL RESTART AFTER POWER FAILURE (factory setting; two-pin jumper removed from the "Auto R" (J60) terminals). | When power is restored, press the COMPRESSOR switch to STOP/RESET position and then to START position. | 25 |
| AC UNDERVOLTAGE - AUTOSTART | Cycling shutdown — compressor proved not running while Control Center in RUN mode (AC undervoltage / loss of start signal). | Control Center was in RUN mode, displaying SYSTEM RUN - LEAVING TEMP CONTROL, but motor current was less than 10% FLA for 25 continuous seconds, indicative of an AC undervoltage condition that caused the start relay (1R) to de-energize. Checked when the Control Center goes into RUN mode (after 30 second pre-lube). Can be caused by failure of any component that would cause a loss of the start signal from the Control Center. Check is not performed when program jumper JP4 is removed (Steam Turbine applications). | Autostart (automatic restart). | 25 |
| MON XX:XX AM - INTERNAL CLOCK - AUTOSTART | Cycling shutdown — daily schedule stop time reached. | The operator-programmed daily stop schedule has shut down the chiller. | Will automatically restart when the operator-programmed daily start schedule indicates a start; can be overridden by pressing the COMPRESSOR switch to the START position. | 26 |
| REMOTE STOP | Cycling shutdown — remote stop command. | A remote device (typically an Energy Management System) has commanded the chiller to shut down. Message only displayed when Control Center is in REMOTE mode. | Chiller will restart upon application of a separate start signal from the remote device. | 26 |
| MON XX:XX AM - LOW EVAP PRESSURE | Safety shutdown — low evaporator pressure. | Evaporator pressure has decreased to 25.0 psig (172 kPa) (R-134a). | Chiller allowed to start when pressure increases to 25.1 psig (173 kPa) (R-134a). Press COMPRESSOR switch to STOP/RESET position and then to START position. | 26 |
| MON XX:XX AM - LOW EVAP PRESSURE - BRINE | Safety shutdown — external brine low evaporator pressure safety tripped. | The brine Low Evaporator Pressure (LEP) safety contacts have opened. The brine LEP safety is located external to the Control Center (not included with standard Control Center); cut-out settings vary with the brine application. | Wait until the safety contacts close, then press COMPRESSOR switch to STOP/RESET position and then to START position. | 26 |
| MON XX:XX AM - OIL PUMP DRIVE - AUTOSTART | Shutdown — oil pump variable speed drive protection tripped. | Oil pump VSD internal protection circuit has initiated a drive shutdown. | Message displayed until the oil pump VSD internal protection circuit permits the drive to run (autostart). | 26 |
| MON XX:XX AM - LOW OIL PRESSURE | Safety shutdown — low differential oil pressure. | Oil pressure has decreased to 15 PSID while running, or never achieved 25 PSID before the compressor start during the oil pump pre-lube run. Differential pressure is sensed by two pressure transducers. | Chiller allowed to restart when pressure increases to 25 PSID (173 kPa). Press COMPRESSOR switch to STOP/RESET position and then to START position. | 26 |
| MON XX:XX AM - HIGH OIL FLOW | Shutdown — oil pressure outside expected band (high oil flow condition). | Oil pressure is < 35 PSID (241 kPa) for 5 continuous seconds during the last 10 seconds of the compressor pre-lube or during the first 15 seconds of SYSTEM RUN; or the oil pressure is < the programmed OIL PRESSURE SETPOINT and the speed command is at 60Hz for 5 continuous seconds anytime after the first 30 seconds of SYSTEM RUN. | 27 | |
| MON XX:XX AM - HIGH PRESSURE | Safety shutdown — high condenser pressure. | Condenser pressure has increased to 180 psig (1241 kPa) (R-134a), prompted by the opening of the High Pressure (HP) safety control contacts; HP safety control is located on a mounting bracket above the oil-pump starter located on the condenser. | System allowed to restart when pressure decreases to 120 psig (827 kPa) (R-134a). Press COMPRESSOR switch to STOP/RESET position and then to START position. | 26 |
| MON XX:XX AM - EVAP TRANS OR PROBE ERROR | Safety shutdown — evaporator transducer/probe plausibility check failed. | Leaving chilled water temperature minus evaporator saturation temperature outside the range of -2.5°F (-19°C) to +25°F (-3.9°C) continuously for 10 minutes. On brine applications (program jumper JP3 removed) this check is not performed when the evaporator transducer is reading a pressure below its "out-of-range" threshold. On Steam Turbine applications (Micro Board program jumper JP4 removed) with EPROM version C.02F(T).12 or later, this check is bypassed for the first 20 minutes of chiller run time and then performed at the regular 10 minute intervals thereafter. | Press COMPRESSOR switch to STOP/RESET position and then to START position. | 26 |
| MON XX:XX AM - MOTOR CONTROLLER - EXT. RESET | Safety shutdown — starter / drive initiated shutdown requiring external reset. | A current module (CM-2 Electro-Mechanical starter application), the YORK Solid State Starter or the Variable Speed Drive initiated a shutdown. NOTE: the Solid State Starter 110°F (43.3°C) start inhibit does not require an external reset — anytime the chiller has been shut down for any reason, this message is displayed until the SCR heatsink temperatures decrease to below 110°F (43.3°C). | Reset the external device that caused the shutdown; the chiller will then automatically restart. | 27 |
| MON XX:XX AM - POWER FAULT - AUTOSTART | Cycling shutdown — motor controller power fault. | Solid State Starter or current module (CM-2 Electro-Mechanical starter application) "Power Fault" shutdown, sensed by the motor controller input to the digital input board; initiated by the motor controller contacts (CM-1) opening and reclosing in one second (less than 3 seconds per Table 1). If Solid State Starter application, the shutdown could have been caused by: phase rotation/loss, Trigger Board out of lock (OOL), Power Fault, or Half Phase — the appropriate light on the Solid State Starter Logic Board will be illuminated. | Chiller will automatically restart (following coastdown). | 27 |
| MON XX:XX AM - HIGH DISCHARGE TEMP | Safety shutdown — high discharge temperature. | Discharge temperature has increased to 220°F (104°C); sensed by thermistor RT2. | System allowed to restart when temperature has decreased to 219°F (103°C). Press COMPRESSOR switch to STOP/RESET position and then to START position. | 27 |
| MON XX:XX AM - HIGH OIL TEMP | Safety shutdown — high oil temperature. | Oil temperature has increased to 180°F (82.2°C); sensed by thermistor RT3. | System allowed to restart when temperature decreases to 179°F (81.6°C). Press COMPRESSOR switch to STOP/RESET position and then to START position. | 27 |
| MON XX:XX AM - HIGH OIL PRESSURE | Safety shutdown — high differential oil pressure. | Oil pressure has increased to 90 PSID (620 kPa). | Chiller allowed to restart when oil pressure decreases to 59 PSID (407 kPa). Press COMPRESSOR switch to STOP/RESET position and then to START position. | 27 |
| MON XX:XX AM - FAULTY COND PRESSURE XDCR | Safety shutdown — condenser pressure transducer out of range. | Condenser transducer is indicating a pressure of less than 6.8 psig (46.8 kPa) (R-134a) or a pressure greater than 300 psig (2068 kPa) (R-134a); generally indicative of a defective condenser transducer or the transducer has been disconnected. | After the problem has been corrected, press COMPRESSOR switch to STOP/RESET position and then to START position. | 27 |
| MON XX:XX AM - FAULTY OIL PRESSURE XDCR | Safety shutdown — oil pressure transducer out of range. | Either the high side or low side oil pressure transducer was out-of-range (displaying x's) while the chiller was running. | Press COMPRESSOR switch to STOP/RESET position and then to START position. | 27 |
| VANE MOTOR SWITCH OPEN | Safety shutdown — prerotation vanes not fully closed at start. | A system-start sequence has been initiated, but the pre-rotation vanes are not fully closed. Vanes are set improperly. | Restart automatically after the vane motor linkage is set properly; reset vane linkage and check vane positions using the SERVICE key switch and proper keys on the Microcomputer Control Center, then press COMPRESSOR switch to STOP/RESET and then to START switch. | 27 |
| MON XX:XX AM - STARTER MALFUNCTION DETECTED | Safety shutdown — motor current detected while compressor-start signal de-energized. | Control Center has detected a motor-current value greater than 15% FLA for 10 seconds minimum anytime the compressor-start signal is not energized. | Press COMPRESSOR switch to STOP/RESET position and then to the START position. Check motor starter operation; motor current value greater than 15% FLA. | 27 |
| MON XX:XX AM - LOW OIL TEMP DIFF - AUTOSTART | Cycling shutdown — insufficient oil-to-condenser saturation temperature difference. | Shut down for one of the following reasons: (1) chiller shut down for 30 minutes or less and oil temperature minus condenser saturation temperature is less than 20°F (11°C); (2) chiller shut down for more than 30 minutes and oil temperature minus condenser saturation temperature is less than 30°F (16.7°C); (3) following a power failure, oil temperature minus condenser saturation temperature is less than 30°F (16.7°C). This check is made only when the chiller is shut down — not when running or in "Start Sequence Initiated". | Chiller will restart automatically after the condition clears if the COMPRESSOR switch is in the RUN position. | 29 |
| DAY - TIME - OIL PRESSURE XDCR ERROR | Shutdown — oil pressure transducer auto-zero check failed. | Difference between the High Side Oil Pressure Transducer output and the Low Side Transducer output was greater than 15.0 PSID (103 kPa) during the "Transducer Auto-Zeroing Sequence" that occurs 10 seconds after a chiller start is initiated; message displayed immediately after the auto-zeroing sequence has completed. Indicates one of the transducer outputs is incorrect, possibly due to an incorrect or defective transducer. | Press COMPRESSOR switch to STOP/RESET position and then to START position. | 29 |
| MON XX:XX AM - FAULTY DISCHARGE TEMP SENSOR | Safety shutdown — discharge temperature sensor fault. | Discharge temperature has fallen below 30°F (-1°C), or the discharge temperature sensor is disconnected from the Micro Board. Probable cause: faulty discharge temp thermistor (RT2) or thermistor disconnected from Analog Input Board. | To restart when the discharge temperature rises or the sensor has been connected, press COMPRESSOR switch to STOP/RESET position and then to START position. Connect or replace open sensor. | 29 |
| MON XX:XX AM - PROX SENSOR SAFETY SHUTDOWN | Safety shutdown — high speed thrust collar axial position out of range. | "Proximity/Temperature Sensor" detected that the distance between the compressor high speed thrust collar and the sensor probe has increased by 10 mils or more, or decreased by 20 mils or more (25 mils with EPROM version C.02F(T).12 or later) from the "Reference Position". With EPROM version C.02F(T).11, if the reference position is < 42 mils the minimum allowed distance is 22 mils; with EPROM version C.02F(T).12 or later, if the reference position is < 44 mils the minimum allowed distance is 19 mils. | LOCKOUT — cannot be restarted until a qualified service technician performs a visual inspection of the high speed thrust bearing and performs the special reset procedure detailed in YORK Service manual Form 160.49-M2. Failure to perform the visual inspection prior to restarting the chiller could result in severe compressor damage. | 29 |
| DAY - TIME - FAULTY PROXIMITY PROBE | Safety shutdown — proximity probe fault (possible compressor damage). | "Proximity/Temperature Sensor" detected that the distance between the compressor high speed thrust collar and the sensor probe has decreased to 17 mils or less. Generally indicative of a defective proximity probe, but it is possible that the compressor has been damaged. | LOCKOUT — chiller cannot be restarted until the "Special Reset Procedure" in YORK Service manual Form 160.49-M2 is performed by a qualified service technician; the high speed thrust bearing must be inspected by a qualified service technician prior to starting the chiller, or further severe compressor damage could result. | 29 |
| MON XX:XX AM - HIGH SPEED DRAIN TEMP | Safety shutdown — high speed drain line temperature. | "Proximity/Temperature Sensor" detected the temperature of the high speed drain line has reached 250°F (121°C) or greater. | LOCKOUT — cannot be restarted until a qualified service technician performs a visual inspection of the high speed thrust bearing and performs the special reset procedure detailed in YORK Service manual Form 160.49-M2. Failure to perform the visual inspection prior to restarting the chiller could result in severe compressor damage. | 29 |
| MON XX:XX AM - OPEN DRAIN TEMP THERMOCOUPLE | Safety shutdown — open thermocouple / wiring fault in high speed drain temperature circuit. | "Proximity/Temperature Sensor" thermocouple or high speed drain temperature wiring between the "Proximity/Temperature Sensor" module and the Microcomputer Control Center has been disconnected or has a poor electrical connection. | Bearing inspection is not required (open thermocouple shutdowns typically indicate hardware or wiring defects and must not result in any damage to the compressor high speed thrust bearing); however, due to the critical nature of these circuits, a special reset procedure must be performed by a qualified service technician before the chiller can be restarted (Service manual Form 160.49-M2). | 30 |
| MON XX:XX AM - DC UNDERVOLTAGE | Safety shutdown — low +24 VDC supply to the Proximity/Temperature Sensor module. | The Micro Board monitors the +24VDC supply to the "Proximity/Temperature Sensor" module (which becomes unstable in operation at +17VDC); when the supply decreases to +19VDC the chiller is shut down, preventing invalid "Proximity Sensor Safety" or "High Speed Drain Temp" safety shutdowns. | Chiller will automatically restart when the voltage increases to greater than +19.7 VDC. | 30 |
| MON XX:XX AM - AUX SAFETY SHUTDOWN | Safety shutdown — user-defined auxiliary safety input. | An external device, connected to digital input board TB 1-31 (Auxiliary Safety Shutdown Input), has initiated a system shutdown. This input is a general purpose input that can be used to annunciate a user-defined safety shutdown. | Press COMPRESSOR switch to STOP-RESET position and then to START position. | 30 |
| REPLACE RTC U16 - REPROGRAM SETPOINTS | Alarm — real-time clock battery defective. | The battery located inside the REAL-TIME CLOCK IC chip (U16 on the Micro Board) is defective; this battery provides back-up power to the RTC memory (RAM) in the event of a utility AC power failure, assuring the system setpoints are maintained. | Replace RTC IC chip U16 (order YORK part number 031-00955-000): with AC power removed, remove existing RTC chip from socket and discard; observe anti-static precautions and install new chip with orientation notch UP. If there had been a power failure while this message was displayed, the setpoints were lost and must be reprogrammed; then proceed with normal start-up. | 30 |
| MON 10:00 AM LOW LINE VOLTAGE | Cycling shutdown — AC line voltage below undervoltage threshold (Solid State Starter applications). | AC power line voltage below the LOW LINE VOLTAGE CUTOUT point for the programmed supply voltage range for 20 continuous seconds. Trip/reset values: 380V range — cutout 305V, cutin 331V; 400V — 320/349V; 415V — 335/362V; 440-480V — 370/400V; 550-600V — 460/502V; Supply Voltage Range Disabled — protection none. | Chiller automatically restarts when all phases of line voltage increase to the minimum required starting level. Overvoltage/undervoltage protection can be disabled (SUPPLY VOLTAGE RANGE DISABLED); supply voltage range is factory-programmed and may only be changed by a service technician with special access code. | 11 |
| MON 10:00AM HIGH LINE VOLTAGE | Cycling shutdown — AC line voltage above overvoltage threshold (Solid State Starter applications). | AC power line voltage above the HIGH LINE VOLTAGE CUTOUT point for the programmed supply voltage range for 20 continuous seconds. Cutout (on rise)/cutin (on fall) values: 380V range — 415/414V; 400V — 436/435V; 415V — 454/453V; 440-480V — 524/523V; 550-600V — 655/654V; Supply Voltage Range Disabled — protection none. | Protection can be disabled (SUPPLY VOLTAGE RANGE DISABLED); supply voltage range is factory-programmed and may only be changed by a service technician with special access code. | 11 |
| Program Initiated Reset | Cycling shutdown — watchdog timer reset of the software program (shutdown cause listed in Table 1). | Watchdog timer circuit has reset the software program. | Chiller will automatically restart. | 47 |
| MTR Phase Current Unbalance (SSS Units only) | Safety shutdown — motor phase current unbalance (Solid State Starter applications; shutdown cause listed in Table 1). | Motor phase current unbalance; governed by the SSS Logic Board (operating point — see legend on wiring diagram / "Section 2"). | Press STOP/START switch then START switch. | 47 |
From YK Style E MaxE with OptiView Control Center for Electro-Mechanical Starter, Solid State Starter and Variable Speed Drive 160.54-O2
Original: docs.johnsoncontrols.com
Table 1 – Operation analysis chart
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Abnormally high discharge pressure | Temperature difference between condensing temperature and water off condenser higher than normal. | Air in condenser. | 23 | |
| Abnormally high discharge pressure | High discharge pressure. | Condenser tubes dirty or scaled | Clean condenser tubes. Check water conditioning. | 23 |
| Abnormally high discharge pressure | High condenser water temperature. | Reduce condenser water inlet temperature. (Check cooling tower and water circulation.) | 23 | |
| Abnormally low suction pressure | Temperature difference between leaving chilled water and refrigerant in evaporator greater than normal with high discharge temperature. | Insufficient charge of refrigerant in evaporator | Check for leaks and charge refrigerant into system. | 23 |
| Abnormally low suction pressure | Temperature difference between leaving chilled water and refrigerant in evaporator greater than normal with high discharge temperature. | Variable orifice problem. | Remove obstruction. | 23 |
| Abnormally low suction pressure | Temperature difference between leaving chilled water and refrigerant in the evaporator greater than normal with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean evaporator tubes. | 23 |
| Abnormally low suction pressure | Temperature of chilled water too low with low motor amperes. | Insufficient load for system capacity. | Check prerotation vane motor operation and setting of low water temperature cutout. | 23 |
| High evaporator pressure | High chilled water temperature. | Prerotation vanes fail to open. | Check the prerotation vane motor positioning circuit. | 23 |
| High evaporator pressure | System overload. | Be sure the vanes are wide open (without overloading the motor) until the load decreases. | 23 | |
| No oil pressure when the SYSTEM START button is pressed | Low oil pressure displayed on control center; compressor does not start. | Oil pump running in wrong direction. | Check rotation of oil pump (Electrical Connections). | 23 |
| No oil pressure when the SYSTEM START button is pressed | Low oil pressure displayed on control center; compressor does not start. | Oil pump not running. | Troubleshoot electrical problem with oil pump VSD. | 23 |
| Unusually high oil pressure develops when the oil pump runs | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure transducer defective. | Replace low or high oil pressure transducer. | 24 |
| Oil pump vibrates or is too noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. | Oil not reaching pump suction inlet in sufficient quantity. | Check oil level. | 24 |
| Oil pump vibrates or is too noisy | When the oil pump is run without an oil supply it vibrates and becomes extremely noisy. | Worn or failed oil pump. | Repair/Replace oil pump. | 24 |
| Reduced oil pump capacity | Oil pump pumping capacity. | Excessive end clearance pump. | Inspect and replace worn parts. | 24 |
| Reduced oil pump capacity | Oil pump pumping capacity. | Other worn pump parts. | Inspect and replace worn parts. | 24 |
| Reduced oil pump capacity | Oil pump pumping capacity. | Partially blocked oil supply inlet. | Check oil inlet for blockage. | 24 |
| Oil pressure gradually decreases (Noted by Observation of Daily Log Sheets) | When oil pump VSD frequency increases to 55 + hz to maintain target oil pressure. | Oil filter is dirty. | Change oil filter. | 24 |
| Oil pressure system ceases to return an oil or refrigerant sample | Oil refrigerant return not functioning. | Filter-drier in oil return system dirty. | Replace old filter-drier with new. | 24 |
| Oil pressure system ceases to return an oil or refrigerant sample | Jet or orifice of oil return jet clogged. | Remove jet, inspect for dirt. Remove dirt using solvent and replace. | 24 | |
| Oil pump fails to deliver oil pressure | No oil pressure registers when pressing OIL PRESSURE display key when oil pump runs. | Faulty oil pressure transducer | Replace oil pressure transducer. | 24 |
| Oil pump fails to deliver oil pressure | No oil pressure registers when pressing OIL PRESSURE display key when oil pump runs. | Faulty wiring/connectors. | 24 |
From YK Style F MaxE with OptiView Control Center for Electro-Mechanical Starter, Solid State Starter and Variable Speed Drive, Control Panel 160.73-O2
Original: docs.johnsoncontrols.com
Table 2: Operational analysis chart
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE | Temperature difference between condensing temperature and water off condenser higher than normal. High discharge pressure. | Air in condenser. | 25 | |
| 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE | Temperature difference between condensing temperature and water off condenser higher than normal. High discharge pressure. | Condenser tubes dirty or scaled. | Clean condenser tubes. Check water conditioning. | 25 |
| 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE | Temperature difference between condensing temperature and water off condenser higher than normal. High discharge pressure. | High condenser water temperature. | Reduce condenser water inlet temperature. (Check cooling tower and water circulation.) | 25 |
| 1. SYMPTOM: ABNORMALLY HIGH DISCHARGE PRESSURE | Temperature difference between condenser water on and water off higher than normal, with normal evaporator pressure. | Insufficient condensing water flow. | Increase the quantity of water through the condenser to proper value. | 25 |
| 2. SYMPTOM: ABNORMALLY LOW SUCTION PRESSURE | Temperature difference between leaving chilled water and refrigerant in evaporator greater than normal with high discharge temperature. | Insufficient charge of refrigerant. | Check for leaks and charge refrigerant into system. | 25 |
| 2. SYMPTOM: ABNORMALLY LOW SUCTION PRESSURE | Temperature difference between leaving chilled water and refrigerant in evaporator greater than normal with high discharge temperature. | Variable orifice problem. | Remove obstruction. | 25 |
| 2. SYMPTOM: ABNORMALLY LOW SUCTION PRESSURE | Temperature difference between leaving chilled water and refrigerant in the evaporator greater than normal with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean evaporator tubes. | 25 |
| 2. SYMPTOM: ABNORMALLY LOW SUCTION PRESSURE | Temperature of chilled water too low with low motor amperes. | Insufficient load for system capacity. | Check prerotation vane motor operation and setting of low water temperature cutout. | 25 |
| 3. SYMPTOM: HIGH EVAPORATOR PRESSURE | High chilled water temperature. | Prerotation vanes fail to open. | Check the prerotation vane motor positioning circuit. | 25 |
| 3. SYMPTOM: HIGH EVAPORATOR PRESSURE | High chilled water temperature. | System overload. | Be sure the vanes are wide open (without overloading the motor) until the load decreases. | 25 |
| 4. SYMPTOM: NO OIL PRESSURE WHEN SYSTEM START BUTTON PUSHED | Low oil pressure displayed on control center; compressor will not start. | Oil pump running in wrong direction. | Check rotation of oil pump (Electrical Connections). | 25 |
| 4. SYMPTOM: NO OIL PRESSURE WHEN SYSTEM START BUTTON PUSHED | Low oil pressure displayed on control center; compressor will not start. | Oil pump not running. | Troubleshoot electrical problem with oil pump VSD. | 25 |
| 5. SYMPTOM: UNUSUALLY HIGH OIL PRESSURE DEVELOPS WHEN OIL PUMP RUNS | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure transducer defective. | Replace low or high oil pressure transducer. | 26 |
| 6. SYMPTOM: OIL PUMP VIBRATES OR IS NOISY | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. | Oil not reaching pump suction inlet in sufficient quantity. | Check oil level. | 26 |
| 6. SYMPTOM: OIL PUMP VIBRATES OR IS NOISY | When oil pump is run without an oil supply it will vibrate and become extremely noisy. | Worn or failed oil pump. | Repair/Replace oil pump. | 26 |
| 7. SYMPTOM: REDUCED OIL PUMP CAPACITY | Oil pump pumping capacity. | Excessive end clearance pump. | Inspect and replace worn parts. | 26 |
| 7. SYMPTOM: REDUCED OIL PUMP CAPACITY | Oil pump pumping capacity. | Other worn pump parts. | Inspect and replace worn parts. | 26 |
| 7. SYMPTOM: REDUCED OIL PUMP CAPACITY | Oil pump pumping capacity. | Partially blocked oil supply inlet. | Check oil inlet for blockage. | 26 |
| 8. SYMPTOM: OIL PRESSURE GRADUALLY DECREASES (Noted by Observation of Daily Log Sheets) | When oil pump VSD frequency increases to 55 + hz to maintain target oil pressure. | Oil filter is dirty. | Change oil filter. | 26 |
| 9. SYMPTOM: OIL PRESSURE SYSTEM CEASES TO RETURN AN OIL/REFRIGERANT SAMPLE | Oil refrigerant return not functioning. | Filter-drier in oil return system dirty. | Replace old filter-drier with new. | 26 |
| 9. SYMPTOM: OIL PRESSURE SYSTEM CEASES TO RETURN AN OIL/REFRIGERANT SAMPLE | Oil refrigerant return not functioning. | Jet or orifice of oil return jet clogged. | Remove jet, inspect for dirt. Remove dirt using solvent and replace. | 26 |
| 10. SYMPTOM: OIL PUMP FAILS TO DELIVER OIL PRESSURE | No oil pressure registers when pressing OIL PRESSURE display key when oil pump runs. | Faulty oil pressure transducer. | Replace oil pressure transducer. | 26 |
| 10. SYMPTOM: OIL PUMP FAILS TO DELIVER OIL PRESSURE | No oil pressure registers when pressing OIL PRESSURE display key when oil pump runs. | Faulty wiring/connectors. | 26 |
From YK Style G Operation and Maintenance 160.75-O1
Original: docs.johnsoncontrols.com
Troubleshooting
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Leaving Chilled Liquid – Low Temperature Control | Safety control that shuts down the chiller. | Load continues to decrease after the pre-rotation vanes are entirely closed. | 15 | |
| Oil pressure safety cutout | Safety cutout that actuates and stops the system. | Excessive refrigerant absorbed in the oil during long idle periods; violent oil foaming as the pressure within the system is lowered on starting; if the foam reaches the oil pump suction, the bearing oil pressure fluctuates with a possible temporary loss of lubrication. | Actuates and stops the system. Refer to OptiView™ Control Center – Operation and Maintenance (Form 160.54-O1). | 23 |
| 1. Symptom: Abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Air in condenser. | 28 | |
| 1. Symptom: Abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Condenser tubes dirty or scaled. | Clean the condenser tubes. Check water conditioning. | 28 |
| 1. Symptom: Abnormally high discharge pressure | High discharge pressure. | High condenser water temperature. | Reduce the condenser water inlet temperature. Check the cooling tower and water circulation. | 28 |
| 1. Symptom: Abnormally high discharge pressure | The temperature difference between condenser water on and water off higher than normal, with normal evaporator pressure. | Insufficient condensing water flow. | Increase the quantity of water through the condenser to correct value. | 28 |
| 2. Symptom: Abnormally low suction pressure | Insufficient charge of refrigerant. | Check for leaks and charge refrigerant into the system. | 28 | |
| 2. Symptom: Abnormally low suction pressure | The temperature difference between the leaving chilled water and refrigerant in evaporator is greater than normal, with high discharge temperature. | Variable orifice problem. | Remove the obstruction. | 28 |
| 2. Symptom: Abnormally low suction pressure | The temperature difference between the leaving chilled water and refrigerant in the evaporator is greater than normal, with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean the evaporator tubes. | 28 |
| 2. Symptom: Abnormally low suction pressure | The temperature of chilled water is too low with low motor amperes. | Insufficient load for system capacity. | Check the pre-rotation vane motor operation and setting of the low water temperature cutout. | 28 |
| 3. Symptom: High evaporator pressure | Pre-rotation vanes fail to open. | Check the pre-rotation vane motor positioning circuit. | 28 | |
| 3. Symptom: High evaporator pressure | High chilled water temperature. | System overload. | Make sure that the vanes are wide open, without overloading the motor, until the load decreases. | 28 |
| 4. Symptom: No oil pressure when System Start button pressed | Low oil pressure displayed on Control Center; compressor does not start. | Oil pump is running in the wrong direction. | Check the rotation of oil pump (Electrical Connections). | 28 |
| 4. Symptom: No oil pressure when System Start button pressed | Low oil pressure displayed on Control Center; compressor does not start. | Oil pump is not running. | Troubleshoot electrical problem with oil pump VSD. | 28 |
| 5. Symptom: Unusually high oil pressure develops when oil pump runs | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure. Transducer defective. | Replace the low or high oil pressure transducer. | 28 |
| 6. Symptom: Oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. Note: When the oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Oil not reaching pump suction inlet in sufficient quantity. | Check the oil level. | 28 |
| 6. Symptom: Oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing OIL PRESSURE display key. Note: When the oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Worn or failed oil pump. | Repair or replace the oil pump. | 28 |
| 7. Symptom: Reduced oil pump capacity | Oil pump pumping capacity. | Excessive end clearance pump. Other worn pump parts. | Inspect and replace all worn parts. | 28 |
| 7. Symptom: Reduced oil pump capacity | Oil pump pumping capacity. | Partially blocked oil supply inlet. | Check the oil inlet for a blockage. | 28 |
| 8. Symptom: Oil pressure gradually decreases (Noted by observation of daily log sheets) | When oil pump VSD frequency increases to >55 Hz to maintain target oil pressure. | Oil filter is dirty. | Change the oil filter. | 28 |
| 9. Symptom: Oil pressure system ceases to return an oil or refrigerant sample | Oil refrigerant return not functioning. | Filter-drier in oil return system dirty. | Replace the old filter-drier with a new filter-drier. | 28 |
| 9. Symptom: Oil pressure system ceases to return an oil or refrigerant sample | Oil refrigerant return not functioning. | Jet or orifice of oil return jet clogged. | Remove the jet, and inspect for dirt. Remove all dirt using solvent and replace. | 28 |
| 10. Symptom: Oil pump fails to deliver oil pressure | No oil pressure registers when pressing OIL PRESSURE display key when oil pump runs. | Faulty oil pressure transducer. Faulty wiring or connectors. | Replace the oil pressure transducer. | 29 |
| high oil temperature (HOT) | Condition on which the unit shuts down. | Incorrect lubrication brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. However, if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed, notify the nearest Johnson Controls office to request the presence of a Johnson Controls Service Technician. | 35 |
| low oil pressure (OP) | Condition on which the unit shuts down. | Incorrect lubrication brought about by restricted oil lines, passages, or dirty oil filters. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. However, if aluminum particles continue to accumulate and the same conditions continue to stop the unit operation after a new filter is installed, notify the nearest Johnson Controls office to request the presence of a Johnson Controls Service Technician. | 35 |
From YK Style H Operation and Maintenance 160.76-O1
Original: docs.johnsoncontrols.com
Troubleshooting
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 1. Symptom: abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Air is in the condenser. | 30 | |
| 1. Symptom: abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Condenser tubes dirty or scaled. | Clean condenser tubes. Check water conditioning. | 30 |
| 1. Symptom: abnormally high discharge pressure | High discharge pressure. | High condenser water temperature. | Reduce condenser water inlet temperature. Check cooling tower and water circulation. | 30 |
| 1. Symptom: abnormally high discharge pressure | The temperature difference between condenser water on and water off is higher than normal, with normal evaporator pressure. | Insufficient condensing water flow. | Increase the quantity of water through the condenser to proper value. | 30 |
| 2. Symptom: abnormally low suction pressure | Insufficient charge of refrigerant. | Check for leaks and charge refrigerant into system. | 30 | |
| 2. Symptom: abnormally low suction pressure | The temperature difference between the leaving chilled water and the refrigerant in the evaporator is greater than normal with high discharge temperature. | Variable orifice problem. | Remove obstruction. | 30 |
| 2. Symptom: abnormally low suction pressure | The temperature difference between the leaving chilled water and the refrigerant in the evaporator is greater than normal with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean evaporator tubes. | 30 |
| 2. Symptom: abnormally low suction pressure | The temperature of chilled water is too low with low motor amperes. | Insufficient load for system capacity. | Check the motor operation of the pre-rotation vane and check the setting of the low water temperature cutout. | 30 |
| 3. Symptom: high evaporator pressure | Pre-rotation vanes fail to open. | Check the pre-rotation vane motor positioning circuit. | 30 | |
| 3. Symptom: high evaporator pressure | High chilled water temperature. System overload. | Be sure the vanes are wide open (without overloading the motor) until the load decreases. | 30 | |
| 4. Symptom: no oil pressure when system start button pushed | Oil pump running in wrong direction. | Check rotation of oil pump (Electrical Connections). | 30 | |
| 4. Symptom: no oil pressure when system start button pushed | Low oil pressure is displayed on the control center; the compressor does not start. | Oil pump not running. | Troubleshoot electrical problem with oil pump VSD. | 30 |
| 5. Symptom: unusually high oil pressure develops when oil pump runs | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure. The transducer is defective. | Replace low or high oil pressure transducer. | 30 |
| 6. Symptom: oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing the Oil Pressure display key. Note: When the oil pump is run without an oil supply, it vibrates and becomes extremely noisy. | Oil not reaching pump suction inlet in sufficient quantity. | Check oil level. | 30 |
| 6. Symptom: oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing the Oil Pressure display key. | Worn or failed oil pump. | Repair or, if necessary, replace the oil pump. | 30 |
| 7. Symptom: reduced oil pump capacity | Oil pump pumping capacity. | Excessive end clearance pump. Other worn pump parts. | Inspect and replace worn parts. | 30 |
| 7. Symptom: reduced oil pump capacity | Oil pump pumping capacity. | The oil supply inlet is partially blocked. | Check the oil inlet for blockage. | 30 |
| 8. Symptom: oil pressure gradually decreases (noted by observation of daily log sheets) | When the oil pump VSD frequency increases to 55 + Hz to maintain target oil pressure. | Oil filter is dirty. | Change oil filter. | 30 |
| 9. Symptom: oil pressure system ceases to return an oil/refrigerant sample | Filter-drier in oil return system dirty. | Replace old filter-drier with new. | 30 | |
| 9. Symptom: oil pressure system ceases to return an oil/refrigerant sample | Oil refrigerant return not functioning. | Jet or orifice of oil return jet clogged. | Remove jet, inspect for dirt. Remove dirt using solvent and replace. | 30 |
| 10. Symptom: oil pump fails to deliver oil pressure | No oil pressure registers when pressing the Oil Pressure display key when the oil pump runs. | Faulty oil pressure transducer. Faulty wiring/connectors. | Replace oil pressure transducer. | 31 |
Safety controls and panel warnings
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Oil heater thermostat (1HTR) | Protective thermostat, set to open at 180°F (82°C) to prevent overheating of the oil in the event of a control center component failure. | 15 | ||
| Leaving Chilled Liquid – Low Temperature Control | Safety control that shuts down the chiller. | Load continues to decrease after the pre-rotation vanes are entirely closed. | 16 | |
| Oil pressure safety cutout | Actuates and stops the system. | Excessive refrigerant in the oil causes violent oil foaming as the pressure within the system is lowered on starting (refrigerant boiling out of the oil); foam reaches the oil pump suction, so the bearing oil pressure fluctuates with possible temporary loss of lubrication. | 25 | |
| HOT | Unit shutting down on high oil temperature. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. If aluminum particles continue to accumulate, contact Johnson Controls Service. | 37 | |
| OP | Unit shutting down on low oil pressure. | Change the oil filter element. Examine the oil filter element for the presence of aluminum particles. Aluminum gas seal rings can contact the impeller and account for some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. If aluminum particles continue to accumulate, contact Johnson Controls Service. | 37 | |
| Warning message to re-lubricate | OptiView panel warning message; at the programmed value plus 400 hours this feature shuts down the chiller if re-lubrication is not addressed. | Programmed number of motor operating hours reached (default value is 1000 hours). | Re-lubricate the motor bearings. In plants where chillers run 24/7, there is more than 16 days of advance warning prior to shutting down the chiller. | 40 |
| Bearing temperature warning | Warning issued when bearing temperature exceeds 65°C (normal operating temperature for grease lubricated bearings is 40°C to 65°C / 100°F to 150°F). Indicates either the bearings are in need of lubrication or something is wrong. If temperature reaches 70°C, it generally indicates some type of problem. | Bearing temperature exceeds 65°C. | Operation should be checked. | 44 |
| Bearing RTD shutdown | Bearing RTDs are normally set to shut down the motors at 90°C (194°F); once this temperature is reached, the bearings most likely have already been compromised. | Bearing temperature reaches 90°C (194°F). | 42 |
From YK and YT Millennium Variable Speed Drive, Drives and Starters 160.00-O1
Original: docs.johnsoncontrols.com
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 |
From YK-CP with OptiView Control Center Operation and Maintenance Guide 160.96-O1
Original: docs.johnsoncontrols.com
Functional identification
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| PAH | Pressure alarm high (alarm) | 21 | ||
| PAHH | Pressure alarm high (shutdown) | 21 | ||
| PAL | Pressure alarm low (alarm) | 21 | ||
| PALL | Pressure alarm low (shutdown) | 21 | ||
| PDAL | Oil differential pressure alarm low (alarm) | 21 | ||
| PDALL | Oil differential pressure alarm low (shutdown) | 21 | ||
| PDAH | Oil differential pressure alarm high (alarm) | 21 | ||
| PDAHH | Oil differential pressure alarm high (shutdown) | 21 | ||
| TAH | Temperature alarm high (alarm) | 21 | ||
| TAHH | Temperature alarm high (shutdown) | 21 | ||
| TAL | Temperature alarm low (alarm) | 21 | ||
| TALL | temperature alarm low (shutdown) | 21 | ||
| TDALL | Oil temperature alarm low (shutdown) | 21 | ||
| FSALL | Flow switch alarm low (shutdown) | 21 | ||
| XC | Stall control | 21 | ||
| ZC | Thrust control | 21 | ||
| ZAH/ZAL | Thrust bearing probe alarm high or low (alarm) | 21 | ||
| ZAHH/ZALL | Thrust bearing probe alarm high or low (shutdown) | 21 | ||
| HPCO | High pressure cutoff | 21 | ||
| LOP | Low oil pressure | 21 | ||
| EHOP | High oil pressure, economizer compressor | 21 | ||
| PHOP | High oil pressure, primary compressor | 21 |
Maintenance
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Quarterly maintenance warning item (OptiView) | Monthly items are still required and appear on OptiView as a quarterly maintenance warning item. | Perform the monthly maintenance requirements. | 28 | |
| High oil temperature (HOT) shutdown | Unit shutting down on high oil temperature. | Change the oil filter element. Examine the oil filter element for aluminum particles. Aluminum gas seal rings can contact the impeller and cause some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. If aluminum particles continue accumulating, contact Johnson Controls Service. | 33 | |
| Low oil pressure (OP) shutdown | Unit shutting down on low oil pressure. | Change the oil filter element. Examine the oil filter element for aluminum particles. Aluminum gas seal rings can contact the impeller and cause some aluminum particles to accumulate in the oil filter, especially during the initial start up and first several months of operation. If aluminum particles continue accumulating, contact Johnson Controls Service. | 33 | |
| Warning message to re-lubricate (OptiView panel) | Motor bearing relubrication (greasing) due. Current YORK OptiView panels provide a warning message to re-lubricate beginning at a programmed number of operating hours (the default value is 1000 hours). | Programmed number of operating hours reached (default value 1000 hours). | Address re-lubrication. At the programmed value plus 400 hours this feature shuts down the chiller if re-lubrication is not addressed. In plants where chillers run 24/7, there is more than 16 days of advance warning prior to shutting down the chiller. | 37 |
| Bearing temperature warning (above 149°F (65°C)) | If the temperature exceeds 149°F (65°C), a warning is issued; it is an indication that either the bearings are in need of lubrication or that something is wrong. If temperature reaches 158°F (70°C), it generally indicates some type of problem. | Bearings in need of lubrication, or something is wrong. | Operation should be checked. | 41 |
| Bearing RTD motor shutdown (194°F (90°C)) | Bearing RTDs are normally set to shut down the motors at 194°F (90°C); when this temperature is reached, the bearings most likely have already been compromised. | 39 |
Troubleshooting
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 1. Issue: abnormally high discharge pressure | The temperature difference between the condensing temperature and water off condenser is higher than normal. | Air is in the condenser. | 42 | |
| The temperature difference between the condensing temperature and water off condenser is higher than normal. | Condenser tubes dirty or scaled. | Clean condenser tubes. Check water conditioning. | 42 | |
| High discharge pressure. High condenser water temperature. | Reduce condenser water inlet temperature. Check cooling tower and water circulation. | 42 | ||
| The temperature difference between condenser water on and water off is higher than normal, with normal evaporator pressure. | Insufficient condensing water flow. | Increase the quantity of water through the condenser to proper value. | 42 | |
| 2. Issue: abnormally low suction pressure | Insufficient charge of refrigerant. | Check for leaks and charge refrigerant into system. | 42 | |
| The temperature difference between the leaving chilled water and the refrigerant in the evaporator is greater than normal with high discharge temperature. | Variable orifice problem. | Remove obstruction. | 42 | |
| The temperature difference between the leaving chilled water and the refrigerant in the evaporator is greater than normal with normal discharge temperature. | Evaporator tubes dirty or restricted. | Clean evaporator tubes. | 42 | |
| The temperature of chilled water is too low with low motor amperes. | Insufficient load for system capacity. | Check the motor operation of the PRV and check the setting of the low water temperature cutout. | 42 | |
| 3. Issue: high evaporator pressure | PRVs fail to open. | Check the PRV motor positioning circuit. | 42 | |
| High chilled water temperature. | System overload. | Ensure the vanes are wide open (without overloading the motor) until the load decreases. | 42 | |
| 4. Issue: no oil pressure when system start button pushed | Low oil pressure is displayed on the control center; the compressor does not start. | Oil pump running in wrong direction. | Check rotation of oil pump (Electrical Connections). | 42 |
| Low oil pressure is displayed on the control center; the compressor does not start. | Oil pump not running. | Troubleshoot electrical problem with oil pump VSD. | 42 | |
| 5. Issue: unusually high oil pressure develops when oil pump runs | Unusually high oil pressure is displayed when the oil pressure display key is pressed when the oil pump is running. | High oil pressure. The transducer is defective. | Replace low or high oil pressure transducer. | 42 |
| 6. Issue: oil pump vibrates or is noisy | Oil pump vibrates or is extremely noisy with some oil pressure when pressing the Oil Pressure display key. Note: When the oil pump runs without an oil supply, it vibrates and becomes extremely noisy. | Oil not reaching pump suction inlet in sufficient quantity. | Check oil level. | 42 |
| Oil pump vibrates or is extremely noisy with some oil pressure when pressing the Oil Pressure display key. Note: When the oil pump runs without an oil supply, it vibrates and becomes extremely noisy. | Worn or failed oil pump. | Repair or, if necessary, replace the oil pump. | 42 | |
| 7. Issue: reduced oil pump capacity | Oil pump pumping capacity. | Excessive end clearance pump. Other worn pump parts. | Inspect and replace worn parts. | 42 |
| Oil pump pumping capacity. | The oil supply inlet is partially blocked. | Check the oil inlet for blockage. | 42 | |
| 8. Issue: oil pressure gradually decreases as noted by observation of daily log sheets | When the oil pump VSD frequency increases to 55 + Hz to maintain target oil pressure. | Oil filter is dirty. | Change oil filter. | 42 |
| 9. Issue: oil return system ceases to return an oil or refrigerant sample | Oil refrigerant return not functioning. | Filter-drier in oil return system dirty. | Replace old filter-drier with new. | 42 |
| Oil refrigerant return not functioning. | Jet or orifice of oil return jet clogged. | Remove jet, inspect for dirt. Remove dirt using solvent and replace. | 42 | |
| 10. Issue: oil pump fails to deliver oil pressure | No oil pressure registers when pressing the Oil Pressure display key when the oil pump runs. | Faulty oil pressure transducer. | Replace oil pressure transducer. | 43 |
| No oil pressure registers when pressing the Oil Pressure display key when the oil pump runs. | Faulty wiring or connectors. | 43 |
From YS and YK Water Cooled Refrigerant Recovery and Recycling Units Operation and Maintenance 50.40-OM1
Original: docs.johnsoncontrols.com
Detection and Removal of Non-Condensible Gases
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Pressure in the storage vessel exceeds the saturation pressure of the refrigerant at the ambient temperature | Presence of non-condensible gases – if the pressure exceeds the saturation pressure by the amount shown in Table 8, there is a need to vent the non-condensible gases | Vent the non-condensible gases from the Schraeder type valve located on the top of the storage vessel for a period of fifteen seconds; repeat until the saturation pressure in the storage vessel is within the pressure range shown in Table 8; allow the storage vessel and contained refrigerant to equalize to ambient temperature between ventings | 17 |
Checking Compressor for Performance
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Discharge pressure drops more than 5 Ibs. (34.5 kPa) in one minute | Indicates the discharge valves of the valve assembly are leaking | Leaking discharge valves of the valve assembly | Discharge valves should be replaced; if in doubt as to whether the discharge valves leak, turn the compressor over by hand – if pressure rises and falls with each revolution, this will confirm the discharge valve leak | 31 |
| Failure of a compressor to reach 25” (85 kPa) vacuum | Indicates leaky suction valves; all compressors should pump a 25” (85 kPa) vacuum against normal head pressures | Leaky suction valves | 31 |
Gurgling Noise – Vacuum Pump Model CRR-1
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Gurgling noise | The vacuum pump will gurgle when the oil level in the pump is low | Oil level in the pump is low | 43 | |
| Gurgling noise | The vacuum pump will gurgle when a large leak is present in the system being evacuated | Large leak present in the system being evacuated | 43 |
Suction and Discharge Pressure Problems – Vacuum Pump Model CRR-1
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Insufficient suction pressure | Insufficient suction or discharge pressure | Leakage; oil contamination; V-belt slippage; low oil level – four major causes of insufficient suction or discharge pressure | Determine the pump’s ultimate pressure capability: if the suction obtainable is very poor, the pump may be badly contaminated, low on oil or malfunctioning; if the pressure is only slightly higher than the guaranteed ultimate pressure of the pump, an oil change may be all that is required | 43 |
| Insufficient discharge pressure | Discharge pressure insufficient although the recovery and/or recycle system is free from leaks and sufficient suction exists | Insufficient flow of refrigerant vapor into the vacuum pump; low oil level; V-belt slippage; leak in the oil case of the vacuum pump | Check to see that the tubing connecting the suction port to the chiller is not obstructed; if none of these explanations fit the observations, the pump may be malfunctioning and should be sent back to a repair facility | 43 |
From 3630 OptiView Software V14B for YK Mod G to YK Mod J and YZ SI0637
Original: docs.johnsoncontrols.com
Updated Cycling Fault
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| MOTOR CONTROLLER - FAULT CONTACTS OPEN | Cycling fault for medium voltage variable speed compressor drives; no longer a hybrid safety fault. | At no time will this cycling fault become a safety fault for all starter applications. | 2 |
From 3630 OptiView Software Version V14 for YK Mod G and later, YK Mod H and J, YZ Mod A and YZD SI0610
Original: docs.johnsoncontrols.com
Display messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| WARNING – PURGE – EQ LOW SUCTION TEMP | Auto reset warning. Starting with Y.OPT.01.14.308 it does not inhibit purge operation. | Set conditions are the same as the previous WARNING – PURGE – EQUALIZATION LOW SUCTION TEMP. | Auto reset. | 13 |
| WARNING – PURGE – EQ LOW SUCTION TEMP INHIBIT | Manual reset warning. Inhibits purge operation. | Set when the WARNING – PURGE – EQ LOW SUCTION TEMP has been set 3 times in 1 hour. | Manual reset. | 13 |
| WARNING – PURGE – LOW COIL TEMP INHIBIT | Manual reset warning. Inhibits purge operation. | Purge coil temperature is less than -35°F. | Inhibits purge operation until the coil temperature is over -35°F and the Warning Reset key is pressed. | 13 |
| UPS – PERFORM BATTERY HEALTH CHECK | Start inhibit. | Set when the chiller shuts down on a MBC – POWER FAIL LANDING event. | The Battery Health Check must pass in order to clear the Power Failing fault. | 13 |
| OIL – HIGH VISCOSITY | Immediate safety fault. Only applies when the Oil Quality Protection AND Oil Cooling control are enabled. | Chiller has been running for 30 minutes and the Oil Kinematic Viscosity has been greater than the JCI Service programmable High Viscosity Trip Threshold (default is 30.0 cSt) for 5 minutes. | Fault can be cleared after the chiller has stopped and the Clear Fault key is selected. | 13 |
| OIL – LOW VISCOSITY | Safety fault. Only applies when the Oil Quality Protection AND Oil Cooling control are enabled. | Chiller has been running for 10 minutes and the Oil Kinematic Viscosity has been less than the JCI Service programmable Low Viscosity Trip Threshold Long Trip (default is 8.0 cSt) for 5 minutes; or the chiller has been running for 1 minute and the Oil Kinematic Viscosity has been less than the JCI Service programmable Low Viscosity Trip Threshold Short Trip (default is 6.0 cSt) for 10 seconds. | Fault can be cleared after the chiller has stopped and the Clear Fault key is selected. | 13 |
| OIL – HIGH DILUTION | Safety fault. Only applies when the Oil Quality Protection is enabled. | Chiller has been running for 10 minutes and the Oil Dilution is greater than the JCI Service programmable High Dilution Safety Trip Threshold (default is 15.0%). | Fault can be cleared when the chiller has stopped and the Clear Fault key is selected. | 13 |
| OIL – HIGH DILUTION INHIBIT | Start inhibit. Only applies when the Oil Quality Protection is enabled. | Oil Dilution is greater than the JCI Service programmable High Dilution Inhibit Trip Threshold (default is 20.0%). | Chiller can be started when the Oil Dilution is less than the High Dilution Start Inhibit Dilution Trip Threshold minus 0.2%. | 13 |
| OIL – LOW VISCOSITY INHIBIT | Start inhibit. Only applies when the Oil Quality Protection and Oil Cooling control are enabled. | Oil Viscosity is less than the JCI Service programmable Low Viscosity Inhibit Trip Threshold (default is 5.0 cSt) after 48 seconds of Pre-lube. | Chiller can be restarted after the Oil Viscosity is greater than the Low Viscosity Inhibit Trip Threshold plus 0.2 cSt. | 13 |
| MBC – INVALID SOFTWARE | Start inhibit. | MBC software major revision is greater than 0 and anything other than 5. | 13 | |
| WARNING – PURGE – EQUALIZATION LOW SUCTION TEMP | Auto reset warning (name used before Y.OPT.01.14.308). Inhibited purge operation while active. Renamed to WARNING – PURGE – EQ LOW SUCTION TEMP. | Auto reset. | 2 | |
| EVAPORATOR - TRANSDUCER OR LEAVING LIQUID PROBE | Safety fault. Starting with Y.OPT.01.14.308, only set when the head pressure is greater than or equal to 5 PSID. | 2 | ||
| MBC – POWER FAIL LANDING | Shutdown event; sets the Power Failing fault. | Battery Health Check must pass in order to clear the Power Failing fault (see UPS – PERFORM BATTERY HEALTH CHECK). | 2 | |
| WARNING - MOTOR - HIGH WINDING TEMPERATURE | Warning (YZ motor cooling). Threshold is the Motor High Winding Temp Fault Threshold minus 27.0°F. | 4 | ||
| MOTOR - HIGH WINDING TEMPERATURE | Safety shutdown (YZ motor cooling). Set at the Motor High Winding Temp Fault Threshold value (Admin programmable setpoint, default 270.0°F / 132.2°C). | 4 | ||
| MOTOR CURRENT > 15 %FLA | Start inhibit. Changed from a 5 second trip time to an immediate shutdown. | 6 | ||
| VSD - FREQUENCY > 0 HZ | Start inhibit. Changed from a 5 second trip time to an immediate shutdown. | 6 | ||
| VSD - HIGH PHASE A,B,or C INSTANTANEOUS CURRENT | Cycling fault for PYT model variable speed compressor drives only. Becomes a Safety fault if it occurs 6 times in 90 minutes (change from 3 times in 90 minutes). | 6 | ||
| VSD - HIGH PHASE A2,B2,or C2 INSTANTANEOUS CURRENT (dual) | Cycling fault for PYT model variable speed compressor drives only (dual). Becomes a Safety fault if it occurs 6 times in 90 minutes (change from 3 times in 90 minutes). | 6 | ||
| WARNING - OIL - HIGH SUMP PRESSURE | Auto reset warning (oil sump pressure events while in Heat Pump mode). | Any of the following, for the JCI programmable High Sump Pressure Trip Time (Oil Sump Setpoints screen): Oil Sump Pressure > 130.0 PSIG (42 C) AND Run Time < 10 Minutes; Oil Sump Pressure > 100.0 PSIG (34 C) AND Run Time >= 10 Minutes; or the oil sump pressure > 200 PSIG. | Auto reset. | 6 |
| OIL - HIGH SUMP PRESSURE | Safety fault (oil sump pressure events while in Heat Pump mode). | Any of the following, for the JCI programmable High Sump Pressure Trip Time (Oil Sump Setpoints screen): Oil Sump Pressure > 140.0 PSIG (42 C) AND Run Time < 10 Minutes; Oil Sump Pressure > 110.0 PSIG (34 C) AND Run Time >= 10 Minutes; or the oil sump pressure > 220 PSIG. | 7 | |
| OIL – LOW TEMPERATURE DIFFERENTIAL | Start inhibit. | Sets when the Oil Sump Temperature minus the Condenser Saturation Temperature is less than 40.0°F while the oil pump is running. | 8 | |
| OIL - HIGH SUMP PRESSURE – STOPPED | Start inhibit. | Oil Sump Pressure greater than 133.0 PSIG (changed from 132.0 PSIG). | Released when the pressure drops below 130.0 PSIG. | 8 |
From V.26 YK OptiView Chiller Control Panel, Control Panel SI0283
Original: docs.johnsoncontrols.com
Unit Safety Fault Codes
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| MVVSD – Excessive Shutdowns | Unit Safety Fault Code number 113, added with panel software version C.OPT.01.26.308 (P/N 031-02474-001) | 4 |
MVVSD Faults
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Input Power Supply fault | Fault generated by the MVVSD drive after 10 seconds of input power loss. During the first 10 seconds the drive deactivates the output to the compressor motor while maintaining adequate bus voltage charge level, and the OptiView control panel holds the condenser level control, PRV, VGD, and Hot Gas at the current commanded positions. | Input power supply drops below 85% of nominal voltage overall and is not restored within 10 seconds. | If the input power is restored within 10 seconds, the condenser level control, PRV, VGD, and Hot Gas are returned to automatic control and the VSD speed command is set to the same or slightly less than the VSD speed command prior to the input power loss. If the input power is restored within 30 seconds, an enhanced quick start is initiated: the condenser level control, PRV, VGD, and Hot Gas are returned to automatic control, coastdown is shortened and the chiller is transitioned to run while the compressor is potentially rotating. | 2 |
| Low Frequency Fault | Fault occurring when the VSD speed remains below the minimum speed longer than the allowed VSD Low Frequency Fault Time. | VSD speed below the minimum speed for longer than the VSD Low Frequency Fault Time. The VSD Low Frequency Fault Time (Power Fault Recovery screen, Button 8) is adjustable from 60 sec to 120 sec with a default of 60 sec, visible in view mode but only editable in Admin access level and above. When Power Fault Recovery Control is not enabled, this setting has no affect and the Low Frequency Fault will be the standard time of 25 seconds. | 3 |
From V24 YK OptiView Chiller Control Panel SI0265
Original: docs.johnsoncontrols.com
Subcooler Tube Freeze Prevention Logic
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Warning – Condenser – Freeze Threat From Low Pressure | Panel warning of a potential condenser/subcooler tube freeze threat while the chiller is stopped. | The chiller is Stopped and the Saturated Condenser Temperature falls below 35.0 °F. | This warning will automatically reset whenever the chiller is running or the Saturated Condenser Temperature is > 40.0 °F. | 2 |
| Condenser – Freeze Threat – Flow Switch Open | Panel warning of a potential condenser/subcooler tube freeze threat with the condenser flow switch open while the chiller is stopped. | The Chiller is Stopped, the Saturated Condenser Temperature < 35.0 °F and the Condenser Flow Switch has been open for > 60 seconds or longer. | This warning will automatically reset whenever the chiller is running or the Saturated Condenser Temperature is > 40.0 °F or the Condenser Flow Switch closes. | 2 |
From YK Centrifugal Chiller - Software Enhancements (V23), Control Panel SI0252
Original: docs.johnsoncontrols.com
VGD Screens
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Surge Avoidance Surge Detected | LED on the VGD screen (replaces the former "Surge Detected" LED). Illuminates when full speed surges are detected. | Full speed surges detected. | 1 | |
| ACC Surge Detected | LED added to the VGD screen; present when the Motor Drive Type setpoint is set to VSD and the Motor Communications Protocol setpoint is set to MODBUS. Illuminates when running at less than full speed. | Running at less than full speed. | 1 |
OIL SYSTEM
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Oil – Low Temperature Differential | Start inhibit. In this software version the condition is checked only when the chiller is stopped; previously it was checked while the chiller was stopped and during the first 10 seconds of Pre-lube. It is no longer checked during Pre-lube. | 2 | ||
| Warning - Standby Lube – Low Oil Pressure | Warning. In addition to the existing required conditions, it is now set when either the Pump Oil Pressure or the Sump Oil Pressure is less than 2 PSIG. | Pump Oil Pressure or Sump Oil Pressure less than 2 PSIG (with the existing required conditions also met). | Manual reset warning — cleared using the WARNING RESET key; the acknowledgement is entered in the Security Log. | 2 |
FAULTS
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD – High Phase (X) Instantaneous Fault | VSD Cycling fault. | If this Cycling fault occurs 3 times in 10 minutes, the third shutdown becomes a Safety fault. | 2 |
Warnings
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Warning – Harmonic Filter – Not Running | New warning added in this software version. | Set when ALL of the following are true for 20 continuous seconds: chiller is running; filter is enabled; filter present status is true; run time greater than 20 seconds; filter operating mode is "stopped". | The warning is released when the chiller is stopped, but will be displayed until manually cleared using the WARNING RESET key when logged in at Operator (or higher) Access Level. | 2 |
PUMP CONTROL
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Leaving Chilled Liquid – Flow Switch Open | Cycling shutdown. With this software version, the Chilled Water Pump contacts (TB2-44/45) remain closed while the chiller is shutdown on this cycling shutdown. | While the chiller is shutdown on this cycling shutdown, the Chilled Water Pump contacts (TB2-44/45) remain closed until the chiller is given a stop command or has another fault. | 3 | |
| Condenser – Flow Switch Open | Cycling shutdown. With this software version, the Condenser Pump contacts (TB2-150/151) remain closed while the chiller is shutdown on this cycling shutdown. | While the chiller is shutdown on this cycling shutdown, the Condenser Pump contacts (TB2-150/151) remain closed until the chiller is given a stop command or has another fault. | 3 |
SECURITY LOG – MANUAL RESET WARNINGS
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Condenser or Evaporator Transducer Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Standby Lube Low Oil Pressure Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Pump Oil Pressure or Sump Oil Pressure less than 2 PSIG (in addition to the existing required conditions). | Reset using the WARNING RESET key. | 4 |
| Excess Surge Detected Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Condenser or VGD Sensor Failure warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Conditions Override VGD Warning Reset | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Purge High Pressure Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Purge Float Switch Error Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Excess Purge Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Purge canister #X Full Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Setpoint Override Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Reset using the WARNING RESET key. | 4 | |
| Filter Not Running Warning | Manual reset warning. When acknowledged (by pressing the WARNING RESET button), the actual warning message being reset is now entered in the Security Log; previous versions logged a generic "Warning Reset" message. | Set when all of the following are true for 20 continuous seconds: chiller is running; filter is enabled; filter present status is true; run time greater than 20 seconds; filter operating mode is "stopped". | Released when the chiller is stopped; displayed until manually cleared using the WARNING RESET key when logged in at Operator (or higher) Access Level. | 4 |
From YK Centrifugal Chiller Software Enhancements (v21), Control Panel SI0212
Original: docs.johnsoncontrols.com
VSD High Instantaneous Current Fault
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD-High Phase X Instantaneous Current (VSD) VSD-High Instaneous Current (MVVSD) |
High instantaneous current fault on the variable speed drive; reported per phase (“Phase X”) on VSD units and as a general fault on MVVSD units. | Shutdown behaviour changed in software V21: previously a Cycling shutdown. In this version, the fault becomes a Safety shutdown if the same fault (on any phase) occurs 3 times in 90 minutes. The first 2 shutdowns within the 90-minute window remain Cycling shutdowns; if a third occurs within 90 minutes of the first, the third is a Safety shutdown that requires a manual restart. The 90-minute window applies to a High Instantaneous Fault on any phase: three faults on any phase in 90 minutes, or one fault on each of the three phases, results in the 3rd fault becoming a Safety shutdown. | 3 |
Oil Sump Enhancements
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Oil – Low Temperature Differential | Condition that prevents a chiller start. | Arises after the chiller has been running at low load conditions for extended periods, when the oil temperature gets too low. | Avoided in software V21 on P, Q and H9 compressor chillers: while the compressor is running, the Oil Return Solenoid (1SOL) is now cycled closed (de-energizing K12 relay) when the Oil Sump Temperature < OIL RETURN MIN Setpoint (programmable 80.0ºF to 110.0ºF, default 95.0ºF), and opened (energizing K12 relay) when Oil Sump Temperature > OIL RETURN MIN + 7°F, so the condition no longer prevents a chiller start. During coastdown and startup, solenoid operation is unchanged from standard logic (remains closed). | 4 |
From YK Centrifugal Chiller Software Enhancements Effective February 2003, Control Panel SI0058
Original: docs.johnsoncontrols.com
Oil Pressure Threshold
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Oil – High Differential Pressure | Safety shutdown; with this Flash Memory Card version the trip threshold for this safety shutdown is changed from 90 PSID to 120 PSID | 1 |
VSD Cycling Shutdown Messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD – Low Phase A Inverter Baseplate Temperature | Cycling shutdown message applicable to this VSD (p/n 371-03789-xxx) | The chiller has shutdown because the Baseplate temperature has decreased to <37 ºF. | 2 | |
| VSD – Low Phase B Inverter Baseplate Temperature | Cycling shutdown message applicable to this VSD (p/n 371-03789-xxx) | Same as Phase A: the chiller has shutdown because the Baseplate temperature has decreased to <37 ºF. | 2 | |
| VSD – Low Phase C Inverter Baseplate Temperature | Cycling shutdown message applicable to this VSD (p/n 371-03789-xxx) | Same as Phase A: the chiller has shutdown because the Baseplate temperature has decreased to <37 ºF. | 2 |
VSD Safety Shutdown Messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD – High Phase A Inverter Baseplate Temperature | Safety shutdown message applicable to this VSD (p/n 371-03789-xxx) | The chiller has shutdown because the Baseplate temperature has increased to >158 ºF. | 2 | |
| VSD – High Phase B Inverter Baseplate Temperature | Safety shutdown message applicable to this VSD (p/n 371-03789-xxx) | Same as Phase A: the chiller has shutdown because the Baseplate temperature has increased to >158 ºF. | 2 | |
| VSD – High Phase C Inverter Baseplate Temperature | Safety shutdown message applicable to this VSD (p/n 371-03789-xxx) | Same as Phase A: the chiller has shutdown because the Baseplate temperature has increased to >158 ºF. | 2 | |
| Harmonic Filter – High Baseplate Temperature | Safety shutdown message applicable to this VSD (p/n 371-03789-xxx) | The chiller has shutdown because the Baseplate temperature has increased to >194 ºF. | 2 |
From YK Centrifugal Chiller Software Enhancements Effective May 2004, Control Panel SI0089
Original: docs.johnsoncontrols.com
High Condenser Pressure Fault While Shutdown
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Condenser – High Pressure - Stopped | Anticipatory safety fault that annunciates a condenser high pressure condition while the chiller is stopped. | While the chiller is stopped, the condenser pressure exceeds 160.0 PSIG (R134a), 240.0 PSIG (R22). High temperature condenser water flowing through the condenser while the chiller is shutdown can cause a condenser high pressure condition resulting in loss of refrigerant. | The chiller can be started after the condenser pressure decreases to less than 160.0 PSIG (R134a), 240.0 PSIG (R22) and a special reset procedure is performed: 1. Place the COMPRESSOR switch in the Stop-reset position. 2. At the keypad, login at Service access level using code 1 3 8 0. 3. Select COMPRESSOR screen. 4. Press the FAULT ACKNOWLEDGE key on the COMPRESSOR Screen. A dialog box appears displaying "Enter Password to Clear Fault". 5. Enter 1 3 9 7 and press the ENTER key (√). | 1 |
| Condenser – High Pressure | Condenser high pressure fault detected while the chiller is in Pre-lube, System Run or Coastdown. | Handled in the normal way; does not require the special reset procedure. | 1 |
Style B Solid State Starter Faults
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| LCSSS – OPEN SCR | Open SCR (Silicon Controlled Rectifier) fault message displayed by the Optiview Control Center when the fault data returned from the starter does not identify the phase in which the fault occurred (starters equipped with eprom version C.SSS.01.00 through C.SSS.01.02 in the starter Logic/Trigger Board). | Open SCR fault detected by the Style B Liquid Cooled Solid State Starter (LCSSS). When the Solid State Starter initiates a shutdown, the fault data transferred to the Optiview Control Center is a function of the eprom (U16) in the starter Logic/Trigger Board. | 2 | |
| LCSSS – Phase X Open SCR | Open SCR fault message that identifies the defective phase (X replaced by A, B or C as appropriate). Displayed when this Flash Memory Card version is used with a starter Logic/Trigger Board equipped with version C.SSS.01.03 (and later) eprom. | Open SCR condition detected by the Style B Liquid Cooled Solid State Starter; the C.SSS.01.03 (and later) eprom returns fault data that identifies the phase in which the Open SCR condition is detected. | 2 | |
| LCSSS – Phase X Heatsink Temperature – Stopped | Start Inhibit Fault (X replaced by A, B or C as appropriate) detected by the Style B Liquid Cooled Solid State Starter. | No longer logged on the History Screen in this software version; continues to be displayed on the System Details line of the display and transferred to the MicroGateway. | 2 |
From YK Centrifugal Chiller Using OptiView Control Center Microboard Update Effective January 2004, Control Panel SI0072
Original: docs.johnsoncontrols.com
DIAGNOSTIC DISPLAY CODES
Microboard boot-up self-test codes shown on the 7-segment LED display (U22) and/or the white boot-up screen. Pass codes appear briefly as each test runs; the entries below show the documented fail indications.
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 00 | First init table complete (boot-up test step) | On fail: watchdog will cause reboot | 4 | |
| 01 | SDRAM regs. Configured (boot-up test step) | On fail: watchdog will cause reboot | 4 | |
| 02 | Switch to Protected Mode (boot-up test step) | On fail: watchdog will cause reboot | 4 | |
| 03 | Jump to 32-bit code (boot-up test step) | On fail: watchdog will cause reboot | 4 | |
| 04 | Low memory test start (boot-up test step) | On fail: watchdog will cause reboot | 4 | |
| F1 | Low memory test failed (“Low memory test complete” step) | “F1” on display and halt | 4 | |
| F2 | Full memory test failed (“Full memory test complete” step) | “F2” on display and halt | 4 | |
| P2 (remains on LED display) | FPGA configuration failed (note: P2 is also the pass code for “Full memory test complete”) | “P2” will remain on LED display | 4 | |
| 05 (remains on LED display) | Display Cont. configuration failed | “05” will remain on LED display | 4 | |
| F3 | Flash Checksum Test failed | “F3” will remain on LED display | 4 | |
| F4 | BRAM test failed | “F4” will remain on LED display | 4 | |
| Flash Query Test – “failed” | Flash Query Test failed | “failed” and halt (displayed on white screen) | 4 | |
| Flash checksum – “failed” | Flash checksum failed | “failed”, halt & display code = F3 (displayed on white screen) | 4 | |
| BRAM Test – “failed” | BRAM Test failed | “failed” and halt (displayed on white screen) | 4 |
MISCELLANEOUS CODES
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| FF | FPGA Configuration failed, trying again | 4 |
CRITICAL CODES
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Ni | NMI handler invoked (should never occur) | 4 |
From YK Chiller - Software Enhancements (V20), Control Panel SI0210
Original: docs.johnsoncontrols.com
Medium Voltage Variable Speed Drive
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| INVALID | The MV VSD Model, shown on the MV VSD Screen in the data box labeled “MV VSD Model”, cannot be resolved. | The model number derived from the Motor Rated Voltage (Modbus Address 40012) and the Programmed Drive Current (Modbus Address 40013) results in a model that is not defined in the lookup table. | The chiller will not be allowed to run while this is displayed. | 2 |
| INVALID | Invalid Motor Voltage Rating received from the MV VSD; “INVALID” replaces the voltage reading in the “Motor Voltage Rating” display on the MV VSD Screen. | An invalid “Motor Voltage Rating” value was received from the MV VSD. | The chiller will not be allowed to run while this is displayed. | 2 |
| INVALID | Invalid rated output frequency received from the MV VSD; “INVALID” is shown in the “Output Frequency Rating” data box on the MV VSD Screen. | The rated output frequency (Modbus Address 40033) received from the MV VSD is not 50Hz or 60Hz. | In this case the “Motor Voltage Rating” determines the maximum frequency: 2300 or 4160V = 60Hz; 3300V = 50Hz. | 2 |
| VSD – Low Frequency Detected | Safety fault on the variable speed drive output frequency. | After a 20 second bypass after entering “System Run”, the frequency is below 1Hz less than the minimum allowed running frequency for 25 consecutive seconds. (Software enhancement: the previous requirement to reach the minimum frequency before the fault can be detected has been eliminated, and 20 and 25 second timers have been added.) | The fault will shutdown the chiller. | 2 |
From YK Chiller Software Enchancements - Vers19, Control Panel SI0201
Original: docs.johnsoncontrols.com
Extended Condenser Temperature Range
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Warning – High Pressure Limit | Warning threshold belonging to the warning and safety shutdown thresholds affected by the CONDENSER TEMPERATURE RANGE setpoint on the Setup Screen. When that setpoint is set to "Extended", the maximum allowable value is 193.0 PSIG, with no change to the default value. When set to "Standard", the threshold is unchanged. | 11 | ||
| Condenser – High Pressure – Stopped | Condenser high pressure safety shutdown threshold ("Stopped" variant). When the CONDENSER TEMPERATURE RANGE setpoint is set to "Extended", the Trip/Reset threshold is 170 PSIG. When set to "Standard", the threshold is unchanged. | Trip/Reset threshold is 170 PSIG (Extended range setting). | 11 |
Italian Language Corrections
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Condenser-Pressure Transducer out Of Range | Message listed in this bulletin only because its Italian translation was corrected in this software version; no cause or action details are given for it in this document. | 10 | ||
| VSD-Low Converter Heatsink Temperature | Message listed in this bulletin only because its Italian translation was corrected in this software version; no cause or action details are given for it in this document. | 10 | ||
| Control Panel-Power Failure | Message listed in this bulletin only because its Italian translation was corrected in this software version; no cause or action details are given for it in this document. | 10 | ||
| Vane Motor Switch Open | History Screen message listed in this bulletin only because its Italian translation was corrected in this software version; no cause or action details are given for it in this document. | 10 | ||
| Leaving Chilled Liquid – Flow Switch Open | History Screen message listed in this bulletin only because its Italian translation was corrected in this software version; no cause or action details are given for it in this document. | 10 |
From YK Chiller Software Enhancements (Ver 16), Control Panel SI0164
Original: docs.johnsoncontrols.com
CHILLED AND CONDENSER WATER – FLOW SWITCH SHUTDOWNS
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Leaving Chilled Liquid – Flow Switch Open | Chilled water flow switch shutdown. | The chilled water flow switch has remained open for 5 continuous seconds (2 continuous seconds with software version C.OPT.01.15A.xxx and earlier) while the chiller is running, or failed to close during the Pre-Lube period. | The chiller will automatically restart when the flow switch closes. | 1 |
| Condenser – Flow Switch Open | Condenser flow switch shutdown. | The condenser flow switch has remained open for 30 continuous seconds (2 continuous seconds with software version C.OPT.01.15A.xxx and earlier) while the chiller is running. This check is bypassed for the first 30 seconds of "System Run". | 1 |
CURRENT IMBALANCE MESSAGES
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Motor or Starter – Output Current Imbalance | Safety shutdown message, used for both Variable Speed Drives and Style B Solid State Starters. Combines the former messages "Motor or Starter – Current Imbalance" and "LCSSS – Output Current Imbalance" into one message. | 1 | ||
| Motor or Starter – Current Imbalance | Former safety shutdown message; combined into "Motor or Starter – Output Current Imbalance" in this software version. | 1 | ||
| LCSSS – Output Current Imbalance | Former safety shutdown message; combined into "Motor or Starter – Output Current Imbalance" in this software version. | 1 |
MOTOR LUBRICATION WARNINGS AND SHUTDOWN
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Motor-Bearing Lube Suggested | Motor lubrication warning (reminder); sent to the Microgateway as Warning Code 36. | Occurs at the associated elapsed run time since last lubrication when the AUTO LUBE setpoint is DISABLED (chiller not equipped with automatic Motor Lubrication hardware). | When the chiller is equipped with Automatic Motor Lubrication hardware, the AUTO LUBE Setpoint must be ENABLED; with this setting, no lubrication warnings or shutdown will occur. | 3 |
| Motor-Bearing Lube Required | Motor lubrication warning (reminder); sent to the Microgateway as Warning Code 37. | Occurs at the associated elapsed run time since last lubrication when the AUTO LUBE setpoint is DISABLED (chiller not equipped with automatic Motor Lubrication hardware). | When the chiller is equipped with Automatic Motor Lubrication hardware, the AUTO LUBE Setpoint must be ENABLED; with this setting, no lubrication warnings or shutdown will occur. | 3 |
| Motor-Lack of Bearing Lubrication | Motor lubrication safety shutdown; sent to the Microgateway as Warning Code 38. | Occurs at 1400 hours since last lubrication when the AUTO LUBE setpoint is DISABLED and the SHUTDOWN Setpoint enables the safety shutdown. | The SHUTDOWN Setpoint enables or disables this safety shutdown per the customer's preference. If enabled, the safety shutdown will occur at the normal 1400 hours; if disabled, a warning will be displayed but the safety shutdown will not occur. | 3 |
MICROGATEWAY - MOTOR LUBRICATION WARNING CODE CORRECTION
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Condenser – High Pressure Limit | Microgateway warning code 5. Listed only as the code that previous software versions incorrectly sent to the Microgateway for the Motor Lubrication Warning "Motor-Bearing Lube Suggested"; corrected in this software version. | 3 |
From YK Mod G Later and Mod H, Software Changes V09 SI0454
Original: docs.johnsoncontrols.com
FAULTS & WARNINGS
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| WARNING - QUARTERLY SERVICE REQUIRED - CONTACT JCI Event Code: 330 GPIC Warning Code: 145 |
Manual Reset Warning (planned maintenance alert). Shutdown Type: None. | Set when Days Since Last Quarterly Service >= 90 Days. Enable: Always; Allowed States: All; Bypass Time: None; Trip Time: Instantaneous. | Manual reset; Reset Password: 0726. Clear/Disable: when Quarterly Service Warning is Disabled. Release after set. Manual reset is added to the Security Log with the message “Quarterly Service Required Warning Reset”; Days Since Last Quarterly Service is set to 0 when the warning is cleared. Can be cleared via Maintenance Acknowledge (select “Quarterly Service”, then enter the Maintenance Acknowledge Password). When commissioning the chiller for updating the software to V09, each planned maintenance warning must be acknowledged in order to set zero days. | 2 |
| WARNING - YEARLY SERVICE REQUIRED - CONTACT JCI Event Code: 331 GPIC Warning Code: 146 |
Manual Reset Warning (planned maintenance alert). Shutdown Type: None. | Set when all of the following are true: Days Since Last Yearly Service >= 365 Days; Operating Hours Since Last Yearly Service > 2,890 Hours (33% of a year’s run hours = 24*365*0.33). Enable: Always; Allowed States: All; Bypass Time: None; Trip Time: Instantaneous. | Manual reset; Reset Password: 0726. Clear/Disable: when Yearly Service Warning is Disabled. Release after set. Manual reset is added to the Security Log with the message “Yearly Service Required Warning Reset”. When cleared: Days Since Last Yearly Service is set to 0, Operating Hours Since Last Yearly Service is set to 0, and Purge Count Since Last Filter-Drier Replacement is set to 0. Can be cleared via Maintenance Acknowledge (“Yearly Service”). | 3 |
| WARNING - 3 YEAR SERVICE REQUIRED - CONTACT JCI Event Code: 332 GPIC Warning Code: 147 |
Manual Reset Warning (planned maintenance alert). Shutdown Type: None. | Set when Days Since Last 3 Year Service >= 1095 Days. Enable: Always; Allowed States: All; Bypass Time: None; Trip Time: Instantaneous. | Manual reset; Reset Password: 0726. Clear/Disable: when 3 Year Service Warning is Disabled. Release after set. Manual reset is added to the Security Log with the message “3 Year Service Required Warning Reset”; Days Since Last 3 Year Service is set to 0 when the warning is cleared. Can be cleared via Maintenance Acknowledge (“3 Year Service”). | 3 |
| WARNING - CONDENSER - HIGH SMALL TEMP DIFFERENCE Event Code: 13 GPIC Warning Code: 149 |
Manual Reset Warning. Shutdown Type: None. Uses the “Condenser Small Temp Difference Warning Threshold” setpoint (default 6.0 °F diff; minimum 6.0 °F diff, maximum 30.0 °F diff). | Set when Condenser Small Temp Difference > Condenser Small Temp Difference Warning Threshold. Enable: Always; Allowed States: Running; Bypass Time: None; Trip Time: 30 Minutes. | Manual reset; Reset Password: 0726. Clear/Disable: when Condenser High Small Temp Difference Warning is Disabled. Release when Condenser Small Temp Difference <= Condenser Small Temp Difference Warning Threshold. Manual reset is added to the Security Log with the message “Condenser High Small Temp Difference Warning Reset”. Can be cleared via Maintenance Acknowledge (“Cond High Small Temp Diff”). | 4 |
| WARNING - SYSTEM - REPLACE FILTER-DRIER GPIC Warning Code: 150 |
Listed in Unit Warning Codes (SC.4); the Setpoints Report shows “System Replace Filter-Drier Warning = Enabled”. No event definition is given in this bulletin. | Acknowledgeable via the Maintenance screen choice “Filter-Drier Replacement” (only shown when Unit Model is YZ); after the Maintenance Acknowledge Password is entered, the respective Maintenance Acknowledge is set and the respective warning clear action is executed. | 7 |
FAULTS & WARNINGS – YTCS BALL TUBE CLEANING (YORK TUBE CLEANING SYSTEM)
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| WARNING - CONDENSER - HIGH TUBE CLEANING TIME Event Code: 12 GPIC Warning Code: 8 |
Auto Reset Warning. Shutdown Type: None. YTCS total cleaning run time has exceeded the Max Cleaning Time setpoint (Service Access; minimum 1000 hours, maximum 5000 hours, default 2000 hours). | Set when YTCS Total Run Time > YTCS Max Cleaning Time. Enable: Always; Allowed States: All; Bypass Time: None; Trip Time: Instantaneous. | Auto reset: releases when the set criteria is not true; Reset Password: None; Special Handling: None. Clear/Disable: when YTCS Auto Clean Enable is Disabled. YTCS time can be cleared with the “Reset YTCS Time” button on the YTCS Screen (Service Access; sets Reset YTCS Time to 1 while the button is pressed). | 10 |
From YK Mod G and H V05 03630 OptiView Chiller Control Panel Software SI0396
Original: docs.johnsoncontrols.com
System Status
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| SYSTEM COASTDOWN (and countdown timer) | Chiller is in coastdown and the highest active event is a Safety Fault. Message is shown in red. | 2 | ||
| SYSTEM COASTDOWN (and countdown timer) | Chiller is in coastdown and the highest active event is a Cycling Fault or a Start Inhibit. Message is shown in orange. | 2 | ||
| SAFETY SHUTDOWN – MANUAL RESTART | Chiller is stopped and the highest active event is a Safety Fault. Message is shown in red. | Manual restart required. | 2 | |
| CYCLING SHUTDOWN – AUTO RESTART | Chiller is stopped and the highest active event is a Cycling Fault. Message is shown in orange. | Restart is automatic. | 2 | |
| START INHIBIT | Chiller is stopped and the highest active event is a Start Inhibit. Message is shown in orange. | 2 | ||
| MVVSD STARTUP – DRIVE NOT READY | Chiller is in the MVVSD Startup state and the drive is not ready. Message is shown in yellow. | 2 |
From YK Mod G and Later, YK Mod H and YZ/YZD Mod A, 3630 Optiview Software Version V10 SI0564
Original: docs.johnsoncontrols.com
YZ Purge Control
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Purge Equalization Low Suction Temp Warning | Low Purge Suction Temperature during the equalization period. | Purge Suction Temperature is less than the Purge Suction Temperature Threshold during the entire equalization period. | No longer initiates a Purge System Inhibit. Resets automatically when the Purge Suction Temperature is greater than the Purge Suction Temperature Threshold. | 2 |
Access code entry attempts
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Access Code not processed - Wait 5 seconds between attempts. | Message displayed when an access code entry is attempted too soon after the previous attempt. | Access code entry attempt made within the 5 second delay between access code entry attempts. | Wait 5 seconds between access code entry attempts. | 8 |
| Access Code not processed - 1 Minute lockout active. | Message displayed when the system prevents additional logon attempts for 1 minute. | An invalid access code was entered consecutively within 5 minutes for the number of times as defined by the maximum logon attempts. | Lockout is active for 1 minute; no additional logon attempts are possible during that time. | 8 |
| Invalid Access Code | The code entered does not match the encrypted structure for the chiller. | An invalid Access Code was entered; displays in the dialog error box if no lockout is in effect. | Constitutes a failed login attempt and is logged in the Access Log. | 8 |
| Expired Access Code | The code entered is valid, but the access code duration has expired. | Access code duration has expired; displays in the dialog error box if no lockout is in effect. | Constitutes a failed login attempt and is logged in the Access Log. | 8 |
| Inactive Access Code | The code entered is valid, but the access time is in the future. | Access time of the code is in the future; displays in the dialog error box if no lockout is in effect. | Constitutes a failed login attempt and is logged in the Access Log. | 8 |
New Warnings
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| WARNING - SALES ORDER - INVALID SERIAL NUMBER | New warning added with this software version; indicates the Unit Serial Number is blank. | The Unit Serial Number is blank. | Resets automatically when the Unit Serial Number is populated. | 13 |
Miscellaneous changes
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Chilled Liquid Flow Switch Open | Fault. In software version V09 this fault did not trip during the end Prelube for YK. | Corrected in this version so that only the first 44 seconds of Prelube are bypassed. | 13 |
From YK Mod G and later, YK Mod H, YZ Mod A and YZD, 3630 OptiView Software Version V12 Service Information Letter SI0609
Original: docs.johnsoncontrols.com
Display messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| WARNING - OIL - HIGH SUPPLY TEMPERATURE | Auto reset warning (oil cooling control) | When oil cooling control is enabled, displayed after the unit has been running for 30 minutes and the oil supply temperature is higher than the oil supply temperature setpoint + 10.0°F for 1 continuous minute. | Auto reset — the warning resets when the oil supply temperature is lower than the oil supply temperature + 5.0°F. | 5 |
| WARNING - OIL - LOW SUPPLY TEMPERATURE | Auto reset warning (oil cooling control) | When oil cooling control is enabled, displayed after the unit has been running for 30 minutes and the oil supply temperature is lower than the oil supply temperature setpoint − 10.0°F for 1 continuous minute. | Auto reset — the warning is reset when the oil supply temperature is higher than the oil supply temperature − 5.0°F. | 5 |
| OIL - HIGH SUPPLY TEMPERATURE | Safety fault (oil cooling control) | When oil cooling control is enabled, displayed after the unit has been running for 30 minutes and the oil supply temperature is higher than the oil supply temperature setpoint + 15.0°F for 1 continuous minute. | Manual clear — the fault is released when the oil supply temperature is lower than the oil supply temperature + 15.0°F and the Clear Fault key is pressed. | 5 |
| OIL - LOW SUPPLY TEMPERATURE | Safety fault (oil cooling control) | When oil cooling control is enabled, displayed after the unit has been running for 30 minutes and the oil supply temperature is lower than the oil supply temperature setpoint − 15.0°F for 1 continuous minute. | Manual clear — the fault is released when the oil supply temperature is higher than the oil supply temperature − 15.0°F and the Clear Fault key is pressed. | 5 |
| MBC - LOW BEARING J TEMPERATURE | MBC generated cycling fault | Occurs when the J Bearing temperature is lower than −22°F (−30°C). This would indicate an open temperature circuit. | Auto reset — the fault automatically clears when the temperature rises above −22°F (−30°C). | 5 |
| MBC - LOW BEARING H1 TEMPERATURE | MBC generated cycling fault | Occurs when the H1 Bearing temperature is lower than −22°F (−30°C). This would indicate an open temperature circuit. | Auto reset — the fault automatically clears when the temperature rises above −22°F (−30°C). | 5 |
| MBC - LOW BEARING H2 TEMPERATURE | MBC generated cycling fault | Occurs when the H2 Bearing temperature is lower than −22°F (−30°C). This would indicate an open temperature circuit. | Auto reset — the fault automatically clears when the temperature rises above −22°F (−30°C). | 5 |
| MBC - LOW BEARING K TEMPERATURE | MBC generated cycling fault | Occurs when the K Bearing temperature is lower than −22°F (−30°C). This would indicate an open temperature circuit. | Auto reset — the fault automatically clears when the temperature rises above −22°F (−30°C). | 5 |
| MBC - LOW HEATSINK TEMPERATURE | MBC generated cycling fault | Occurs when the MBC Heatsink temperature is lower than −22°F (−30°C). This would indicate an open temperature circuit. | Auto reset — the fault automatically clears when the temperature rises above −22°F (−30°C). | 5 |
| WARNING - COMPRESSOR - LOW DISCHARGE SUPERHEAT | Manual reset warning | Displayed when the compressor discharge superheat is less than 2.0°F for 5 minutes. It is bypassed for the first 30 minutes of run time. | Manual reset — the warning can be reset when the discharge superheat temperature is greater than 2.0°F and the Warning Reset key is pressed. | 6 |
| WARNING - CONDENSER - LIQUID LEVEL STABILITY | Manual reset warning (YK chillers only) | Displayed after the condenser liquid level minimum and maximum value has been greater than the Liquid Level Stability Threshold for 30 consecutive minutes (three consecutive 10 minute monitoring windows, starting after the chiller has been running for 30 minutes). | Manual reset — the warning can be reset when the difference is less than the threshold for 10 minutes and the Warning Reset key is pressed. | 6 |
Miscellaneous
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| CONDENSER – HIGH PRESSURE | Safety fault (YZ chillers, Condenser Temperature Range set to Extended) | Triggered when the condenser pressure is equal to or higher than 53.7 psia. | Released when the condenser pressure is less than 43.7 psia. | 4 |
| Condenser High Pressure Warning | Warning (YZ chillers, Condenser Temperature Range set to Extended) | Enhanced programmable high limit and default value is now 51.7 psia. | 4 |
YK Low Discharge Superheat
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Low Discharge Superheat | Safety fault (changed behaviour in this software version) | Set when the discharge superheat is less than 1.0°F for 5 minutes; bypassed for the first 30 minutes of run time. | 4 |
From YK Software Enchancements (Version 15), Control Panel SI0148
Original: docs.johnsoncontrols.com
Cycling Shutdowns (apply to 575V/60Hz VSD)
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD-PRECHARGE-LOW DC BUS VOLTAGE | The DC Link voltage does not reach at least 60VDC (within 4 seconds) or at least 600VDC (within 20 seconds) after the precharge command has been received. | This shutdown is performed. | 1 | |
| VSD—PRECHARGE-DC BUS VOLTAGE IMBALANCE | The Half DC Link voltage does not remain within +106VDC of the DC Link Voltage divided by 2 during the precharge interval. | This shutdown is performed. | 1 | |
| VSD-LOW DC BUS VOLTAGE | The DC Link Voltage falls below 600VDC while running. | This shutdown is performed. | 1 | |
| VSD-DC BUS VOLTAGE IMBALANCE | The Half DC Link Voltage does not remain within +106VDC of the DC Link Voltage divided by 2 while running. | This shutdown is performed. | 1 | |
| VSD-HARMONIC FILTER-PRECHARGE-LOW DC BUS VOLTAGE | The DC Link voltage does not reach at least 60VDC (within 100 milliseconds) or at least 630VDC (within 5 seconds) after the filter precharge command has been received. | This shutdown is performed. | 1 | |
| VSD-HARMONIC FILTER-DC BUS VOLTAGE IMBALANCE | The Half DC Link Voltage does not remain within +63VDC of the DC Link Voltage divided by 2. | This shutdown is performed. | 1 |
Safety Shutdowns (apply to 575V/60Hz VSD)
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD-HARMONIC FILTER-HIGH BASEPLATE TEMPERATURE | The Baseplate temperature rises above the following limits: 424HP – 70.0°F, 174.2°C 608HP – 88.0°F, 190.4°C | This shutdown is performed. | 2 |
From YK Software Enhancements (V.25), Control Panel SI0271
Original: docs.johnsoncontrols.com
Warning – DC Bus Active
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Warning – VSD – DC Bus Active | Non-annunciating warning, displayed in yellow text, alerting the user that the MVVSD, VSD or Harmonic Filter DC bus voltage is above 50 VDC, posing a potential safety issue if the cabinet is opened. | MVVSD, VSD or Harmonic Filter DC bus voltage above 50 VDC while the chiller is in the Stopped State. Only applies when the Motor Drive Type is VSD 50Hz, VSD 60Hz, or MVVSD (VSD 50 and 60Hz includes Vyper and Raptyr designed drives). | Active only when the chiller is in the Stopped State; automatically cleared in any other state. The Warning Relay is not activated for this warning. | 2 |
Subcooler Tube Failure
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Warning – Liquid Level Setpoint not Achieved | Automatic Reset Warning. | Set when all of the following are true for 10 continuous minutes: • Chiller is Running • Run Time > 30 minutes • Refrigerant Level > (Refrigerant Level setpoint +15%) OR Refrigerant Level < (Refrigerant Level setpoint -15%) |
Automatic reset — released when: • Chiller is not Running • (Refrigerant Level setpoint -15%) < Refrigerant Level < (Refrigerant Level setpoint +15%) When this warning occurs, it shall be added to the security log. |
3 |
| Warning - Loss of Subcooler Liquid Seal | Warning indicating loss of the subcooler liquid seal. | The chiller has been running for 30 minutes or more and the Drop Leg Temperature is less than the Return Condenser Liquid Temperature continuously for two minutes. | This warning requires a manual reset when the above conditions are no longer true. The message "Loss of Subcooler Liquid Seal Warning Reset" is added to the Security Log when the warning is reset. | 3 |
Faults
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Isolation Valves - Not Closed | Cycling fault (Isolation Valves option). | Set when the following conditions exist for 3 continuous seconds: Isolation Valves Close Output is energized > 40 seconds, but Isolation Valves Closed Feedback is not energized. | Released when Isolation Valves Closed input is energized. | 5 |
| Isolation Valves - Not Opened | Safety fault (Isolation Valves option). | Set when the following conditions exist for 3 continuous seconds: Isolation Valves Open Output is energized > 40 seconds, but Isolation Valves Opened Feedback is not energized. | Released when the Compressor is in stopped state and the Compressor switch is placed into the stop position. | 5 |
Seal Lubrication Timer and Warning
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Warning – Seal Lubrication In Progress | Non-annunciating warning (changed to be a non-annunciating warning in this software version). | When Standby Lube is enabled, seal lubrication is performed by running the Oil Pump for two minutes, once every twenty-four hours since the Oil Pump was last run for at least two minutes. | 9 |
From YK Software Enhancements Effective October 2004, Control Panel SI0104
Original: docs.johnsoncontrols.com
Safety Shutdowns
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Oil – Variable Speed Pump – Setpoint Not Achieved | Shutdown of “P” compressors when the minimum allowed oil pressure is not achieved. | Oil pressure did not achieve the minimum allowed value during the last 10 seconds of System Prelube and the first 15 seconds of System Run. Previously the threshold was 25.0 PSID; effective October 2004 the threshold is 35.0 PSID, making it consistent with all other compressors. | 1 |
From YK Style G V04 03630 OptiView and Microboard Software Release, Control Panel SI0373
Original: docs.johnsoncontrols.com
Warnings and Safeties
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| HARMONIC FILTER: OPERATION INHIBITED | Warning that Harmonic Filter operation has been inhibited. | Displayed only when the operator inhibits the Harmonic Filter Operation and the filter is present. Software version V04 fixes this warning message, which previously could be displayed incorrectly. | 3 | |
| Loss of Sub-Cooler Liquid Seal Warning | Warning indicating loss of the sub-cooler liquid seal. | In software release V04 the warning is excluded during Soft Shutdown of the unit, and the time to set the warning is increased from 2 continuous minutes to 5 continuous minutes. | 3 | |
| VSD - LINE VOLTAGE PHASE ROTATION | VSD safety. | In software version V04 this safety is changed from a Safety Lockout to a Cycling Safety. | 4 | |
| VSD - PHASE LOCKED LOOP | VSD safety. | In software version V04 this safety is changed from a Safety Lockout to a Cycling Safety. | 4 | |
| Phase Rotation Fault Message | Fault message displayed after a power cycling event. Software version V04 fixes a bug that displayed "Requesting Fault Data..." instead of this message. | 4 |
From YK and YZ/YZD 3630 OptiView Software Version V10A Service Information Letter SI0591
Original: docs.johnsoncontrols.com
YK High Temp Heat Pump
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Oil Sump Pressure is Too High | Trip. | Discovered on YK High Heat Pump units with auxiliary condensers (U compressors): unit would trip on Oil Sump Pressure is Too High when the leaving evaporator water temperature was greater than 86°F (30°C). | Changes were made in software version Y.OPT.01.10A.308 to the Oil Sump Condenser and Compressor Vent Line Control; a JCI Service programmable setpoint, Compressor Vent LCHLT Threshold (71.6°F – 89.6°F; default 80.6°F), has been added to the Oil Sump Condenser Screen. Software only upgrade kit: YK 331-03601-602, YZ/YZD 331-03601-603. | 2 |
| failed to start with start inhibit | Unit failed to start; start inhibit active. | Discovered on YK High Heat Pump units with auxiliary condensers (U compressors): unit failed to start with start inhibit when the entering evaporator water temperature was greater than 104°F (40°C). | Changes were made in software version Y.OPT.01.10A.308 to the Oil Sump Condenser and Compressor Vent Line Control; a JCI Service programmable setpoint, Compressor Vent LCHLT Threshold (71.6°F – 89.6°F; default 80.6°F), has been added to the Oil Sump Condenser Screen. Software only upgrade kit: YK 331-03601-602, YZ/YZD 331-03601-603. | 2 |
From YK v.27/V0 v.27/v.0 YK OptiView Chiller Control Panel SI0300
Original: docs.johnsoncontrols.com
UNIT SAFETY FAULT CODES
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 15 Motor - Lack of Motor Oil Change |
Unit safety fault — lack of motor oil change. | Displayed at 6000 operating hours since the last motor lubrication ("Warning – Lack of Motor Oil Change"). If the Shutdowns setting is set to Enabled, this message is treated as a Safety Fault. | Shuts down the chiller until the motor lubrication is performed and acknowledged. A completed lube acknowledgement will clear the message. | 5 |
UNIT CYCLING FAULT CODES
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 69 Motor Auto Lubrication In Progress |
Unit cycling fault — motor auto lubrication in progress. | The chiller runs 1400 hours since the last lubrication without stopping (P203 auto-lubrication system). | The chiller shuts down and the bearings are automatically lubricated. The chiller will then restart at the completion of the lubrication. Chiller startup is inhibited during the auto-lube process. | 5 |
UNIT WARNING CODES
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 19 Warning – Auto Lube Req’d On Next Shutdown |
Auto lubrication required on next shutdown. | 5 | ||
| 20 Warning – Auto Lube Grease Level Low |
Auto-lubrication grease level low. | 5 | ||
| 21 Warning – Auto Lube Failed |
Auto lubrication failed. | 5 | ||
| 22 Warning – Motor Oil Change Suggested |
Motor oil change suggested. | Displayed at 4000 operating hours since the last motor lubrication. | A completed lube acknowledgement will clear the message. | 5 |
| 23 Warning – Motor Oil Change Required |
Motor oil change required. | Displayed at 5000 operating hours since the last motor lubrication. | A completed lube acknowledgement will clear the message. | 5 |
| 24 Warning – Lack of Motor Oil Change |
Lack of motor oil change. | Displayed at 6000 operating hours since the last motor lubrication. If the Shutdowns setting is set to Enabled, this message is treated as a Safety Fault. | A completed lube acknowledgement will clear the message. If treated as a Safety Fault, the chiller shuts down until the motor lubrication is performed and acknowledged. | 5 |
| WARNING – LOSS OF SUBCOOLER LIQUID SEAL | Loss of subcooler liquid seal detected. | Calculated Subcooler Effectiveness is less than the Subcooler Effectiveness Low value (0.4) or greater than the Subcooler Effectiveness High value (1.5) continuously for two minutes after running for at least 30 minutes. Subcooler Effectiveness = (Cond Sat Temp − Drop Leg Ref Temp) / (Cond Sat Temp − Entering Cond Liq Temp). |
The warning can be manually reset when any of the warning conditions are no longer in effect. | 1 |
| Warning – Condenser – Freeze Threat from Low Pressure | Condenser freeze threat from low pressure while the chiller is stopped. | If the Drop Leg Temperature Sensor is Enabled, the warning is set when ALL of the following are true: • Chiller State is Stopped • Saturated Condenser Temperature is < 34.0°F • Drop Leg Temperature is < 35.0°F If the Drop Leg Temperature Sensor is Not Enabled, the warning is set when ALL of the following are true: • Chiller State is Stopped • Saturated Condenser Temperature is < 34.0°F |
The warning is released when ANY of the following are true: • Chiller State is not Stopped • Saturated Condenser Temperature is > 36.0°F • Drop Leg Temperature is > 38.0°F (sensor enabled) |
2 |
| Warning - Condenser – Freeze Threat – Flow Switch Open | Condenser freeze threat with flow switch open while the chiller is stopped. | If the Drop Leg Temperature Sensor is Enabled, the warning is set when ALL of the following are true: • Chiller State is Stopped • Saturated Condenser Temperature is < 34.0°F • Drop Leg Temperature is < 35.0°F • Condenser Flow Switch is Open Continuously for > 1 minute If the Drop Leg Temperature Sensor is Not Enabled, the warning is set when ALL of the following are true: • Chiller State is Stopped • Saturated Condenser Temperature is < 34.0°F • Condenser Flow Switch is Open Continuously for > 1 minute |
The warning is released when ANY of the following are true: Sensor Enabled: • Chiller State is not Stopped • Saturated Condenser Temperature is > 36.0°F • Drop Leg Temperature is > 36.0°F for 5 continuous minutes • Condenser Flow Switch is closed Sensor Not Enabled: • Chiller State is not Stopped • Saturated Condenser Temperature is > 36.0°F • Condenser Flow Switch is closed |
2 |
From YMC2 and YK Smart Sensor System (SSS) Capacitor Inspection and Troubleshooting Circuit Breaker Trip SI0438
Original: docs.johnsoncontrols.com
DETERMINING IF THE CIRCUIT BREAKER TRIPPED BECAUSE OF AN OVER CURRENT, GROUND FAULT, OR DUE TO THE SMART SENSOR SYSTEM
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| SSS indicator Red |
The SSS has indicated a fault. (Fault condition of the Smart Sensor System flip-dot indicator.) | Perform Safe Entry Procedure. Contact JCI Service for a proper evaluation of this fault. The SSS board is located on the back side of the door closure rail, except on the 1100, 1278 and 1300 models, where it is located on the back side of the right door closure rail; the indicator faces down. | 3 | |
| Circuit breaker has automatically tripped open | The drive circuit breaker has tripped open; the trip must be traced to either the Smart Sensor System or an over current / ground fault. | If the SSS indicator is Black: the circuit breaker has tripped due to an over current, or ground fault. If the SSS indicator is Red: the SSS has indicated a fault. | Perform Safe Entry Procedure. Find the SSS indicator and check its color. Red: contact JCI Service for a proper evaluation of this fault. Black (over current / ground fault path): perform resistance test on input power fuses; validate all of the circuit breaker settings match the setting found in the referenced service manual (refer to forms 160.78-M3 for M1 motor application, 160.84-M3 for M2 and M6 application, or 160.00-M10 for YK applications); inspect the VSD for visible signs of a ground fault, such as the input inductor, input capacitor assembly, and rectifier assembly; perform megger test on input inductors, testing phase to phase and phase to ground, replace inductor if required; inspect the common mode fuses — if any opened, ensure customer power wiring for ground and neutral are correct and replace failed fuses; inspect the common mode and input capacitors for any signs of damage or overheating and replace components as needed; perform resistance tests on all rectifiers and inverters and replace any failed parts. If all power fuses failed: replace all of the power fuses and all of the rectifier assemblies (and replace the inverter where the inverter resistance test failed). If only some power fuses failed: replace all of the power fuses and replace the rectifier assemblies in the phases where the power fuses failed (and replace the inverter where the test failed). Then begin the repairs. | 3 |
From YMC2 and YK Smart Sensor System (SSS) Installation Troubleshooting Instructions SI0440
Original: docs.johnsoncontrols.com
PROBLEM: VSD Stop Contacts Open Fault Appears
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| VSD Stop Contacts Open | Fault appears on the OptiView panel display when 120 V AC is applied. | Possible causes identified by the troubleshooting procedure: fault indicated by the VSD logic board (fault LED lit near the J16 connector); wiring fault between J4 on the 031-03958 board and J14 on the 031-02911 board; 24 VDC power supply output outside 23–26 VDC or failed supply; missing 120 V AC feed to the power supply (HOT/NTRL miswired or open fuse); J1 not installed correctly or reversed polarity on the 031-03958 board; faulty cable between the boards; 031-02911 board in fault; failed 031-03958 board. | Check the fault LED near the J16 connector on the VSD logic board. If lit, the logic board is indicating a fault — refer to form 160.78-M3 (M1 motor), 160.84-M3 (M2 and M6 motor, YMC2 applications), or 160.00-M10 (YK applications, maximum 1100 HP [50 Hz] and 1300 HP [60 Hz] motors). If not lit, validate all wiring between J4 on the 031-03958 board and J14 on the 031-02911 board. Check the LED on the 24 VDC power supply: if lit, measure the output voltage (marked + and −) — if 23–26 VDC replace the 031-03958 board; if not, remove the J1 connector and re-measure (23–26 VDC → replace the 031-03958 board; not 23–26 VDC → replace the power supply). If the supply LED is not lit, measure 120 V AC between L and N: if present, replace the power supply; if absent, ensure the HOT and NTRL wires are properly connected (HOT to J2 pin 2 on the 031-03958 board and to the appropriate fuse, fuse not open; NTRL per the connection diagram). Check that J1 is installed correctly on the 031-03958 board; measure DC between J1 pin 1 (red lead) and pin 2 (black lead) — if 24 VDC is present but negative, ensure the brown (POS) wire is on the positive supply terminal and J1 pin 1 and the black (NEG) wire on the negative terminal and J1 pin 2; replace the 031-03958 board if unresolved. If 24 VDC is not present, remove J1 and measure the harness connector: 24 VDC → replace the 031-03958 board; no 24 VDC → correct the power-supply output wiring or replace the power supply. Measure AC voltage from J4 pin 2 to ground on the 031-03958 board: if not 120 V AC, measure J14 pin 4 on the 031-02911 board — if 120 V AC, correct or replace the cable (P/N 571-09367-205); if not 120 V AC, determine the reason the 031-02911 board is in fault. If J4 pin 2 reads 120 V AC, measure J4 pin 1 to ground: 120 V AC → the 031-03958 board is working properly; not 120 V AC → problem with the 24 VDC supply, the cable, or a failed 031-03958 board. If the problem is still not solved, contact PTS. | 2 |
PROBLEM: Flip Dot Does Not Turn Black or Flips from Black to Red
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Flip Dot Does Not Turn Black or Flips from Black to Red |
When power is applied, the flip dot does not turn black or flips from black to red. | 24 VDC not present between TB1 terminals R and L or at TB1 terminal L1 on the 031-03958 board; sensor bases wired incorrectly or sensors not installed correctly into the bases; L1 wire at TB1 installed incorrectly or wire insulation present in the terminal; failed 031-03958 board. | Measure DC voltage between TB1 terminal R and L on the 031-03958 board. If the voltage is 24 VDC, replace the 031-03958 board. If not 24 VDC, measure the DC voltage at TB1 terminal L1 on the 031-03958 board; ensure the base of the sensors is wired correctly and the sensors are installed correctly into the base. Remove the TB1 connector and re-measure at TB1 terminal L1: if 24 VDC, ensure the L1 wire connected to TB1 terminal L1 is installed correctly and no wire insulation is present in the terminal; if not 24 VDC, replace the 031-03958 board. If the problem is still not solved, contact PTS. | 3 |
PROBLEM: Circuit Breaker Does Not Open
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Circuit Breaker Does Not Open | The flip dot is red, but the circuit breaker does not open. | Shunt trip not latched correctly into the circuit breaker; incorrect connections between the SHNT wire and the YEL wire to the shunt trip, or the WHT wire from the shunt trip to the NTRL wire and back to the terminal block; long HOT wire not connected to the appropriate fuse or open fuse; failed 031-03958 board. | Measure AC voltage between J2 pin 2 on the 031-03958 board and ground. If 120 V AC, connect a jumper between J2 pin 2 and J2 pin 3 on the 031-03958 board (care: 120 V AC is present; do not apply the jumper for more than a few seconds — damage to the shunt trip may occur). If the shunt trip triggers but the circuit breaker does not open, ensure the shunt trip is installed according to the instructions — it may not be latched correctly into the circuit breaker. If the shunt trip does not trigger, check the connections between the SHNT wire and the YEL wire to the shunt trip, and the WHT wire from the shunt trip to the NTRL wire and back to the terminal block per the connection diagram; if the wiring is correct, replace the 031-03958 board. If the voltage is not 120 V AC, ensure the long HOT wire is connected to the appropriate fuse and the fuse is not open. If the problem is still not solved, contact PTS. | 3 |
PROBLEM: When Conducting the Optical Sensor Test the Flip Dot Does Not Turn Red.
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| When Conducting the Optical Sensor Test the Flip Dot Does Not Turn Red. |
The flip dot does not turn red during the optical sensor test. | Optical sensor test not conducted according to the instructions on the can of smoke; can of smoke not directed at the sensor with the black grill; wiring to the base of the sensors or at TB1 on the 031-03958 board installed incorrectly; sensor (white-grill or black-grill) whose LED does not light. | Determine if the optical sensor test is being conducted according to the instructions on the can of smoke; if not, repeat the test correctly. Make sure the can of smoke is directed at the sensor with the black grill. Remove the 120 V AC and remove both sensors; ensure the wiring to the base of both sensors and the wiring at TB1 on the 031-03958 board is correctly installed per the wiring diagram provided in the kit; correct any wiring error. Reinstall the sensor with the black grill, apply 120 V AC and repeat the test — the LED on the black-grill sensor should light. Then remove 120 V AC, reinstall the sensor with the white grill and reapply 120 V AC (this will reset the sensor); repeat the test — the LED on the black-grill sensor should light, and the system is working properly. If an LED is not lit, install a new sensor with the white grill, and if still not lit a new sensor with the black grill, repeating the optical sensor test after each replacement. If the problem is still not solved, contact PTS. | 4 |
PROBLEM: When Conducting the CO Sensor Test the Flip Dot Does Not Turn Red.
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| When Conducting the CO Sensor Test the Flip Dot Does Not Turn Red. |
The flip dot does not turn red during the CO sensor test. | CO sensor test not conducted per the installation instructions; can of CO not directed at the sensor with the white grill; wiring to the base of the sensors or at TB1 on the 031-03958 board installed incorrectly; sensor (black-grill or white-grill) whose LED does not light. | Determine if the CO sensor test is being conducted per the installation instructions; if not, repeat the test correctly. Make sure the can of CO is directed at the sensor with the white grill. Remove the 120 V AC and remove both sensors; ensure the wiring to the base of both sensors and the wiring at TB1 on the 031-03958 board is correctly installed per the wiring diagram provided in the kit; correct any wiring error. Reinstall the sensor with the white grill, apply 120 V AC and repeat the test — the LED on the white-grill sensor should light. Then remove 120 V AC, reinstall the sensor with the black grill and reapply 120 V AC (this will reset the sensor); repeat the test — the LED on the white-grill sensor should light, and the system is working properly. If an LED is not lit, install a new sensor with the black grill, and if still not lit a new sensor with the white grill, repeating the CO sensor test after each replacement. If the problem is still not solved, contact PTS. | 5 |
From YORK Chiller Access Manager Installation and Setup Instructions SI0622
Original: docs.johnsoncontrols.com
Possible errors when installing the private key
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| SD card is not present | The SD card interface port is not detecting that a SD card is installed. | SD card did not seat all the way in J26; SD card lock switch on; incompatible SD card; J26 hardware issue. | If the Initialize Security button does not disappear, correct the error and repeat the required procedure. | 5 |
| Key file is missing | There is no file on the SD card named NEWCKEY.dat. | This error can be caused when extra numbers or characters are added to the file name. | If the Initialize Security button does not disappear, correct the error and repeat the required procedure. | 5 |
| Invalid file | The NEWCKEY.dat file does not have the correct file ID. | This error can occur if you are not using the correct key file for the chiller. | If the Initialize Security button does not disappear, correct the error and repeat the required procedure. | 5 |
| Signature error | The security signature associated with the software version is not correct. | This error can occur if you are not using the correct key file for the chiller. | If the Initialize Security button does not disappear, correct the error and repeat the required procedure. | 5 |
| Incorrect software version | The software version used to create the key does not match the software installed on the panel. | This error can occur if you were provided with the incorrect software version when requesting the private key. | If the Initialize Security button does not disappear, correct the error and repeat the required procedure. | 5 |
| Time error | The private key is more than 30 days old. | Incorrect panel date; private key has expired, and you need to request a new one. | If the Initialize Security button does not disappear, correct the error and repeat the required procedure. | 5 |
| Incorrect serial number | The serial number that was used to create the key does not match the serial number entered in the panel. | This error could occur if you entered the incorrect serial number in the panel but the correct number was provided when the key was requested. | If the Initialize Security button does not disappear, correct the error and repeat the required procedure. | 5 |
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