Fault, warning and safety-shutdown messages documented by Johnson Controls for the YORK YVAA. Each row cites the page of the manual it was taken from — nothing here is summarised or reworded.
From YVAA Style A with VSD, Frame size 015-027 2-Compressor, Frame size 054-098, 2-Compressor 50 Hz (525-950 KW) R-134a or R-513A Installation, Operation and Maintenance 201.28-NM1.1.EN.GB
Original: docs.johnsoncontrols.com
Commissioning
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| Sys2 - single phase input Volts | Fault reported by the unit; the unit does not start. | Power-on sequence reversed on YVAA0373/0375/0413/0443/0483/0490/0500/0523 units (independent circuit breaker/disconnect switches in each conduit of Sys1 and Sys2): Sys1 powered before Sys2. | Ensure that the Sys2 power is on first and then Sys1 by closing the corresponding circuit breaker or disconnect switch. | 89 |
Unit Warnings
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT WARNING: !! LOW BATTERY !! CHECK SETPOINTS/PROGRAM/OPTIONS/TIME | Low RTC battery condition detected at micropanel power-up; warning displayed indefinitely. Warnings are not logged to the history buffer; message is displayed when the STATUS key is pressed. | RTC battery voltage determined to be low when checked at unit power-up. | All programmed setpoints, program values, time, schedule, and history buffers will have been lost and reset to default values. Unit is prevented from running until the MANUAL OVERRIDE key is pressed (anti-recycle timers then set to the programmed default anti-recycle time to allow the operator time to check setpoints, program values, etc.). Replace the battery as soon as possible; if a low battery is detected and not replaced, the programmed values will all be lost and the unit will be prevented from running on the next power interruption. | 102 |
| UNIT WARNING: INVALID NUMBER OF COMPRESSORS SELECTED | Warning displayed indefinitely after the VSD has been initialized. | No jumpers installed or more than 1 jumper installed ("Number of Compressors Select" message displayed). | To clear this warning, both the control panel and VSD control voltage must be turned OFF and the jumpers correctly installed in the VSD wiring harness. Jumpers are factory installed in the wire harness plug and should not require changes. | 111 |
| UNIT WARNING: INVALID SERIAL NUMBER ENTER UNIT SERIAL NUMBER | The appearance of this message may mean the chiller has lost important factory programmed information; the serial number and other important data may need to be reprogrammed. | Immediately contact Johnson Controls Product Technical Support. The serial number can be entered using the SERVICE key (date and time must be set on the chiller before programming; factory-provided password required). This status message can be bypassed to view additional messages under the STATUS key by pressing the STATUS key repeatedly. | 111 |
Unit safeties
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT YYYYYYYY HIGH AMBIENT TEMP | Unit safety shutdown on high ambient temperature (auto-reset unit fault; YYYYYYYY indicates FAULT condition). | Ambient temperature rises above 55°C (131°F). | Controlled ramped shutdown. Restart will automatically occur, if demand allows, when temperature falls 1.1°C (2°F) below the cutout (53.9°C [129°F]). This fault cannot cause a lockout. Message present only while ambient temperature is causing the fault condition. Unit also inhibited from starting any time the temperature is above 53.9°C (129°F). | 112 |
| UNIT YYYYYYYY LOW AMBIENT TEMP | Unit safety shutdown on low ambient temperature (auto-reset unit fault; YYYYYYYY indicates FAULT condition). | Ambient temperature falls below the programmable Low Ambient Temp Cutout. This fault only occurs if the Low Ambient Cutout is "ENABLED" under the OPTIONS key. | Controlled ramped shutdown. Restart can occur, if demand allows, when temperature rises 1.1°C (2°F) above the cutout. This fault cannot cause a lockout. Unit also inhibited from starting any time the temperature is below the cutout plus 1.1°C (2°F). | 112 |
| UNIT YYYYYYYY LOW LEAVING CHILLED LIQUID TEMP | Protects the chiller from an evaporator freeze-up should the chilled liquid temp drop below the freeze point (auto-reset unit fault; YYYYYYYY indicates FAULT condition). | Leaving chilled liquid temperature (water or brine) drops below the programmable cutout point. Situation could occur under low flow conditions or if the Micro Panel setpoint values are incorrectly programmed. | Fault and controlled ramped shutdown. Restart can occur, if demand allows, when chilled liquid temperature rises 2.2°C (4°F) above the cutout. This fault cannot cause a lockout. Unit inhibited from starting any time the chilled liquid temperature is below the cutout plus 2.2°C (4°F). | 112 |
| UNIT YYYYYYYY VSD COMMUNICATIONS FAILURE | Prevents the unit from trying to run if the Chiller Control Board never initializes communications with the VSD Logic Board; shuts the unit down if communications are lost while the chiller is operating. | On power-up, no reply from the VSD Logic Board within 8 seconds; during normal operation, no valid response to messages received for 8 seconds. | All compressors shut down on a Comms fault with a controlled ramped shutdown. Unit inhibited from starting until communications is established. Fault automatically resets when the Chiller Control Board receives a valid response from the VSD for a data request. Note: if any 3 VSD unit faults occur within 90 minutes, the unit will be locked out on the last fault; a VSD lockout requires a manual reset using the system switches — both system switches must be cycled OFF and ON to clear. | 113 |
System safeties (faults)
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| SYS X YYYYYYYY HIGH DISCHARGE PRESSURE | Software high discharge pressure cutout. X indicates the system; YYYYYYYY indicates the system is in a FAULT condition (restarts when the 120 second anti-recycle timer times out) or LOCKOUT (will not restart until the operator clears the fault using the keypad). | Discharge pressure rises above 22.4 barg (325 psig) for 0.5 seconds. | Controlled ramped shutdown. System allowed to restart when the discharge pressure falls to 20.3 barg (295 psig); system also inhibited from starting if the pressure is above 20.3 barg (295 psig). Lockout occurs on the third fault in 90 minutes; lockout cleared by cycling the respective system switch OFF and ON. | 113 |
| SYS X YYYYYYYY HPCO FAULT | Mechanical (hardware) High Pressure Cutout protecting the system from dangerously high discharge pressure. X indicates the system; YYYYYYYY indicates FAULT or LOCKOUT. | Mechanical high pressure cutout contacts open — cutout opens at 23.2 barg ± 0.55 barg (337 psig ± 8 psig) and closes at 17.4 barg ± 0.69 barg (252 psig ± 10 psig). Wired in series with the VSD Run Signal and only checked when the system is running; fault occurs immediately and does not wait the 3 seconds typical of most system faults. | Immediate shutdown. Restart when the 120 second anti-recycle timer times out, or LOCKOUT until the operator clears the fault using the keypad. | 114 |
| SYS X YYYYYYYY LOW SUCTION PRESSURE | Programmable Low Suction Pressure Cutout — protects the chiller from an evaporator freeze-up if the system attempts to run with a low refrigerant charge. X indicates the system number. | Suction pressure falls below the programmable Suction Pressure Cutout. Cutout is ignored at system start for the programmed Suction Pressure Startup Bypass Time, then linearly ramped from 10% to 100% of the programmed Suction Pressure Cutout; shutdown occurs if the suction pressure falls below the ramped cutout during the ramp or below the programmed cutout after the ramp. | System shuts down. Causes a lockout on the third fault in 90 minutes; lockout cleared by cycling the respective system switch OFF and ON. | 114 |
| SYS X YYYYYYYY LOW SUCT PRES SMART FREEZE | Low suction pressure smart freeze safety (R-134a and R-513A refrigeration systems). X indicates the system number. | Suction Pressure is below the programmable Suction Pressure Override Threshold (Suction Pressure Cutout in psig + 1.7 psig) longer than the programmable Smart Freeze Timer. | Safety fault is released when the Suction Pressure >= Suction Pressure Override Threshold. Causes a lockout on the third fault in 90 minutes. | 114 |
| SYS X YYYYYYYY LOW MOTOR CURRENT | Motor Current Cutout — shuts the system down when the microprocessor detects the absence of motor current, usually indicating that a compressor is not running. X indicates the system; YYYYYYYY indicates FAULT or LOCKOUT. | Motor current less than 10% FLA; safety is ignored for the first 10 seconds of operation. | Controlled ramped shutdown. Restart when the 120 second anti-recycle timer times out, or LOCKOUT until the operator clears the fault using the keypad. | 114 |
| SYS X YYYYYYYY HIGH DIFF OIL PRESSURE | Protects the compressor from low oil flow and insufficient lubrication, possibly from a dirty oil filter. X indicates the system; YYYYYYYY indicates FAULT or LOCKOUT. | Discharge to Oil Differential Pressure rises above the cutout of 4.48 barg (65 psid) — measures the pressure differential between discharge and oil pressure (pressure drop across the oil filter); safety ignored for the first 90 seconds of run time. | Controlled ramped shutdown. Restart when the 120 second anti-recycle timer times out, or LOCKOUT until the operator clears the fault using the keypad. | 114 |
| SYS X YYYYYYYY LOW DIFF OIL PRESSURE | Protects the compressor from low oil flow and insufficient lubrication; ensures the compressor is pumping sufficiently to push oil through the oil cooling circuit and internal compressor lubrication system. X indicates the system; YYYYYYYY indicates FAULT or LOCKOUT. | Differential between oil and suction pressure falls below the cutout. Safety ignored for the first 60 seconds of run time; thereafter the cutout is linearly ramped from 0 barg to 2.09 barg (0 psid to 30 psid) in 5 to 10 minutes based on ambient temperature (Table 15). A 30 second safety bypass below 50 Hz is employed during rampdown (needed when another compressor is being brought on and the running compressor is ramped down to 5 Hz) to prevent nuisance low oil differential trips. | Controlled ramped shutdown. Restart when the 120 second anti-recycle timer times out, or LOCKOUT until the operator clears the fault using the keypad. | 115 |
| SYS X YYYYYYYY HIGH DISCHARGE TEMP | Protects the motor and compressor from overheating. X indicates the system; YYYYYYYY indicates FAULT or LOCKOUT. | Discharge Temperature rises above 121°C (250°F); system also inhibited from starting if the discharge temperature is above 93°C (200°F). | Controlled ramped shutdown. Restart when the 120 second anti-recycle timer times out, or LOCKOUT until the operator clears the fault using the keypad. | 115 |
| Low discharge superheat cutout fault (display wording not printed in manual) | Helps protect the compressor from liquid floodback through the economizer line due to a high flashtank level, and from excessive oil in circulation due to excess oil charge in the system (entrained liquid refrigerant drops out once it enters the compressor). | Discharge superheat falls below 2.8°C (5.0°F) for 5 minutes. Safety is ignored for the first 10 minutes of operation if the system economizer feed valve is closed (0%) and for 5 minutes of operation if the economizer feed valve is open greater than 0%. | System shuts down. Restart when the 120 second anti-recycle timer times out, or LOCKOUT until the operator clears the fault using the keypad. | 115 |
| SYS X YYYYYYYY SENSOR FAILURE: ZZZZZZZZZZZZ | Prevents the system from running when a critical sensor (transducer, level sensor, or motor winding temp sensor) is not functioning correctly and reading out of range. X indicates the specific system; YYYYYYYY indicates FAULT (restarts when the fault clears) or LOCKOUT after 3 faults; ZZZZZZZZZZZ indicates the failed sensor. | Sensor failed or reading out of range (high or low); checked at startup and also during operation. Failed sensor indicated as SUCT PRESS, OIL PRESS, DSCH PRESS, or MOTOR TEMP X. Start inhibit sensor thresholds (Table 18): Suction Transducer 0.3 VDC to 4.7 VDC; Oil Transducer 0.3 VDC to 4.7 VDC; Discharge Transducer 0.3 VDC to 4.7 VDC; Motor Temp. Sensor 0°C (0ºF) to 116°C (240ºF). | Prevents the system from running at startup; faults and shuts down a system while in operation if a safety threshold is exceeded or a sensor reads out of range. Restarts when the fault clears, or LOCKOUT after 3 faults until the operator clears the fault using the keypad. The Unit Setup Mode allows a specific motor temperature sensor to be ignored if it fails. | 116 |
| SYS X YYYYYYYY HIGH MOTOR TEMP | Prevents a compressor from running when its motor temperature is too high. X indicates the system; YYYYYYYY indicates FAULT or LOCKOUT. | Any compressor motor temperature sensor rises above 121°C (250°F); system inhibited from starting if its motor temperature sensors indicate temperatures above 116°C (240°F). If any single temperature sensor is being ignored under the Unit Set-up Mode, that sensor is not utilized when evaluating motor temperature. | Fault and shutdown. Restart when the fault clears, or LOCKOUT until the operator clears the fault using the keypad. | 117 |
| SYS X YYYYYYYY CONTROL VOLTAGE | Alerts the operator that the 115 V AC Control voltage to one of the systems is missing. X indicates the system; YYYYYYYY indicates FAULT or LOCKOUT. | System fuse removed or blown. Safety will not shut down a system if the UNIT switch is OFF (which electrically removes the 115 V AC to all systems); only used to indicate a situation where a single system is missing the 115 V AC. | Affected system faults and shuts down immediately when the 115 V AC supply is lost. Will not cause a lockout; the system fault resets when power is returned. | 117 |
| EDUCTOR CLOG FAULT | Senses a loss of oil return to the compressor — the eductor clog detection safety monitors the temperature of the line between the eductor and the suction line. | Eductor line temperature greater than the saturated suction temperature plus 5.5°C (10°F): the clog timer (set at 600 seconds at start) is decremented one second for each second above the threshold and, if the temperature remains above the threshold for 600 seconds, counts to "0". Timer resets to 600 seconds whenever the eductor line temperature is below the threshold, preventing nuisance faults. | System shuts down and locks out. Whenever this fault occurs, the eductor filter should be changed. | 117 |
Real time error numbers for BAS, SC-EQ or E-Link communications card
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 0 | ALL OK | 108 | ||
| 1 | DATUM TYPE OK TEST FAILED | 108 | ||
| 2 | ENGLISH TEXT TOO LONG | 108 | ||
| 3 | FLOATING POINT EXCEPTION | 108 | ||
| 4 | GET PACKET FAILED | 108 | ||
| 5 | GET TYPE FAILED | 108 | ||
| 6 | INVALID UNIT CONVERSION | 108 | ||
| 7 | INVALID HARDWARE SELECTION | 108 | ||
| 8 | REAL TIME FAULT | 108 | ||
| 9 | SPANISH TEXT TOO LONG | 108 | ||
| 10 | THREAD EXITED | 108 | ||
| 11 | THREAD FAILED | 108 | ||
| 12 | THREAD STALLED | 108 | ||
| 13 | IO BOARD RESET | 108 | ||
| 14 | RTC/BRAM INVALID | 108 | ||
| 15 | BACNET SETUP FAILED | 108 |
Flash card update error
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 0 | Okay | 110 | ||
| 10 | Flash card not found. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 110 | |
| 11 | SOFTWARE.ELF file not found | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 110 | |
| 14 | SOFTWARE.ELF file larger than expected. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 110 | |
| 15 | RAM to IPU Flash transfer of DATABASE.ELF failed. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 110 | |
| 16 | RAM to IPU Flash transfer of SOFTWARE.ELF failed. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 110 | |
| 17 | Could not allocate sufficient memory to read or write file. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 110 | |
| 99 | Internal software error. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 110 |
Troubleshooting guide
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| NO DISPLAY ON CONTROL PANEL UNIT WILL NOT RUN. | Supply to the Panel is missing. High Voltage to the Chiller is missing. Line Fuse is blown. Chiller Control Board is defective. Display Board defective. | Check 1FU, 2FU, 4FU, 5FU 17FU, or 19FU. Check 2T or 10T Transformer. Check Fuses. Replace Chiller Control Board. Replace Display Board. | 170 | |
| LINE FUSE BLOWS. | SCR Diode Module is defective. IBGT Module is defective. VSD Logic Board is defective. SCR Trigger Board is defective. | Check SCR/Diode Module. Check IBGT Module. Replace VSD Logic Board. Replace SCR Trigger Board. | 170 | |
| CHILLER FAULT: LOW AMBIENT TEMPERATURE | Ambient temperature is lower than the programmed operating limit. Ambient Sensor is defective. | Check the programmed cutout and determine if it is programmed correctly. Check the panel against the thermometer reading of ambient temperature. | 170 | |
| CHILLER FAULT: HIGH AMBIENT TEMPERATURE | Ambient Temperature is above the maximum operating limit. Ambient Sensor is defective. | Check outside air temperature. Check the Panel Display against Thermometer reading of Ambient Temperature at the sensor. | 170 | |
| CHILLER FAULT: LOW LEAVING CHILLED LIQUID | Leaving chilled liquid temperature drops faster than the unit can unload. Water loop is too small. Flow is below minimum for chiller. Chilled Water Sensor is defective. | Check for restricted flow. Check for rapid flow changes. Check Sensor against Temp. Gauge in water line. Check Sensor for intermittent operation. Check Wiring for shorts or opens. | 170 | |
| SYSTEM FAULT: CONTROL VOLTAGE | System Fuse is blown. | Check respective system Fuse 20FU or 21FU. NOTE: Always remove power to the chiller and ensure the DC Bus voltage has bled off. | 170 | |
| SYSTEM FAULT: HIGH DISCHARGE PRESSURE | Coils dirty. Coils are damaged. Fans NOT operating. System is overcharged. | Check and clean coils. Comb out fins. Check fan fuses. Check fan rotation. Check fan motor/blade. Remove charge and check subcooling. | 171 | |
| SYSTEM FAULT: HIGH DISCHARGE TEMPERATURE | Discharge Temperature Sensor is defective. Condenser Fans NOT operating or are running backwards. Coils dirty. High Superheat. | Check Sensor. Check Fans. Check and clean Coils. Measure Superheat with gauges and thermocouple. Determine cause. | 171 | |
| SYSTEM FAULT: HIGH MOTOR TEMPERATURE | High Motor temperature input from one of the sensors. Refrigerant charge low. Excess charge in system, High discharge pressure. High Superheat. Motor Sensor reading incorrectly. Economizer Solenoid energized at low speeds. | Check subcooling. Check subcooling. Drain/Feed Valves NOT controlling. Isolate cause. Program panel to ignore a single sensor. Valve is leaking through. | 171 | |
| SYSTEM FAULT: LOW SUCTION PRESSURE | Low charge. Transducer reads incorrectly. Suction Temp. Sensor reads incorrectly. Low flow. Condenser Drain (Flash Tank Feed) Valve NOT operating. Condenser or Drain (Flash Tank Feed) Valve defective. | Check subcooling. Check transducer against a gauge. Check sensor against a thermocouple. Check flow. Check Feed and Drain Valve operation. Check superheat. Check Feed and Drain Valve operation. Check superheat. | 171 | |
| VSD FAULT: HIGH BASEPLATE TEMPERATURE | Coolant level low. Glycol Pump is defective. VSD Board is defective IBGT Module is defective. | Add coolant. Replace Glycol Pump. Replace VSD Logic Board. Check defective IGBT Module. | 172 | |
| VSD FAULT: LOW DC BUS VOLTAGE | SCR / Diode Module is defective. SCR Trigger Board is defective. | Check SCR / Diode Module. Check SCR Trigger Board. NOTE: Always remove power to the chiller and ensure the DC Bus voltage has bled off. | 172 |
From Model YVAA Style B Air-Cooled Screw Liquid Chillers with Variable Speed Drive Frame Sizes 016 to 026 201.47-ICOM1.EN.CE
Original: docs.johnsoncontrols.com
Safety update error messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| MORE THAN ONE FILE FOUND PRESS THE ENTER KEY TO CONTINUE X | Software update aborted; panel waits for operator acknowledgement. | More than one *.bin file found on the selected SD card or USB device. | Press the ENTER key to return to the previous screen (software download). | 190 |
| FILE NOT FOUND PRESS THE ENTER KEY TO CONTINUE X | Software update aborted; panel waits for operator acknowledgement. | No *.bin file on the selected device. | Press the ENTER key. | 190 |
| FILE NOT ABLE TO BE LOADED PRESS THE ENTER KEY TO CONTINUE X | Software update aborted; panel waits for operator acknowledgement. | The *.bin file is not able to be loaded to SPI flash, for example if the embedded checksum verification fails. | Press the ENTER key. | 190 |
| SELECTED DEVICE NOT FOUND PRESS THE ENTER KEY TO CONTINUE X | Software update aborted; panel waits for operator acknowledgement. | User tried to update the software without inserting an SD or USB device. | Press the ENTER key. | 190 |
| FLASH ERROR XX PRESS THE ENTER KEY TO CONTINUE X | Other internal errors during the update; XX corresponds to the flash card update error codes of Table 24. | Other internal errors. | Press the ENTER key. | 190 |
| 10 | Flash card update error code: Flash card not found. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 189 | |
| 11 | Flash card update error code: SOFTWARE.ELF file not found. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 189 | |
| 14 | Flash card update error code: SOFTWARE.ELF file larger than expected. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 188 | |
| 15 | Flash card update error code: RAM to IPU Flash transfer of DATABASE.BIN failed. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 188 | |
| 16 | Flash card update error code: RAM to IPU Flash transfer of SOFTWARE.ELF failed. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 188 | |
| 17 | Flash card update error code: Could not allocate sufficient memory to read or write file. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 188 | |
| 99 | Flash card update error code: Internal software error. | Never reset or power down the chiller until the update is finished. Interrupting the flash update procedure can corrupt the program file and render the control board inoperative. | 190 |
Unit warning
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT WARNING: !! LOW BATTERY !! CHECK SETPOINTS/PROGRAM/OPTIONS/TIME | RTC battery low detected at power-up. All programmed setpoints, program values, time, schedule, and history buffers are lost and reset to default values, which may not be the appropriate operating values. Unit is prevented from running. Warning displays indefinitely; warnings are not logged to the history buffer. | RTC battery voltage low / bad battery, checked when powering up the micropanel. | Replace the battery as soon as possible; the unit cannot run on the next power interruption until values are restored. After detecting a bad battery the unit is prevented from running until the MANUAL OVERRIDE key is pressed; anti-recycle timers are then set to the programmed default anti-recycle time so the operator has time to check setpoints, program values and other parameters. | 191 |
| UNIT WARNING: INVALID NUMBER OF COMPRESSORS SELECTED | Warning displayed indefinitely; invalid number-of-compressors-selected configuration. | Occurs after initializing the VSD if no number-of-compressors-select jumpers are installed, or if more than 1 jumper is installed. | To clear the warning, turn off both the control panel and VSD control voltage and ensure the jumpers are correctly installed in the VSD wiring harness. Jumpers are factory installed in the wire harness plug and do not require changes. | 191 |
| UNIT WARNING: INVALID SERIAL NUMBER ENTER UNIT SERIAL NUMBER | May mean the chiller has lost important factory-programmed information; the serial number and other important data may need to be reprogrammed. | Invalid / lost serial number data. | Immediately contact Johnson Controls Product Technical Support. Enter the serial number using the service key (date and time must be set on the chiller before programming; factory-provided password required). This status message can be bypassed to view additional messages under the STATUS key by pressing the STATUS key repeatedly. | 191 |
| UNIT WARNING QUARTERLY SERVICE REQUIRED – CONTACT JCI | Quarterly service reminder. Warnings are not logged in the history buffer. | Days since the last service exceed 90 days. | When quarterly service is complete, set the days to zero after clearing the warning. | 191 |
| Unit WARNING YEARLY SERVICE REQUIRED – CONTACT JCI | Yearly service reminder. Warnings are not logged in the history buffer. | Days since the last service exceed 365 days and the operating hours since the last service exceed 2,890 hours. | When the yearly service is complete, set the days to zero after clearing the warning. | 192 |
| UNIT WARNING 3 YEAR SERVICE REQUIRED – CONTACT JCI | 3 year service reminder. Warnings are not logged in the history buffer. | Days since the last service exceed 1,095 days. | When the 3 year service is complete, set the days to zero after clearing the warning. | 192 |
| UNIT WARNING 5 YEAR SERVICE REQUIRED – CONTACT JCI | 5 year service reminder. Warnings are not logged in the history buffer. | Days since the last service exceed 1,825 days. | When the 5 year service is complete, set the days to zero after clearing the warning. | 192 |
Unit safeties
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT YYYYYYYY HIGH AMBIENT TEMP | Ambient temperature above allowable range; chiller shuts down with a controlled ramped shutdown. Fault message present only while the ambient temperature is causing the fault condition. | Ambient temperature rises above 55°C. | Auto-reset: restart occurs automatically, if demand allows, when temperature falls 1.1°C below the cutout of 53.9°C. Cannot cause a lockout. Unit is inhibited from starting any time the temperature is above 53.9°C. | 192 |
| UNIT YYYYYYYY LOW AMBIENT TEMP | Ambient temperature below the programmable Low Ambient Temp Cutout; chiller shuts down with a controlled ramped shutdown. Fault message present only while the ambient temperature is causing the fault condition. | Ambient temperature falls below the programmable Low Ambient Temp Cutout. Fault only occurs if the Low Ambient Cutout is ENABLED under the OPTIONS key. | Auto-reset: restart can occur, if demand allows, when temperature rises 1.1°C above the cutout. Cannot cause a lockout. Unit is inhibited from starting any time the temperature is below the cutout plus 1.1°C. | 192 |
| UNIT YYYYYYYY LOW LEAVING CHILLED LIQUID TEMP | Leaving chilled liquid temperature below the programmable cutout; helps protect the chiller from an evaporator freeze-up; chiller faults and shuts down with a controlled ramped shutdown. | Leaving chilled liquid temperature (water or brine) drops below the programmable cutout point — situation could occur under low flow conditions or if the Micro Panel setpoint values are improperly programmed. | Auto-reset: restart can occur, if demand allows, when chilled liquid temperature rises 2.2°C above the cutout. Cannot cause a lockout. Unit is inhibited from starting any time the chilled liquid temperature is below the cutout plus 2.2°C. | 193 |
| UNIT YYYYYYYY VSD COMMUNICATIONS FAILURE | Prevents the unit from trying to run if the Chiller Control Board never initializes communications with the VSD Logic Board; shuts down all compressors with a controlled ramped shutdown if communications are lost while operating. | On power-up, no reply from the VSD Logic Board within 8 s; or during normal operation, no valid response to messages for 8 s. | Unit is inhibited from starting until communications is established. Auto-reset: fault automatically resets when the Chiller Control Board receives a valid response from the VSD for a data request. VSD-related unit fault: if any 3 VSD unit faults occur within 90 min the unit locks out on the last fault; a VSD lockout requires a manual reset — both system switches must be cycled OFF and ON. | 193 |
System safeties, faults
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| SYS X YYYYYYYY HIGH DISCHARGE PRESSURE | High Discharge Pressure Cutout (software fault); system faults and shuts down with a controlled ramped shutdown. | Discharge pressure rises above the programmed discharge pressure cutout for 0.5 seconds. | System allowed to restart when discharge pressure falls below the programmed cutout − 2.07 bar; inhibited from starting above cutout − 2.07 bar. Auto-reset after the 120 s anti-recycle timer; locks out on the 3rd fault within 90 min — cycle the respective system switch OFF and ON to clear. | 194 |
| SYS X YYYYYYYY HPCO FAULT | Mechanical high pressure cutout (hardware) protecting the system from dangerously high discharge pressure; system faults and shuts down immediately. | Mechanical HPCO contacts open (opens at 23.2 barg ± 0.55 barg; closes at 17.4 barg ± 0.69 barg). Wired in series with the VSD Run Signal; only checked when the system is running. Fault occurs immediately, does not wait 3 s. | Auto-reset after the 120 s anti-recycle timer; locks out on the 3rd fault within 90 min — cycle the respective system switch OFF and ON to clear. | 194 |
| SYS X YYYYYYYY LOW SUCTION PRESSURE | Programmable Low Suction Pressure Cutout; protects the chiller from an evaporator freeze-up if the system attempts to run with a low refrigerant charge. | Suction pressure falls below the ramped Suction Pressure Cutout during the startup ramp, or below the programmed Suction Pressure Cutout after the ramp. Cutout is ignored at system start for the programmable Suction Pressure Startup Bypass Time, then linearly ramped from 10% to 100% of the programmed Suction Pressure Cutout. | Causes a lockout on the 3rd fault in 90 min — cycle the respective system switch OFF and ON to clear. | 194 |
| SYS X YYYYYYYY LOW SUCT PRES SMART FREEZE | Smart freeze safety fault. | Suction Pressure below the Suction Pressure Override Threshold longer than the programmable Smart Freeze Timer. Override Threshold = Suction Pressure Cutout + 11.72 kPa (R-134a), + 12.41 kPa (R-513A), + 8.96 kPa (R-1234ze). | Safety released when Suction Pressure ≥ Suction Pressure Override Threshold. Causes a lockout on the 3rd fault in 90 min — cycle the respective system switch OFF and ON to clear. | 194 |
| SYS X YYYYYYYY LOW MOTOR CURRENT | Motor Current Cutout; shuts the system down with a controlled ramped shutdown. | Microprocessor detects absence of motor current (less than 10% FLA), usually indicating that a compressor is not running. Safety ignored for the first 10 s of operation. | Auto-reset after the 120 s anti-recycle timer; locks out on the 3rd fault within 90 min — cycle the respective system switch OFF and ON to clear. | 195 |
| SYS X YYYYYYYY HIGH DIFF OIL PRESSURE | High Differential Oil Pressure Cutout; protects the compressor from low oil flow and insufficient lubrication; shuts down with a controlled ramped shutdown. | Discharge-to-Oil differential pressure rises above the cutout of 4.48 barg (measures the pressure drop across the oil filter — possibly a dirty oil filter). Safety ignored for the first 90 s of run time. | Auto-reset after the 120 s anti-recycle timer; locks out on the 3rd fault within 90 min — cycle the respective system switch OFF and ON to clear. | 195 |
| SYS X YYYYYYYY LOW DIFF OIL PRESSURE | Low Differential Oil Pressure Cutout; protects the compressor from low oil flow and insufficient lubrication; ensures the compressor is pumping sufficiently to push oil through the oil cooling circuit and internal lubrication system; shuts down with a controlled ramped shutdown. | Differential between oil and suction pressure falls below the cutout. Ignored for the first 60 s of run time; then linearly ramped from 0 barg to 2.09 barg in 5–10 min based on ambient temperature (>10°C: 5 min; >7.2°C: 6 min; >4.4°C: 7 min; >1.6°C: 8 min; >1.1°C: 9 min; ≤1.1°C: 10 min). A 30 s safety bypass below 50 Hz is employed during rampdown. | Auto-reset after the 120 s anti-recycle timer; locks out on the 3rd fault within 90 min — cycle the respective system switch OFF and ON to clear. | 195 |
| SYS X YYYYYYYY HIGH DISCHARGE TEMP | High Discharge Temperature Cutout; protects the motor and compressor from overheating; shuts down with a controlled ramped shutdown. | Discharge Temperature rises above 121°C. | System also inhibited from starting if the discharge temperature is above 93°C. Auto-reset after the 120 s anti-recycle timer; locks out on the 3rd fault within 90 min — cycle the respective system switch OFF and ON to clear. | 195 |
| SYS X YYYYYYYYYY LOW ECONOMIZER SUPERHEAT | Protects against excessive liquid refrigerant carryover from the economizer (possible EEV, sensor or other problems) and protects the system compressor from liquid refrigerant flood back from the economizer feed line if the economizer valve fails to close. | Superheat falls below 2.8°C for 5 min under either condition. Safety ignored for the first 10 min of operation if the system economizer feed valve is closed at 0%, and for 5 min of operation if the economizer feed valve is open greater than 0%. | Auto-reset after the 120 s anti-recycle timer; locks out on the 3rd fault within 90 min — cycle the respective system switch OFF and ON to clear. | 198 |
| SYS X YYYYYYYY SENSOR FAILURE: ZZZZZZZZZZZZ | Sensor Failure Cutout; prevents the system from running when a critical sensor, transducer, level sensor, or motor winding temperature sensor is not functioning properly and reading out of range. Checked at startup (prevents running) and faults/shuts down a system during operation if a safety threshold is exceeded or a sensor reads out of range high or low. | Failed sensor indicated by ZZZZZZZZZZZZ: SUCT PRESS, OIL PRESS, DSCH PRESS, ECONOMIZER PRESS, or MOTOR TEMP X. Start inhibit thresholds: suction, oil and discharge transducers 0.3–4.7 VDC; motor temperature sensor 0–116°C. | A specific motor temperature sensor can be ignored using the unit setup mode if it fails; report any failure to Johnson Controls service for investigation. Auto-reset after the 120 s anti-recycle timer; LOCKOUT after 3 faults — cycle the respective system switch OFF and ON to clear. | 197 |
| SYS X YYYYYYYY HIGH MOTOR TEMP | High Motor Temperature Cutout; prevents a compressor from running when its motor temperature is too high; system faults and shuts down. | Any compressor motor temperature sensor rises above 121°C. | System inhibited from starting if its motor temperature sensors indicate temperatures above 116°C. A sensor being ignored under the Unit Set-up Mode is not used when evaluating motor temperature. Auto-reset after the 120 s anti-recycle timer; locks out on the 3rd fault within 90 min — cycle the respective system switch OFF and ON to clear. | 197 |
| SYS X YYYYYYYY CONTROL VOLTAGE | System Control Voltage Cutout; alerts the operator that the 115 V AC control voltage to one of the systems is missing; affected system faults and shuts down immediately when the 115 V AC supply is lost. | 115 V AC supply lost to a single system — may be due to a system fuse that has been removed or is blown. Does not shut down a system if the UNIT switch is OFF (which electrically removes 115 V AC to all systems). | Will not cause a lockout; the system fault resets when power is returned. | 198 |
| Eductor clog fault | Safety sensing a loss of oil return to the compressor by monitoring the temperature of the line between the eductor and the suction line. No display message is documented for this safety. | Eductor line temperature is not less than the saturated suction temperature plus 5.5°C. Control looks at the eductor line temperature once a second; at start a clog timer is set at 600 s and is reset to 600 s each time the temperature is below the threshold. Eductor differential and eductor safety time are programmable under the PROGRAM key. | 198 | |
| SYS X YYYYYYYYYY ISO VALVE FAILED TO CLOSE | Isolation valve open warning; message displayed and fault code communicated. Shall not prevent the system from starting. | System isolation valve digital input J5-1 or J5-2 indicates the isolation valve did not close within 60 s of the evaporator heater outputs being turned on. | Warning clears when the unit begins precharge or the condition clears. | 198 |
| SYS X YYYYYYYYYY ISO VALVE FAILED TO OPEN | Isolation valve closed fault; system fault before compressor start. | Before starting the compressor, after the VSD has completely precharged, the system isolation valve digital input J5-1 or J5-2 indicates the system isolation valve did not open. | Causes a lockout on the first fault — manual reset required (cycle the respective system switch OFF and ON). | 198 |
| SYS X YYYYYYYYYY HIGH DSCH PRESSURE RATE | High Discharge Pressure Rate Cutout; immediate fault with no 3 s delay. | When enabled, during system run the discharge pressure of each running system is monitored once per second; system shuts down when its discharge pressure rate of change exceeds the programmed Discharge Pressure Rate Threshold (Unit Setup Mode). | Locks out on the first fault — manual reset required (cycle the respective system switch OFF and ON). | 198 |
| SYS X WARNING CONDENSER FAN VSD FAULT | System Condenser Fan VSD Fault Warning; auto reset warning monitoring the status of the fault input. | Fault input is low. | Auto reset — resets when the input is high. | 198 |
| SYS X WARNING REPLACE OIL FILTER | System Replace Oil Filter Warning; manual reset warning monitoring the status of the oil filter maintenance cycle. Can be enabled/disabled under Unit Setup Mode. | Differential Oil to Discharge Pressure is greater than 3.447 bar. | Manual reset warning. | 198 |
General status messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT STATUS FLOW SWITCH SHUTDOWN | Flow switch is not allowing the chiller to run. Loss-of-flow protection against evaporator freeze-up; the manual lists flow switch operation among the unit auto-reset safeties. | Flow switch open (no chilled liquid flow). There is a 1 s delay on this safety to ensure the flow switch did not momentarily open. | Auto-reset: unit can run once the flow switch closes (chilled liquid flow re-established). | 200 |
| UNIT STATUS VSD COOLING SHUTDOWN | Chiller is shut down while all condenser fans, the VSD glycol pump, and the VSD fan run to bring the internal VSD ambient temperature down to an acceptable level before allowing the chiller to start. | Internal VSD ambient temperature above the acceptable level. | Chiller is allowed to start once the internal VSD ambient temperature is brought down to an acceptable level. | 200 |
Troubleshooting guide
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| No display on control panel unit will not run | Control panel dead; unit will not run. | Supply to the panel is missing; line fuse is blown; chiller control board is defective; display board defective. | Verify that power is being applied to the unit from the customer supply; check 1FU, 2FU, 4FU, 5FU, 17FU, or 19FU; check 2T or 10T transformer; check fuses; replace chiller control board; replace display board. | 260 |
| Line fuse blows | Line fuse repeatedly blowing. | SCR diode module is defective; IBGT module is defective; VSD logic board is defective; SCR trigger board is defective. | Check SCR/Diode module; check IBGT module; replace VSD logic board; replace SCR trigger board. Always remove power to the chiller and ensure the DC Bus voltage has bled off. | 260 |
| Chiller fault: Low ambient temperature | Chiller shutdown on low ambient temperature. | Ambient temperature is lower than the programmed operating limit; ambient sensor is defective. | Check the programmed cutout and determine if it is programmed correctly; check the panel against the thermometer reading of ambient temperature. | 260 |
| Chiller fault: High ambient temperature | Chiller shutdown on high ambient temperature. | Ambient temperature is above the maximum operating limit; ambient sensor is defective. | Check outside air temperature; check the panel display against thermometer reading of ambient temperature at the sensor. | 260 |
| Chiller fault: Low leaving chilled liquid | Chiller shutdown on low leaving chilled liquid temperature. | Leaving chilled liquid temperature drops faster than the unit can unload (restricted flow; rapid flow changes; water loop too small; flow below minimum for chiller); chilled water sensor is defective. | Check for restricted flow; check for rapid flow changes; check water loop size; check flow against chiller minimum; check sensor against temp. gauge in water line; check sensor for intermittent operation; check wiring for shorts or opens. | 260 |
| System fault: Control voltage | 115 V AC control voltage missing to a system. | System fuse is blown. | Check respective system fuse 20FU or 21FU. Always remove power to the chiller and ensure the DC Bus voltage has bled off. | 260 |
| System fault: high discharge pressure | System shutdown on high discharge pressure. | Coils dirty; coils are damaged; fans not operating; system is overcharged. | Check and clean coils; comb out fins; check fan fuses, fan rotation, fan motor/blade; remove charge and check subcooling. | 261 |
| System fault: high discharge temperature | System shutdown on high discharge temperature. | Discharge Temperature Sensor is defective; condenser fans not operating or are running backwards; coils dirty; high superheat. | Check sensor; check fans; check and clean coils; measure superheat with gauges and thermocouple and determine cause. | 261 |
| System fault: high motor temperature | System shutdown on high motor temperature. | High motor temperature input from one of the sensors: refrigerant charge low; excess charge in system with high discharge pressure; high superheat (drain or feed valves not controlling); motor sensor reading incorrectly; economizer solenoid energized at low speeds with valve leaking through. | Check subcooling (charge low); check subcooling (excess charge); isolate cause (high superheat); program panel to ignore a single sensor; check economizer solenoid/valve leakage. | 261 |
| System fault: low suction pressure | System shutdown on low suction pressure. | Low charge; transducer reads incorrectly; suction temp. sensor reads incorrectly; low flow; condenser drain valve not operating; condenser or drain valve defective. | Check subcooling; check transducer against a gauge; check sensor against a thermocouple; check flow; check drain valve operation and check superheat. | 261 |
| System fault: low economizer superheat | System shutdown on low economizer superheat. | Economizer line temperature sensor is defective; economizer transducer is defective; economizer feed valve malfunction; economizer line solenoid purge valve malfunction. | Check temperature sensor; check transducer against a gauge; check economizer feed valve operation; check economizer line solenoid purge valve operation. | 261 |
| VSD fault: High baseplate temperature | VSD shutdown on high baseplate temperature. | Coolant level low; glycol pump is defective; VSD board is defective; IBGT module is defective; VSD cooling coil not clean. | Add coolant; replace glycol pump; replace VSD logic board; check defective IGBT module; clean VSD cooling coil. Always remove power to the chiller and ensure the DC Bus voltage has bled off. | 262 |
| VSD fault: Low DC Bus voltage | VSD shutdown on low DC Bus voltage. | SCR/Diode module is defective; SCR trigger board is defective. | Check SCR/diode module; check SCR trigger board. Always remove power to the chiller and ensure the DC Bus voltage has bled off. | 262 |
From YVAA Style A with VSD, Frame size 015-027 2-Compressor 60 Hz (150-350 tons), Frame size 054-098, 2-Compressor 50 Hz (525-950 KW) R-134a or R-513A 201.28-NM1.1
Original: docs.johnsoncontrols.com
Unit warning
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT WARNING: !! LOW BATTERY !! CHECK SETPOINTS/PROGRAM/OPTIONS/TIME | Low Real Time Clock (RTC) battery voltage detected at micropanel power-up. | On micropanel power-up the RTC battery is checked to see if it is still operational; if the battery voltage is determined to be low, this warning message is displayed indefinitely. | All programmed setpoints, program values, time, schedule, and history buffers have been lost and are reset to their default values, which may not be the correct operating values. After a bad battery is detected, the unit is prevented from running until the manual override key is pressed; after pressing the manual override key, the anti-recycle timers are set to the programmed default anti-recycle time to allow the operator sufficient time to check setpoints, program values, and other relevant values. Replace the battery as soon as possible — the programmed values will all be lost and the unit will be prevented from running on the next power interruption. | 139 |
| UNIT WARNING: INVALID NUMBER OF COMPRESSORS SELECTED | Invalid Number of Compressors Select jumper configuration. | Occurs after the VSD has been initialized, if no jumpers are installed or if more than 1 jumper is installed. | To clear this warning, both the control panel and VSD control voltage must be turned OFF and the jumpers properly installed in the VSD wiring harness. | 139 |
| UNIT WARNING: INVALID SERIAL NUMBER ENTER UNIT SERIAL NUMBER | Chiller serial number invalid or lost. | The appearance of this message may mean the chiller has lost important factory programmed information. | Immediately contact Johnson Controls Product Technical Support. The serial number can be entered using the SERVICE key. This status message can be bypassed to view additional messages under the STATUS key by pressing the STATUS key repeatedly to scroll through as many as three STATUS messages that could possibly be displayed at any time. | 139 |
Unit safeties
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT YYYYYYYY HIGH AMBIENT TEMP | Ambient air temperature above the maximum allowable value. | Ambient temperature rises above 55°C (131°F). | Chiller shuts down with a controlled ramped shutdown. Restart will automatically occur, if demand allows, when temperature falls 1.1°C (2°F) below the cutout (53.9°C [129°F]). This fault cannot cause a lockout. The fault display message is present only during the time when the ambient temperature is causing a fault condition. The unit is also inhibited from starting any time the temperature is above 53.9°C (129°F). | 140 |
| UNIT YYYYYYYY LOW AMBIENT TEMP | Ambient air temperature below the programmed cutout. | Ambient temperature falls below the programmable Low Ambient Temp Cutout. This fault only occurs if the Low Ambient Cutout is ENABLED under the OPTIONS key. | Chiller shuts down with a controlled ramped shutdown. Restart can occur, if demand allows, when temperature rises 1.1°C (2°F) above the cutout. This fault cannot cause a lockout. The fault display message is present only during the time when the ambient temperature is causing a fault condition. The unit is also inhibited from starting any time the temperature is below the cutout plus 1.1°C (2°F). | 140 |
| UNIT YYYYYYYY LOW LEAVING CHILLED LIQUID TEMP | Leaving chilled liquid temperature below the freeze-protection cutout. | The leaving chilled liquid temperature (water or brine) drops below the programmable cutout point. Helps protect the chiller from an evaporator freeze-up; this situation could occur under low flow conditions or if the Micro Panel setpoint values are improperly programmed. | Chiller faults and shuts down with a controlled ramped shutdown. Restart can occur, if demand allows, when chilled liquid temperature rises 2.2°C (4°F) above the cutout. This fault cannot cause a lockout. The unit is inhibited from starting any time the chilled liquid temperature is below the cutout plus 2.2°C (4°F). | 140 |
| UNIT YYYYYYYY VSD COMMUNICATIONS FAILURE | Loss of communications between the Chiller Control Board and the VSD Logic Board. | On power-up, the Chiller Control Board fails to initialize communications with the VSD Logic Board (no reply from the VSD Logic Board within 8 seconds), or during normal operation the Chiller Control Board receives no valid response to messages for 8 seconds. | Prevents the unit from trying to run; while operating, the unit shuts down all compressors with a controlled ramped shutdown. The Chiller Control Board continues to send messages to the VSD while faulted. The unit is inhibited from starting until communications is established. The fault automatically resets when the Chiller Control Board receives a valid response from the VSD for a data request. | 140 |
System safeties, faults
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| SYS X YYYYYYYY HIGH DISCHARGE PRESSURE | Software high discharge pressure cutout. | Discharge pressure rises above 22.4 barg (325 psig) for 0.5 seconds. | System faults and shuts down with a controlled ramped shutdown. The system is allowed to restart when the discharge pressure falls to 20.3 barg (295 psig). The system is also inhibited from starting if the pressure is above 20.3 barg (295 psig). YYYYYYYY = FAULT (system restarts when the 120 second anti-recycle timer times out) or LOCKOUT (does not restart until the operator clears the fault using the keypad). | 141 |
| SYS X YYYYYYYY HPCO FAULT | Mechanical (hardware) high pressure cutout trip. | The mechanical high pressure cutout contacts open, protecting the system from dangerously high discharge pressure. The cutout opens at 23.2 barg ± 0.55 barg (337 psig ± 8 psig) and closes at 17.4 barg ± 0.69 barg (252 psig ± 10 psig). The HPCO is wired in series with the VSD Run Signal and is only checked by the Chiller Control Board when the system is running. The fault occurs immediately and does not wait 3 seconds. | System faults and shuts down immediately. YYYYYYYY = FAULT (system restarts when the 120 second anti-recycle timer times out) or LOCKOUT (will not restart until the operator clears the fault using the keypad). | 141 |
| SYS X YYYYYYYY LOW SUCTION PRESSURE | Suction pressure below the programmable cutout. | If the system attempts to run with a low refrigerant charge, the programmable LOW SUCTION PRESSURE CUTOUT protects the chiller from an evaporator freeze-up. The cutout is ignored at the system start to allow the initial programmable SUCTION PRESSURE STARTUP BYPASS TIME; immediately after the bypass time expires, the cutout is linearly ramped from 10% to 100% of the programmed Suction Pressure Cutout. | The system shuts down if at any time during the ramp the suction pressure falls below the ramped Suction Pressure Cutout, or if at any time after the ramp the suction pressure falls below the programmable Suction Pressure Cutout. This causes a lockout on the 3rd fault in 90 minutes. | 142 |
| SYS X YYYYYYYY LOW SUCT PRES SMART FREEZE | Suction pressure held below the override threshold longer than permitted (R-134a and R-513A refrigeration systems). | Set when the Suction Pressure is lower than the programmable Suction Pressure Override Threshold (Suction Pressure Cutout in psig + 1.7 psig) for longer than the programmable Smart Freeze Timer. The safety fault is released when the Suction Pressure >= Suction Pressure Override Threshold. | This fault causes a lockout on the 3rd fault in 90 minutes. | 142 |
| SYS X YYYYYYYY LOW MOTOR CURRENT | Absence of motor current detected. | The microprocessor detects the absence of motor current (less than 10% FLA), usually indicating that a compressor is not running. This safety is ignored for the first 10 seconds of operation. | Shuts the system down with a controlled ramped shutdown. YYYYYYYY = FAULT (system restarts when the 120 second anti-recycle timer times out) or LOCKOUT (will not restart until the operator clears the fault using the keypad). | 142 |
| SYS X YYYYYYYY HIGH DIFF OIL PRESSURE | Excessive discharge-to-oil differential pressure (pressure drop across the oil filter). | The Discharge to Oil Differential Pressure rises above the cutout of 4.48 barg (65 psid). Protects the compressor from low oil flow and insufficient lubrication, possibly from a dirty oil filter. This safety is ignored for the first 90 seconds of run time. | System faults and shuts down with a controlled ramped shutdown. YYYYYYYY = FAULT (system restarts when the 120 second anti-recycle timer times out) or LOCKOUT (will not restart until the operator clears the fault using the keypad). | 142 |
| SYS X YYYYYYYY LOW DIFF OIL PRESSURE | Oil-to-suction differential pressure below the cutout (protection against low oil flow and insufficient lubrication). | The differential between oil and suction pressure falls below the cutout. The safety ensures the compressor is pumping sufficiently to push oil through the oil cooling circuit and the internal compressor lubrication system. The safety is ignored for the first 60 seconds of run time; after that the cutout is linearly ramped from 0 barg to 2.09 barg (0 psid to 30 psid) in 5 to 10 minutes based on ambient temperature (see Table 17). A 30 second safety bypass below 50 Hz is employed during rampdown (needed when another compressor is being brought on and the running compressor is ramped down to 5 Hz). | System faults and shuts down with a controlled ramped shutdown. YYYYYYYY = FAULT (system restarts when the 120 second anti-recycle timer times out) or LOCKOUT (will not restart until the operator clears the fault using the keypad). | 143 |
| SYS X YYYYYYYY HIGH DISCHARGE TEMP | Discharge temperature above the cutout (motor and compressor overheat protection). | Discharge Temperature rises above 121°C (250°F). | System faults and shuts down with a controlled ramped shutdown. The system is also inhibited from starting if the discharge temperature is above 93°C (200°F). YYYYYYYY = FAULT (system restarts when the 120 second anti-recycle timer times out) or LOCKOUT (will not restart until the operator clears the fault using the keypad). | 143 |
| Low discharge superheat cutout fault | Protection against liquid floodback through the economizer line due to a high flashtank level, and against excessive oil in circulation due to excess oil charge in the system. | Discharge superheat falls below 2.8°C (5.0°F) for 5 minutes. The safety is ignored for the first 10 minutes of operation if the system economizer feed valve is closed (0%), and for 5 minutes of operation if the economizer feed valve is open greater than 0%. Excessive oil in circulation brings back liquid refrigerant entrained in the oil; the liquid drops out once it enters the compressor. | System shuts down. YYYYYYYY = FAULT (system restarts when the 120 second anti-recycle timer times out) or LOCKOUT (will not restart until the operator clears the fault using the keypad). | 143 |
| SYS X YYYYYYYY SENSOR FAILURE: ZZZZZZZZZZZZ | A critical sensor is failed or reading out of range. ZZZZZZZZZZZZ indicates the failed sensor: SUCT PRESS, OIL PRESS, DSCH PRESS, or MOTOR TEMP X * (* a specific motor temperature sensor can be ignored under the Unit Setup Mode). | A critical sensor (transducer, level sensor, or motor winding temp sensor) is not functioning properly and reading out of range. The safety is checked at startup and will also fault and shut down a system while in operation if a safety threshold is exceeded or a sensor reads out of range (high or low). Start inhibit sensor thresholds (Table 20): Suction Transducer 0.3–4.7 VDC; Oil Transducer 0.3–4.7 VDC; Discharge Transducer 0.3–4.7 VDC; Motor Temp. Sensor 0°C (0°F) to 116°C (240°F). | At startup, prevents the system from running if one of the sensors has failed. During operation, the system faults and shuts down. YYYYYYYY = FAULT (system restarts when the fault clears) or LOCKOUT after 3 faults (will not restart until the operator clears the fault using the keypad). | 145 |
| SYS X YYYYYYYY HIGH MOTOR TEMP | Compressor motor temperature too high. | Any compressor motor temperature sensor rises above 121°C (250°F). The system is inhibited from starting if its motor temperature sensors indicate temperatures above 116°C (240°F). If any single temperature sensor is being ignored under the Unit Set-up Mode, that sensor is not utilized when evaluating motor temperature. | System faults and shuts down. YYYYYYYY = FAULT (system restarts when the fault clears) or LOCKOUT (will not restart until the operator clears the fault using the keypad). | 145 |
| SYS X YYYYYYYY CONTROL VOLTAGE | 115 V AC control voltage missing from one system. | The 115 V AC Control voltage to one of the systems is missing; this could be due to a system fuse that has been removed or is blown. The affected system faults and shuts down immediately when the 115 V AC supply is lost. The safety will not shut down a system if the UNIT switch is OFF (which electrically removes the 115 V AC to all systems); it is only used to indicate a situation where a single system is missing the 115 V AC. | This safety will not cause a lockout; the system fault resets when power is returned. | 145 |
| EDUCTOR CLOG FAULT | Loss of oil return to the compressor through the eductor. | The safety monitors the temperature of the line between the eductor and the suction line once a second. At start, a clog timer is set at 600 seconds; the timer resets to 600 seconds whenever the eductor line temperature is less than the saturated suction temperature plus 5.5°C (10°F). If the eductor line temperature is greater than the saturated suction temperature plus 5.5°C (10°F) for 600 seconds, the clog timer counts to 0. | The system shuts down and locks out. Whenever this fault occurs, the eductor filter should be changed. | 146 |
General status messages
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT STATUS FLOW SWITCH SHUTDOWN | Chilled liquid flow switch open — flow switch is not allowing the chiller to run. | The flow switch is not allowing the chiller to run. There is a 1 second delay on this safety to ensure the flow switch did not momentarily open. | Chiller is kept shut down while the flow switch is open. | 148 |
| UNIT STATUS VSD COOLING SHUTDOWN | Chiller shut down while the VSD internal ambient temperature is brought down to an acceptable level. | The chiller is shutdown, but running all the condenser fans, VSD glycol pump, and VSD fan in an effort to bring the internal VSD ambient temperature down to an acceptable level before allowing the chiller to start. | Chiller remains shut down (with condenser fans, VSD glycol pump and VSD fan running) until the internal VSD ambient temperature is at an acceptable level, before the chiller is allowed to start. | 148 |
Flash card update error
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 0 | Okay | 130 | ||
| 10 | Flash card not found. | 130 | ||
| 11 | SOFTWARE.ELF file not found | 130 | ||
| 14 | SOFTWARE.ELF file larger than expected. | 130 | ||
| 15 | RAM to IPU Flash transfer of DATABASE.ELF failed. | 130 | ||
| 16 | RAM to IPU Flash transfer of SOFTWARE.ELF failed. | 130 | ||
| 17 | Could not allocate sufficient memory to read or write file. | 130 | ||
| 99 | Internal software error. | 130 |
Software update errors
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| MORE THAN ONE FILE FOUND | more than on *.bin file on selected device | 132 | ||
| FILE NOT FOUND | *.bin file not on selected device | 132 | ||
| FILE NOT ABLE TO BE LOADED | *.bin file not able to be loaded to flash | 132 | ||
| SELECTED DEVICE NOT FOUND | update attempted without SD or USB | 132 |
Flash errors
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| FILE_BUFFER_APP_HEADER_READ | Error code 90 | 132 | ||
| CANNOT_CALCULATE_BUFFER_DATA_CRC | Error code 91 | 132 | ||
| BAD_FILE_BUFFER_DATA_CRC | Error code 92 | 132 | ||
| SFLASH_DEVICE_WRITE | Error code 93 | 132 | ||
| BAD_SFLASH_CRC | Error code 94 | 132 | ||
| APP_CODE_TOO_BIG | Error code 95 | 132 | ||
| SPI_FLASH_APP_NOT_PRESENT | Error code 96 | 132 | ||
| SPI_FLASH_READ_ERROR | Error code 97 | 132 | ||
| CANNOT_READ_DEVICE_CONFIGURATION | Error code 98 | 132 |
Troubleshooting guide
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| No display on control panel unit will not run. | Supply to the Panel is missing. High Voltage to the Chiller is missing. Line Fuse is blown. Chiller Control Board is defective. Display Board defective. | Check 1FU, 2FU, 4FU, 5FU 17FU, or 19FU. Check 2T or 10T Transformer. Check Fuses. Replace Chiller Control Board. Replace Display Board. | 198 | |
| Line fuse blows. | SCR Diode Module is defective. IBGT Module is defective. VSD Logic Board is defective. SCR Trigger Board is defective. | Check SCR/Diode Module. Check IBGT Module. Replace VSD Logic Board. Replace SCR Trigger Board. | 198 | |
| Chiller fault: Low ambient temperature | Ambient temperature is lower than the programmed operating limit. Ambient Sensor is defective. | Check the programmed cutout and determine if it is programmed correctly. Check the panel against the thermometer reading of ambient temperature. | 198 | |
| Chiller fault: High ambient temperature | Ambient Temperature is above the maximum operating limit. Ambient Sensor is defective. | Check outside air temperature. Check the Panel Display against Thermometer reading of Ambient Temperature at the sensor. | 198 | |
| Chiller fault: Low leaving chilled liquid | Leaving chilled liquid temperature drops faster than the unit can unload. Water loop is too small. Flow is below minimum for chiller. Chilled Water Sensor is defective. | Check for restricted flow. Check for rapid flow changes. Check Sensor against Temp. Gauge in water line. Check Sensor for intermittent operation. Check Wiring for shorts or opens. | 198 | |
| System fault: Control voltage | System Fuse is blown. | Check respective system Fuse 20FU or 21FU. | 198 | |
| System fault: High discharge pressure | Coils dirty. Coils are damaged. Fans NOT operating. System is overcharged. | Check and clean coils. Comb out fins. Check fan fuses. Check fan rotation. Check fan motor/blade. Remove charge and check subcooling. | 199 | |
| System fault: High discharge temperature | Discharge Temperature Sensor is defective. Condenser Fans NOT operating or are running backwards. Coils dirty. High Superheat. | Check Sensor. Check Fans. Check and clean Coils. Measure Superheat with gauges and thermocouple. Determine cause. | 199 | |
| System fault: High motor temperature | High Motor temperature input from one of the sensors. Refrigerant charge low. Excess charge in system, High discharge pressure. High Superheat. Motor Sensor reading incorrectly. Economizer Solenoid energized at low speeds. | Check subcooling. Check subcooling. Drain/Feed Valves NOT controlling. Isolate cause. Program panel to ignore a single sensor. Valve is leaking through. | 199 | |
| System fault: Low suction pressure | Low charge. Transducer reads incorrectly. Suction Temp. Sensor reads incorrectly. Low flow. Condenser Drain (Flash Tank Feed) Valve NOT operating. Condenser or Drain (Flash Tank Feed) Valve defective. | Check subcooling. Check transducer against a gauge. Check sensor against a thermocouple. Check flow. Check Feed and Drain Valve operation. Check superheat. Check Feed and Drain Valve operation. Check superheat. | 199 | |
| System fault: Discharge pressure limiting | Discharge Transducer is defective. Ambient Temp. very high. Fans not operating. Remote or local discharge pressure load limiting is programmed. | Check transducer against a gauge. Normal operation. Check fan operation. Normal operation. | 199 | |
| VSD fault: High baseplate temperature | Coolant level low. Glycol pump is defective. VSD Board is defective. IBGT Module is defective. | Add coolant. Replace Glycol Pump. Replace VSD Logic Board. Check defective IGBT Module. | 200 | |
| VSD fault: Low DC Bus voltage | SCR/Diode Module is defective. SCR Trigger Board is defective. | Check SCR/Diode Module. Check SCR Trigger Board. | 200 |
From Improved clamped voltage design for digital suction pressure transducers SI0602
Original: docs.johnsoncontrols.com
Improved clamped voltage design for digital suction pressure transducers
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| sensor failure fault | Suction pressure transducer output voltage value below 0.3 V and above 4.7 V results in a sensor failure fault on the impacted system on the chiller, which inhibits the operation of that system. Observed on chillers in high ambient climate locations when the chiller was in standby mode; this prevented the system(s) from startup. | The voltage output of the impacted suction pressure transducers (P/N: 025-29583-002, digital type, identified by the 2D matrix barcode stamped on the side of the transducer) was unregulated and could reach up to 4.9 V. These transducers were released to production in January 2021; transducers prior to this date are not impacted by this issue. | Verify the manufacturing date for the digital pressure transducer (identified by 2D barcode) to determine if it has unclamped output voltage and needs to be replaced. The last 3 digits of the serial number depict the code for week and year of manufacturing. If the transducer was manufactured between January 2021 and week 10 of 2022 (date code: 102), replace the transducer with a new part — an improved version of the suction pressure transducer that clamps the maximum output voltage at 4.7 V, thereby preventing the sensor failure fault from occurring during these high ambient conditions. | 1 |
From SOO Do's and Don'ts Workbook / Troubleshooting Guide SI0630
Original: docs.johnsoncontrols.com
Errors (IPU3 Software Update)
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| MORE THAN ONE FILE FOUND PRESS TO CONTINUE (x) | Error message displayed during IPU3 program update. | More than one *.bin file is on the selected device. | Displayed until the user presses the Enter key and returns to the software download display. | 5 |
| FILE NOT FOUND PRESS TO CONTINUE (x) | Error message displayed during IPU3 program update. | No *.bin file is on the selected device. | Displayed until the user presses the Enter key and returns to the software download display. | 5 |
| FILE NOT ABLE TO BE LOADED PRESS TO CONTINUE (x) | Error message displayed during IPU3 program update. | The *.bin file cannot be loaded to SPI flash, for example if the embedded checksum verification fails. | Displayed until the user presses the Enter key and returns to the software download display. | 5 |
| SELECTED DEVICE NOT FOUND PRESS TO CONTINUE (x) | Error message displayed during IPU3 program update. | The software update was attempted without a SD or USB device inserted. | Displayed until the user presses the Enter key and returns to the software download display. | 5 |
| FLASH ERROR XX PRESS TO CONTINUE (x) | Displayed if other internal errors occur during the software update. The Error Code displayed in the XX field is one of: 90 — FILE_BUFFER_APP_HEADER_READ 91 — CANNOT_CALCULATE_BUFFER_DATA_CRC 92 — BAD_FILE_BUFFER_DATA_CRC 93 — SFLASH_DEVICE_WRITE 94 — BAD_SFLASH_CRC 95 — APP_CODE_TOO_BIG 96 — SPI_FLASH_APP_NOT_PRESENT 97 — SPI_FLASH_READ_ERROR 98 — CANNOT_READ_DEVICE_CONFIGURATION | Other internal errors occurred during the software update. | Displayed until the user presses the Enter key. | 5 |
Unit Faults
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 1 Low Ambient Temperature | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 2 High Ambient Temperature | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 3 Low Chilled Liquid Temperature | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 4 VSD Initialization Failure | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 5 Low RTC Battery Voltage | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 6 Invalid Number of Compressors Selected | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 7 VSD Communications Failure | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 8 Pre-charge Low DC Bus Voltage | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 9 Pre-charge DC Bus Voltage Imbalance | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 10 High DC Bus Voltage | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 11 Low DC Bus Voltage | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 12 DC Bus Voltage Imbalance | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 13 High VSD Ambient Temperature | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 14 Single Phase Input | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 15 VSD Power Supply Fault | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 16 VSD Logic Board Fault | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 17 Motor Current Overload (Hardware) | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 18 CT Plug Fault | Unit fault — VSD source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. If any 3 (or more) VSD-related unit faults occur within 90 minutes, the unit triggers a lockout on the last fault in the range. A lockout requires manual reset, done via the System Switches button on the keypad or HMI. | 16 | |
| 19 High Harmonic Filter Temperature | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 20 Evap Anti-Freeze Pump Fault | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 21 SPARE | Unit fault — Panel source | 16 | ||
| 22 Replace RTC Battery | Unit fault — Panel source | If unit faults exceed a set threshold for 3 seconds, all running compressors are shut down. Unit faults are logged in the history buffer. Most unit faults are auto-reset; the unit can restart automatically after the fault condition is cleared. | 16 | |
| 23 SPARE | Unit fault — source not listed | 16 | ||
| 24 SPARE | Unit fault — source not listed | 16 | ||
| 25 SPARE | Unit fault — source not listed | 16 | ||
| 26 SPARE | Unit fault — source not listed | 16 |
System Faults
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| 27 High Discharge Pressure (Software) | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 16 | |
| 28 High Differential Oil Pressure | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 16 | |
| 29 Low Differential Oil Pressure | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 16 | |
| 30 Low Suction Pressure | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 16 | |
| 31 High Discharge Temperature | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 16 | |
| 32 SPARE | System fault — Panel source | 17 | ||
| 33 Eductor Clog Fault | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 34 Sensor Failure | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 35 Low Motor Current | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 36 High Motor Temperature | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 37 Pre-charge Low DC Bus Voltage | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 38 Pre-charge DC Bus Voltage Imbalance | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 39 High DC Bus Voltage | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 40 Low DC Bus Voltage | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 41 DC Bus Voltage Imbalance | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 42 High Motor Current | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 43 Motor Current Overload (Software) | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 44 IGBT Gate Driver Fault | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 45 High Baseplate Temperature | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 46 Single Phase Input | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 47 VSD Run Signal Fault | System fault — VSD source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 48 High Discharge Press (Hardware – HPCO) | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 49 Spare | System fault — Panel source | 17 | ||
| 50 Control Voltage Fault | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 51 Low Discharge Superheat | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 52 Low Suction Pressure Smart Freeze | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 53 Isolation Valve Failed to Close Warning | System fault — Panel source | 17 | ||
| 54 Isolation Valve Failed to Open Fault | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 55 High Discharge Pressure Rate | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 56 Condenser Fan VSD Warning | System fault — Panel source | 17 | ||
| 57 Low Economizer Superheat | System fault — Panel source | If a system fault threshold is exceeded for 3 seconds, only the affected system is shut down (not the whole unit/all systems). System faults are auto-reset; the system restarts automatically after the fault condition clears. If 3 faults on the same system occur within 90 minutes, that system is locked out after the third fault. Lockout requires manual reset: the operator must cycle the system switch off then on to clear the lockout. | 17 | |
| 58 SPARE | System fault — source not listed | 17 | ||
| 59 SPARE | System fault — source not listed | 17 | ||
| 60 SPARE | System fault — source not listed | 17 | ||
| 61 SPARE | System fault — source not listed | 17 | ||
| 62 SPARE | System fault — source not listed | 17 |
From YVAA Only Planned Maintenance Warnings Software Version V18 SI0476
Original: docs.johnsoncontrols.com
Faults and Warnings
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| UNIT WARNING QUARTERLY SERVICE REQUIRED - CONTACT JCI |
Quarterly Service Required Warning (Warning Code: 1) | Manual Reset Warning; shutdown type: None. Enabled always. Acknowledge in Maintenance Mode (press the Service Key, enter password 0726, press Enter) to set the counter back to zero days. | 2 | |
| UNIT WARNING YEARLY SERVICE REQUIRED - CONTACT JCI |
Yearly Service Required Warning (Warning Code: 2) | 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) | Manual Reset Warning; shutdown type: None. Allowed states: All; bypass time: None; trip time: Instantaneous. Acknowledge in Maintenance Mode (press the Service Key, enter password 0726, press Enter) to set the counter back to zero days. | 2 |
| UNIT WARNING 3 YEAR SERVICE REQUIRED - CONTACT JCI |
3 Year Service Required Warning (Warning Code: 3) | Set when Days Since Last 3 Year Service >= 1095 Days | Manual Reset Warning; shutdown type: None. Allowed states: All; bypass time: None; trip time: Instantaneous. Acknowledge in Maintenance Mode (press the Service Key, enter password 0726, press Enter) to set the counter back to zero days. | 2 |
| UNIT WARNING 5 YEAR SERVICE REQUIRED - CONTACT JCI |
5 Year Service Required Warning (Warning Code: 4) | Set when Days Since Last 5 Year Service >= 1825 Days | Manual Reset Warning; shutdown type: None. Allowed states: All; bypass time: None; trip time: Instantaneous. Acknowledge in Maintenance Mode (press the Service Key, enter password 0726, press Enter) to set the counter back to zero days. | 3 |
| SYS X WARNING - REPLACE OIL FILTER | System Replace Oil Filter Warning (Warning Code: 5) | Set when Differential Oil to Discharge Pressure > 50 PSID | Manual Reset Warning; shutdown type: None. Allowed states: All; bypass time: 15 Minutes of Run Time; trip time: 10 Minutes. Release after set; warnings are not logged to the History buffer. Acknowledge in Maintenance Mode (press the Service Key, enter password 0726, press Enter). | 3 |
From ZIEHL-ABEGG Variable Speed Fan Troubleshooting Guide SI0640
Original: docs.johnsoncontrols.com
ZIEHL-ABEGG Variable Speed Fan — Motor Fault Codes (LED Status/Fault Light)
| Code / display | Meaning | Cause | Action | Page |
|---|---|---|---|---|
| LED OFF | No voltage supply. Unit is switched off and will automatically turn on when the voltage has been restored. | Check voltage supply. | 3 | |
| 1 No enable = OFF | No enable = OFF | Terminal “D1” – “24V” (Digital In 1) not bridged | Check jumpers/wiring connections. | 3 |
| 2 Temperature management active | The device has integrated active temperature management to protect the device from damage caused by excessively high internal temperatures. | Internal temperature increases above the predetermined limits. | The speed is linearly reduced. When the temperature drops, the speed rises again linearly. Check installation of the device and cooling of the motor. | 3 |
| 3 Error rotor position | Determination of the rotor position has failed. | After 8 starting tests, the error message is displayed. Check whether the motor can rotate freely (without line voltage). | 3 | |
| 4 Line failure (only for 3 ~ types) | The device is provided with a built-in phase-monitoring function for the mains supply. | Mains interruption (failure of a fuse or mains phase). | The unit switches off after a delay (approx. 200 ms). Following a shutoff, a startup attempt is made after approximately 15 seconds, if the voltage supply is present. This will continue to occur until all 3 supply phases are present. Check power supply. | 3 |
| 5 Motor blocked | If after 8 seconds of attempting to rotate no speed is measured, the fault “Motor blocked” is released. | Device switches off, attempt to restart after about 2.5 sec. After the fourth starting test fails, the device locks out. After lockout, it is necessary to reset by disconnecting the line voltage. Check whether the motor can rotate freely (without line voltage). | 3 | |
| 6 Failure power module | Failure power module | Short circuit to earth or short circuit of the motor winding. | EC-Controller switches off, attempt to restart after about 60 sec. If (following a second starting test) a second fault detection is detected within a period of 60 seconds, the device locks out. After lockout, it is necessary to reset by disconnecting the line voltage. | 3 |
| 7 Intermediate undervoltage | If the DC-link voltage drops below a specified limit, the device will switch off. | If the DC-link voltage rises above the limit within 75 seconds, then the controller will attempt to start. Should the DC-link voltage stay, for more than 75 seconds, below the limit, the device will switch off with a fault message. | 3 | |
| 8 Intermediate circuit overvoltage | If the DC-link voltage increases above a specified limit, the motor will switch off. | If the DC-link voltage drops below the limit within 75 seconds, then the controller will attempt to start. Should the DC-link voltage stay above the limit for more than 75 seconds, the device will switch off with a fault message. | 3 | |
| 9 Cooling down period power module | Cooling down period power module for approx. 60 sec. | Final shutoff after 2 cooling-off intervals. | 3 | |
| 10 Communication fault | If the communication watchdog is active, it signals that MODBUS communication is interrupted. | Response dependent on set watchdog mode. Check MODBUS communication. | 4 | |
| 11 Error motor start | If a starting command is given (enable available and Setpoint > 0) and the motor does not start to turn in the correct direction within 5 minutes, then an error message will appear. | If it is possible to start the motor in the correct direction of rotation after the error message, the error message will disappear. Should a voltage interruption occur during the 5 minute duration of the fault, the timer will reset. Check whether the motor can rotate freely (without line voltage). Check if the fan is spinning in reverse direction by air stream. | 4 | |
| 12 Line voltage too low | If the DC-link voltage drops below a specified limit the device will switch off. | If the line voltage rises above a specified limit within 75 seconds, then the controller will attempt to start. Should the line voltage stay below the specified limit for more than 75 seconds, the device will switch off with an error message. | 4 | |
| 13 Line voltage too high | If the line voltage increases above a specified limit, the motor will switch off. | Cause of high input voltage | If the line voltage drops below the specified limit within 75 seconds, then the controller will attempt to start. Should the line voltage stay above the specified limit for more than 75 seconds, the device will switch off with an error message. | 4 |
| 14 Error peak current | If the motor current increases above the specified limit (even in a short timeframe) the device will switch-off. | After a switch off, the controller waits for 5 seconds then the controller attempts to restart. If there are 5 faults within 60 seconds of the first fault, the device locks out. If there are no additional faults, after 60 seconds the counter will be reset. | 4 | |
| 17 Temperature alarm | Excess of the max. permissible internal temperature. | Controller switches off motor. Automatic restarting after cooling down. Check installation of the device and cooling of the controller. | 4 | |
| 18 System error | Device has detected a system error. Only limited operation or no operation is possible. | The error is displayed immediately. The motor is switched off depending on the system error. Reset fault by disconnecting the voltage supply. If the error message persists, replace assembly. | 4 | |
| 20 a) Vibration values | If the vibration velocity rises above the specified limits, an error message is issued. | The error is displayed after the set time. The device will continue to operate. Check the impeller for damage, contamination, or ice formation. | 4 | |
| 20 b) Lifetime | If the remaining service life falls below the defined limit, an error message is issued. | The error is displayed immediately. The device will continue to operate. If the error message persists, replace assembly. | 4 | |
| Continuous short flash Internal communication error | Internal communication failure. Fault indication. | If the error message persists, replace assembly. | 5 | |
| 1 Long, 2 Short MODBUS Recovery function | A failure in the MODBUS communication has been detected, e.g. incorrect communication parameters (baud rate, parity), wiring error. | Incorrect communication parameters (baud rate, parity), wiring error. | The motor can be accessed in recovery mode using the following parameters: Address 254, 19200Baud / 8E1. Check the bus wiring and communication parameters. | 5 |
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