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00282VIP
NOTE
Unless otherwise noted, information in this instruction
is applicable to all style starters of the same size.
Example: 26L-B and 26LK-B
Issue Date:
June 10, 2011
FORM 160.00-O2
ISSUE DATE: 6/10/2011
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During installation, operation maintenance or service, death to themselves and people at the site.
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, This document is intended for use by owner-authorized
materials under pressure, rotating components, and operating/service personnel. It is expected that this in-
both high and low voltage. Each of these items has the dividual posseses independent training that will enable
potential, if misused or handled improperly, to cause them to perform their assigned tasks properly and safe-
bodily injury or death. It is the obligation and respon- ly. It is essential that, prior to performing any task on
sibility of operating/service personnel to identify and this equipment, this individual shall have read and un-
recognize these inherent hazards, protect themselves, derstood this document and any referenced materials.
and proceed safely in completing their tasks. Failure This individual shall also be familiar with and comply
to comply with any of these requirements could result with all applicable governmental standards and regula-
in serious damage to the equipment and the property in tions pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
External wiring, unless specified as an optional connection in the manufacturer’s product line, is
not to be connected inside the OptiView cabinet. Devices such as relays, switches, transducers and
controls and any external wiring must not be installed inside the micro panel. All wiring must be in
accordance with Johnson Controls’ published specifications and must be performed only by a qualified
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.
2 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Operation (Unit) - Model YT, Style G or Later (Centrifugal) 160.55-O1
Operation (Unit) - Model YK, Style E or Later (Centrifugal) 160.54-O1
Operation (Unit) - Model YS, Style E or Later (Screw Chiller) 160.80-NOM1
Operation (Unit) - Model YR, Style A or Later (Screw Chiller) 160.81-O1
Operation (OptiView Control Center) - Model YT, Style G or Later (Centrifugal) 160.55-O1
Operation (OptiView Control Center) - Model YK, Style E or Later (Centrifugal) 160.54-O1
Operation (OptiView Control Center) - Model YS, Style E or Later (Screw Chiller) 160.80-O1
Operation (OptiView Control Center) - Model YR, Style A or Later (Screw Chiller) 160.81-O1
Service (OptiView Control Center) - Model YT, Style G or Later (Centrifugal) 160.55-M1
Service (OptiView Control Center) - Model YK, Style E or Later (Centrifugal) 160.54-M1
Service (OptiView Control Center) - Model YS, Style E or Later (Screw Chiller) 160.80-M1
Service (OptiView Control Center) - Model YR, Style A or Later (Screw Chiller) 160.81-M1
Wiring Diagram (OptiView Control Center) - Model Style G or Later (Centrifugal) 160.55-PW2
Wiring Diagram (OptiView Control Center) - Model YK, Style E or Later (Centrifugal) 160.54-PW8
Wiring Diagram (OptiView Control Center) - Model YS, Style E or Later (Screw Chiller) 160.80-PW2
Wiring Field Connections (Solid State Starter) - Model YT, Style G or Later (Centrifugal) 160.55-PW5
Wiring Field Connections (Solid State Starter) - Model YK, Style E or Later (Centrifugal) 160.54-PW5
Wiring Field Connections (Solid State Starter) - Model YS, Style E or Later (Screw Chiller) 160.80-PW4
Replacement Parts List (Solid State Starter) 160.00-RP3
JOHNSON CONTROLS 3
FORM 160.00-O2
ISSUE DATE: 6/10/2011
4 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
TABLE OF CONTENTS
JOHNSON CONTROLS 5
FORM 160.00-O2
ISSUE DATE: 6/10/2011
6 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
LIST OF FIGURES
LIST OF TABLES
JOHNSON CONTROLS 7
FORM 160.00-O2
ISSUE DATE: 6/10/2011
8 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
COOLANT
PUMP
OPTIONAL
CIRCUIT
BREAKER
JOHNSON CONTROLS 9
FORM 160.00-O2
SECTION 1 – THEORY OF OPERATION
ISSUE DATE: 6/10/2011
10 JOHNSON CONTROLS
FORM 160.00-O2
SECTION 1 – THEORY OF OPERATION
ISSUE DATE: 6/10/2011
CURRENT
TRANSFORMERS
OA SCR
ASSY.
T
OB SCR COMPRESSOR
ASSY. MOTOR
T
OC SCR
ASSY.
T
CONTROL
POWER HEATSINK
XFMR TEMP.
MOTOR
SERIAL COMMUNICATIONS LINK CURRENT
MICRO
BOARD
LD05246
JOHNSON CONTROLS 11
FORM 160.00-O2
SECTION 1 – THEORY OF OPERATION
ISSUE DATE: 6/10/2011
The main system microprocessor performs many func- to a digital driver chip and then to six optical couplers,
tions. It provides the serial communications link be- one for each SCR.
tween the Logic/Trigger Board, and the Micro Board
in the OptiView Control Center. It determines the The optical couplers are the first stage of the trigger
proper current scaling for the size of starter, and in- portion of the Logic/Trigger Board. They isolate the
terrogates the RUN/STOP signal from the OptiView high power circuit from the low power circuit. The
Control Center. This processor also interrogates feed- power for the high power circuit is supplied from the
back signals to determine Open and Shorted SCR, J5 connector. The trigger section is made up of six out-
Phase Loss, Phase Rotation, Motor Overload, High In- put drivers, one for each SCR. Each output driver has
stantaneous Current, High Line Voltage, and Low Line a dedicated transformer, that steps down the incoming
Voltage shutdowns. voltage, and provides isolation between each output
driver.
The VCON signal is generated by the main system
microprocessor. It is a digital signal placed on the A digital signal processor (DSP) is used for many
data bus. This processor compares the starting current timing and calculation functions. Root Mean Square
value, programmed at the OptiView Control Center, (RMS) calculations require that input line voltage and
with the current feedback from the three output cur- output current values be calculated on a cycle-by-cycle
rent transformers. A new value of VCON is generated basis. These calculations are used to display the RMS
every line cycle. This signal is then sent to the pro- voltage and current for each phase, kW, and kWh on
grammable logic device (PLD). The PLD determines the OptiView Control Center. The DSP is also used
the proper firing order for the SCRs to maintain the to interpret the feedback signals from the thermistors
programmed starting current value. As the speed of mounted on the SCR’s assemblies. All of these values
the motor approaches synchronous speed output cur- are placed on the data bus for the main system micro-
rent drops off, the VCON value increases, and the PLD processor to generate faults, if required, and to send
turns the SCRs full on. The output of the PLD is sent data on to the OptiView Control Center via the serial
communication link.
PIPE
PLUG WATER
RESERVOIR
WATER
PUMP
HEAT EXCHANGER
12 JOHNSON CONTROLS
FORM 160.00-O2
SECTION 1 – THEORY OF OPERATION
ISSUE DATE: 6/10/2011
SOLID STATE STARTER COOLING LOOP from mixing with the condenser water. The condenser
water is forced through the heat exchanger by the pres- 1
The SCRs in the LCSSS generate heat during normal
sure differential across the condenser shell input and
running conditions and become very hot during start-
output.
up of the chiller. This heat is generated by the fact that
all of the current flowing to the motor is conducted The cooling loop is filled with coolant
through the SCRs. The SCRs are very reliable, but at system start-up commissioning by the
they do have a slight resistance value when they are service technician. Refer to start-up in-
turned on. The resistance, along with the load current structions. As maintenance, the coolant
of the motor, generates the heat. must be changed every year. If the coolant
is not replaced within this time interval,
The heat must be dissipated, or the SCRs will fail from a potential for corrosion of the SCR’s
an overheating condition. Two methods are commonly heatsink is greatly increased.
used to dissipate the heat. The first method, which was
employed on older solid state starters was forced air The Logic/Trigger Board constantly monitors the tem-
cooling. This method works well, but requires a larg- perature of the three SCR heatsink assemblies with a
er cabinet and the addition of many fans. The second thermistor attached to each assembly. The temperature
method for dissipating the heat is to employ a water of each thermistor is sent to the Micro Board in the
cooling system similar to that used in automobiles. OptiView Control Center via the serial communica-
The cooling system for the LCSSS is different from tions link. Refer to ASSOCIATED LITERATURE on
the system in an automobile. In automobiles, heat is page 3 for details on where this data can be viewed on
transferred to the air, but the starter transfers heat to the OptiView Control Center.
the condenser water. If the temperature of any assembly exceeds a high
Condenser water is used to cool the starter for many value during a running condition, the Logic/Trigger
reasons. One, the condenser water will always be avail- Board will initiate a shutdown. Further, anytime the
able since it is part of the chiller system. The cooling temperature of any assembly exceeds a high value and
is free since the condenser water will be cooled in the the starter is not running, the chiller will be prevented
cooling towers for the chiller needs, and does not add from starting and the closed loop coolant pump will be
any load to the chiller. If the chilled water was used to operated until the temperature has fallen. Also, if the
cool the starter, this would add to the chiller load and temperature of any assembly falls below a preset val-
add cost to the customer. In a few applications where ue, the Logic/Trigger Board will initiate a shutdown.
chilled water is being used because of extremely high Changes have been made to the OptiView Control Cen-
condenser water pressure, a temperature regulating ter software to improve the restart time of the starter.
valve must be used. The temperature regulating valve These changes allow for the control of the condenser
should be set to 85°F so that condensation does not water pump when a style ‘B’ LCSSS is used with the
occur inside the starter cabinet. Using condenser wa- following OptiView Control Center software. On a YK
ter eliminates the concern for condensation occurring chiller, the software is C.MLM.01.04 or later. On a YT
inside of the starter cabinet, which could damage the chiller, the software is C.MLM.02.01 or later. On a YS
starter. The reliability of the starter is improved from chiller, the software is C.MLM.03.01 or later.
the standpoint that the three forced air fans are re-
placed with one circulating pump. The condenser water pump will be turned on any time
the chiller is started, and will continue to run until
The SCR assemblies are cooled by a pump circulating coastdown is complete. After coastdown is completed,
coolant in a closed loop through the SCR’s heatsink the condenser water pump will continue to run if any
and the outer tube of the tube-in-tube heat exchanger. one of the three thermistors indicated that the SCR as-
When the coolant passes through the heatsink, it ab- semblies are too hot. Once the temperature has fallen
sorbs heat from the heatsink. As the coolant passes to a specified level, the condenser water pump will
through the heat exchanger, it gives up its heat to the turn off.
system condenser water that is flowing through the in-
ner tube of the tube-in-tube heat exchanger. The design
of the heat exchanger prevents the closed loop coolant
JOHNSON CONTROLS 13
FORM 160.00-O2
SECTION 1 – THEORY OF OPERATION
ISSUE DATE: 6/10/2011
This new control will cool down the SCR assemblies of the incoming line voltage. (Refer to Fig 6 for loca-
more quickly after the chiller has been stopped. Then tion of JP1.) If the Logic/Trigger Board is a Rev. C,
the LCSSS can be started sooner, as long as the anti- then the JP1 jumper must be cut for generator opera-
recycle timer has been satisfied. tion. If the Logic/Trigger Board is a Rev. D or later, the
JP1 jumper has been removed, and the Logic/Trigger
ELECTRICAL CONDITIONS Board will function properly regardless of whether the
Proper starter operation requires that all phases of the starter is connected to the utility or generator power.
AC power line voltage are present, and in the correct
MOTOR PROTECTION
rotation. A “Power Fault” circuit provides protection
from rapid power line current interruptions and tran- Compressor motor protection circuits are provided on
sient switching. The AC power line voltage also must the Logic/Trigger Board. These circuits protect the
be relatively free of spikes and noise. If these condi- motor from continuous or instantaneous high current
tions are not met, safety circuitry on the Logic/Trig- levels. Another circuit is used to determine if the cur-
ger Board will cause a shutdown of the LCSSS. These rent transformers are connected to the Logic/Trigger
shutdowns will protect the chiller from rotating in the Board. This ensures that the LCSSS has current feed-
wrong direction, or causing transient torque conditions back before the chiller is started. Without the current
on the compressor shaft. As well, the LCSSS will shut feedback, the inrush current cannot be regulated. Also,
down and protect itself and the compressor motor if if the output current becomes imbalanced due to AC
the AC power line voltage is too high or too low. power line voltage instability, or faulty SCR, a shut-
down will occur. Other circuits are employed to sense
If the LCSSS is intended to be used on a generator a signal phase condition to the motor, or if one of the
application, then the JP1 jumper on the Logic/Trigger SCRs is open.
Board may need to be cut. Even if the starter will be
connected to a generator for emergency power, the JP1
jumper may need to be cut. The JP1 jumper changes
how the Logic/Trigger Board will track the frequency
14 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
The following LCSSS components are located in an A control power transformer is attached to the side of
enclosure mounted to the compressor motor terminal the starter enclosure. This supplies 115VAC control
box. (Refer to Figure 4 on page 15 and Figure 5 on power to the starter and OptiView Control Center. The
page 16.) YK chiller uses a transformer which is different from
that used on YT and YS chillers. 2
• SCR Assemblies
• Current Transformers
• Logic/Trigger Board
• Control Circuit Fuses
• Oil Pump Motor Fuses
• Circuit Breaker or Disconnect Switch if used.
INPUT POWER
CONNECTIONS FIBERGLASS
INSULATION
GROUND TERMINAL
POWER CONNECTIONS
TO COMPRESSOR MOTOR
FUSE BLOCK
OPTIONAL
CIRCUIT
BREAKER
LOGIC/TRIGGER
BOARD
00285VIP
BUS BAR
JOHNSON CONTROLS 15
FORM 160.00-O2
SECTION 2 – SYSTEM ARCHITECTURE
ISSUE DATE: 6/10/2011
OUTPUT
CURRENT
TRANSFORMERS
SCR
GATE
SCR LEADS
GATE
LEADS
SCR
HEATSINK
INPUT ASSEMBLIES
BUS
BARS 00286VIP
16 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
Table 2 - CT RATIO
MODEL SIZE PINS JUMPERED TOGETHER ON J1 CT RATIO
7L J1-7 TO J1-8, J1-8 TO J1-9, J1-9 TO J1-10 700:1
14L J1-8 TO J1-10, J1-9 TO J1-10 1400:1
26L J1-7 TO J1-10, J1-9 TO J1-10 2600:1
33L J1-9 TO J1-10 3300:1
JOHNSON CONTROLS 17
FORM 160.00-O2
SECTION 3 – LOGIC/TRIGGER BOARD
ISSUE DATE: 6/10/2011
LOGIC/TRIGGER BOARD INDICATOR LED’S factorily, and the contacts will open when the LCSSS
initiates a Cycling or Safety shutdown. These contacts
The Logic/Trigger Board contains only two LED’s.
will remain open until the cause of the shutdown has
Since all of the shutdown messages are displayed on
been rectified.
the OptiView Control Center, there is no need for
LED’s to annunciate a shutdown condition. The two Relay K2 controls the operation of the closed loop
LED’s are used to verify that the serial communica- coolant pump. When the Micro Board commands the
tions link is working. LCSSS to run, the main system microprocessor, via an
output driver, causes the K2 relay contacts to close. As
CR6 is the Receive LED. This LED will flash green
long as the K2 contacts are closed, the closed loop cool-
every 2 seconds to indicate that the Logic/Trigger
ant pump will run. When the Micro Board commands
Board has received data from the OptiView Control
the LCSSS to stop, the main system microprocessor, via
Center. (Refer to Figure 6 on page 18 for location
an output driver, causes the K2 relay contacts to open
of LED.)
(provided all of the thermistor temperatures are below
CR7 is the Transmit LED. This LED will flash red ev- 110°F). This will stop the closed loop coolant pump.
ery 2 seconds to indicate that the Logic/Trigger Board Therefore, the closed loop coolant pump may start and
has sent data to the OptiView Control Center. (Refer to stop with the compressor motor. Also, the K2 relay will
Figure 6 on page 18 for location of LED.) be energized by the main system microprocessor when
any heatsink temperature exceeds 110°F regardless
RELAY FUNCTIONS of whether the chiller is running or not. When the
Relay K1 shall provide a hardware shutdown signal to temperature falls below 110°F, the main system micro-
the OptiView Control Center via wires 16 and 53. The processor will de‑energize K2 relay causing the pump
relay will provide a normally open set of contacts that to stop.
are driven closed when the LCSSS is operating satis-
J11 J10 J9 J8 J7 J6
J5
J1
J12
00287VIP
TB-2 TB-1 J4 J3 J2 JP1 CR7 CR6 U15 RAM CHIP U16 EPROM
18 JOHNSON CONTROLS
FORM 160.00-O2
SECTION 3 – LOGIC/TRIGGER BOARD
ISSUE DATE: 6/10/2011
JOHNSON CONTROLS 19
FORM 160.00-O2
SECTION 3 – LOGIC/TRIGGER BOARD
ISSUE DATE: 6/10/2011
2 1 2 1 2 1 2 1 2 1 2 1
J11 J10 J9 J8 J7 J6
1
J5
2
J1
12 8 4 J12
11 7 3
2
10 6 2
9 5 1 1
TB2 TB1 J4 J3 J2
1 2 3 4 5 1 2 3 2 1 2 1 2 1
LD05282
20 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
• If the chiller is running at the time of the shut- • Verify that the output CT’s are reading current
down, the Logic/Trigger Board will turn off the correctly.
SCR gate outputs. • Ensure that the output current is balanced.
• If the chiller is running at the time of the shut- • Verify that the pre-rotation vanes or slide valve
down, the OptiView Control Center will start a are working properly.
coastdown period (150 seconds for centrifugal
chillers, or a 2 minute lockout for screw chillers). HIGH TEMPERATURE
• The K1 relay will de-energize causing an open The starter contains three SCR assemblies. Each as-
circuit between TB1-1 wire #16 and TB1-2 wire sembly has a temperature sensor mounted on the mass
#53. This action will indicate to the OptiView block in front of the SCR. The feedback from the tem-
Control Center that the LCSSS has shutdown. perature sensors is compared in the main system mi- 4
The K1 relay will remain de-energized until the croprocessor against a shutdown threshold of 212°F.
cause of the shutdown has been corrected. If any one of the three sensors exceeds the shutdown
threshold, a Safety shutdown will occur. The coolant
• The Logic/Trigger Board will send a shutdown
pump will continue to run until all temperatures are
code via the serial communications link to the
below 109°F.
Micro Board in the OptiView Control Center. The
Micro Board will interpret the shutdown code, The shutdown message displayed will be “LCSSS –
and display a shutdown message on the display of HIGH PHASE X HEATSINK TEMPERATURE -
the OptiView Control Center. RUNNING”, where X is either A, B or C, correspond-
ing to SCR phase assemblies A, B or C respectively.
After the coastdown period has timed out, the chiller
may be restarted, if the shutdown is no longer active. Possible Problems
Place the Compressor Switch in the Stop/Reset posi-
tion, and then into the Start position and release. The • Ensure that the coolant level is proper.
chiller will start if no faults are active. • Verify that the coolant is pink or clear.
105% MOTOR CURRENT OVERLOAD • Verify that the coolant pump is working.
The main system microprocessor receives from the • Verify that the heat exchanger is clean, and that
OptiView Control Center a value of current that cor- there is condenser water flow.
responds to 100% FLA. The Digital Signal Processor
• Ensure that the heatsink assembly is not clogged.
gathers the current information from the output CT’s
and converts this information to RMS current. The HIGH INSTANTANEOUS CURRENT
RMS current is sent to the main system microproces-
sor where the highest value of the three phase currents The RMS starting current is programmed on the
is compared with the 100% FLA times 1.05. When the OptiView Control Center to a value of 20 – 45% x
highest value of current exceeds this threshold, a 40 Delta LRA (normal value is 45% delta LRA). The
second time is started. If this value of current is main- RMS starting current is converted to peak starting
tained for a period of 40 seconds a Safety shutdown current times 115% to generate a shutdown thresh-
will occur. old. If the motor current in any phase ever reaches
this threshold and is maintained for one second, a
The shutdown message displayed will be “LCSSS - Safety shutdown will occur. If the motor current
105% MOTOR CURRENT OVERLOAD”. reaches this threshold for less than one second, a
shutdown will not occur.
JOHNSON CONTROLS 21
FORM 160.00-O2
SECTION 4 – SAFETY SHUTDOWNS
ISSUE DATE: 6/10/2011
22 JOHNSON CONTROLS
FORM 160.00-O2
SECTION 4 – SAFETY SHUTDOWNS
ISSUE DATE: 6/10/2011
The YR chiller has a “MOTOR – PHASE ROTA- age for that phase is approximately 90% of the selected
TION” fault. This is not a fault of the LCSSS. This input voltage range a Safety shutdown will occur. If no
fault is caused when the motor is turning in the wrong voltage range has been selected on the OptiView Control
direction. This fault is caused by the motor wiring be- Center, than the voltage check will not be performed.
tween the LCSSS and the chiller motor being reversed. To help eliminate nuisance trips, this shutdown can be
disabled from the OptiView Control Center. Refer to
The shutdown message displayed will be “LCSSS - the OptiView Control Center Service form for your
PHASE ROTATION”. style of chiller (refer to ASSOCIATED LITERATURE
in this form, page 3, for the proper form number).
Possible Problems
Verify the phasing of the input power wiring. The shutdown message displayed will be “LCSSS -
PHASE X SHORTED SCR”, where X is either A, B
SHORTED SCR or C, corresponding to SCR phase assemblies A, B or
C respectively.
This shutdown is active any time the starter is not run-
ning. Once this shutdown becomes active the main sys- Possible Problems
tem microprocessor starts to evaluate the voltage across
the SCRs via an opto-coupler. If the output of the opto- Verify if one of the SCRs are shorted.
coupler is low (implying the SCR is turned on or short- 4
ed) for 5 continuous seconds, and the RMS phase volt-
JOHNSON CONTROLS 23
FORM 160.00-O2
SECTION 4 – SAFETY SHUTDOWNS
ISSUE DATE: 6/10/2011
24 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
JOHNSON CONTROLS 25
FORM 160.00-O2
SECTION 5 – CYCLING SHUTDOWNS
ISSUE DATE: 6/10/2011
26 JOHNSON CONTROLS
FORM 160.00-O2
SECTION 5 – CYCLING SHUTDOWNS
ISSUE DATE: 6/10/2011
tem microprocessor. The main system microprocessor nal becomes too large then the synchronization with
will compare these voltages to shutdown thresholds in the ‘A’ phase voltage will be lost. If synchronization
Table 4. If the input voltage falls below the shutdown is not maintained, the SCRs will misfire and damage
threshold for 20 continuous seconds, then a Cycling the chiller.
shutdown will occur. This shutdown is disabled for the
first 20 seconds of the starter run, to prevent nuisance The shutdown message displayed will be “LCSSS -
shutdowns from heavily loaded transformers. The PHASE LOCKED LOOP”.
voltage range is programmed on the OptiView Control
Possible Problems
Center. If no voltage range is programmed, then this
shutdown will be disabled (ASSOCIATED LITERA- • Although this circuit is very fast, storms or power
TURE listed on Page 3). problems can cause the frequency of the ‘A’ phase
voltage to change too rapidly.
The shutdown message displayed will be “LCSSS -
LOW SUPPLY LINE VOLTAGE”. • If the problem occurs during generator operation,
ensure that the JP1 jumper has been cut (on Rev
Possible Problems C. or earlier Logic/Trigger Boards).
• Verify that the proper voltage range is selected on • If the problem occurs during generator operation,
the OptiView Control Center. add some standby load to the generator so that the
generator responds more quickly to load changes.
• Verify proper line voltage is being applied to the
starter. PHASE LOSS
• If the problem occurs during generator operation, The three phases of input line voltage are fed back to
add some standby load to the generator so that the Logic/Trigger Board via the cathode connections
the generator can respond more quickly to load of the negative SCRs. The RMS voltage is then com- 5
changes. pared against a threshold value, that is 30% of the pro-
grammed input voltage range. For example, if the pro-
PHASE LOCKED LOOP
grammed input voltage range is 440-480VAC, then the
The cathode connection of the negative SCRs is con- threshold value will be 132VAC. If the voltage range is
nected to the 3-phase AC power line. This informa- disabled in the OptiView Control Center then the shut-
tion is sent to the Logic/Trigger Board, where a circuit down value will be 30% of 200VAC. Thus, the thresh-
generates a waveform that is synchronized to the ‘A’ old value will be 60VAC. Anytime one of the three
phase voltage. This waveform and the ‘A’ phase volt- phases of input line voltage drops below the threshold
age are compared, and the deviation is used to generate value, a Cycling shutdown will occur.
an error signal. The error signal is then used to correct
the waveform and maintain synchronization with the The shutdown message displayed will be “LCSSS -
‘A’ phase voltage. The synchronized waveform is used PHASE LOSS”.
for the firing control of all the SCRs. If the error sig-
JOHNSON CONTROLS 27
FORM 160.00-O2
SECTION 5 – CYCLING SHUTDOWNS
ISSUE DATE: 6/10/2011
Table 7 - PHASE LOSS is opto-coupled, and then sent to the main system mi-
INPUT VOLTAGE RANGE croprocessor, where it is compared with a run signal
SHUTDOWN VALUE
OF THE LCSSS sent from the OptiView Control Center via the serial
Disabled 60VAC communications link (software signal). When either
200 - 208 60VAC of these two signals are received by the main system
220 - 240 66VAC microprocessor, a 5 second timer is started. The timer
stops when the second of the two signals is received by
380 114VAC
the main system microprocessor. If both of the signals
400 120VAC
are not received within 5 seconds, a Cycling shutdown
415 125VAC
will occur.
440 - 480 132VAC
550 - 600 165VAC The shutdown message displayed will be “LCSSS -
RUN SIGNAL”.
Possible Problems
Possible Problems
• Many times this is a normal fault related to a
storm or lightning. • Verify that 115VAC is applied between J5-2 wire
#2, and TB1-3 wire #24.
• Verify the presence of all three phase of input
voltage. An input fuse may be open. • Check for solder cracks around J5 and TB-1.
• Verify that the proper voltage range is selected on • Verify the serial communication link cable.
the OptiView Control Center.
SERIAL COMMUNICATIONS
POWER FAULT This shutdown becomes active after a successful com-
The Power Fault Detector prevents compressor dam- pletion of initialization. If the Micro Board has tried
age due to a momentary interruption of motor current to communicate with the Logic/Trigger Board ten
(transient torque condition). This shutdown is active times, or if the Logic/Trigger Board does not receive a
after the first four seconds of a chiller start, and after transmission from the Micro Board within 20 seconds,
all three phases of motor current have exceeded 25% then a Cycling shutdown will occur. Since the Micro
of FLA for one second. Then, if any one phase of mo- Board attempts to communicate with the Logic/Trig-
tor current drops below a threshold of 10% FLA for ger Board every two seconds, the shutdown will occur
three line cycles, a Cycling shutdown will occur. To in approximately 20 seconds. Under this condition, all
prevent nuisance shutdowns, this shutdown is disabled information about the starter displayed on the OptiV-
just before the chiller is placed into a coastdown con- iew Control Center will be zero.
dition. The shutdown message displayed will be “LCSSS -
The shutdown message displayed will be “LCSSS - SERIAL COMMUNICATIONS”.
POWER FAULT”.
Possible Problems
Possible Problems • Verify the communication cable between the
• Many times this is a normal fault related to a OptiView Control Center and the Logic/Trigger
storm or lighting. Board.
• Verify that the output CT’s are reading current • If CR6 is blinking, but CR7 is not blinking, the
correctly. Logic/Trigger Board has failed. If both CR6 and
CR7 are blinking every 2 seconds, continue to the
RUN SIGNAL next step.
To start the compressor motor, the OptiView Control • If problem is still not detected, then perform the
Center sends a 115VAC start signal to the Logic/Trig- communication loop back test (ASSOCIATED
ger Board. The start signal is applied between J5-2 wire LITERATURE listed on page 3 for OptiView
#2, and TB1-3 wire #24 (hardware signal). This signal Control Center Service).
28 JOHNSON CONTROLS
FORM 160.00-O2
SECTION 5 – CYCLING SHUTDOWNS
ISSUE DATE: 6/10/2011
JOHNSON CONTROLS 29
FORM 160.00-O2
SECTION 5 – CYCLING SHUTDOWNS
ISSUE DATE: 6/10/2011
30 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
JOHNSON CONTROLS 31
FORM 160.00-O2
SECTION 6 – START INHIBIT
ISSUE DATE: 6/10/2011
32 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
JOHNSON CONTROLS 33
FORM 160.00-O2
SECTION 7 – START-UP INSTRUCTIONS
ISSUE DATE: 6/10/2011
Fill Procedure
1. Fill the coolant reservoir with YORK Coolant un-
til the level is 1/2 inch from the top of the coolant
reservoir.
2. Remove J2, J3, J4 connectors and allow the cool-
ant pump to run for a period of 5 minutes. Top off
the level of the coolant.
3. Verify that the level of the coolant is within ¼
inch from the top of the coolant reservoir. If the
coolant level is low, then add more YORK cool-
ant.
4. Run the coolant pump for 10 minutes. Verify that
the level of the coolant is proper. If the coolant
level is low, then add more YORK coolant, and
repeat this step.
5. Verify that all of the air has been worked out of
the coolant. If not, continue to run the coolant
pump, and add YORK coolant as required.
6. Reinstall the J2, J3, J4 connectors.
7. Wrap the plastic pipe plug with Teflon tape, and
install on the coolant reservoir. Be sure to hold the
coolant reservoir when installing the pipe plug.
34 JOHNSON CONTROLS
FORM 160.00-O2
ISSUE DATE: 6/10/2011
JOHNSON CONTROLS 35
FORM 160.00-O2
SECTION 8 – MAINTENANCE AND TROUBLESHOOTING
ISSUE DATE: 6/10/2011
instruction prior to troubleshooting this product. Also, • Insert the ohm meter probes into the connector.
the service technician must understand the system in- The meter should display a good value of 10 – 20
terface, and be able to utilize system wiring diagrams ohms in both polarities.
to follow signal flow throughout the system. Due to the
• If the ohm value is lower than 5 ohms the gate is
integration of the LCSSS with the OptiView Control
shorted, replace the SCR Assembly.
Center, a good working knowledge of the OptiView
Control Center is also necessary (Refer to ASSOCI- • If the ohm value is greater than 50 ohms the gate
ATED LITERATURE Forms listed on page 3). is open, replace the SCR Assembly.
Several levels of documentation are required for the VERIFY GATE DRIVER OUTPUT
troubleshooting process. The LCSSS wiring diagram,
supplied with every starter, is the top level document. It • Remove main input power to the starter.
provides the overall wiring and configuration. Sections • Set ohm meter to Rx1 range. If the ohm meter is a
of this instruction provide the required lower levels, digital model, and has a diode test scale, place the
specifically, block diagrams provide signal flow and meter in the diode test mode.
simplified representations of Logic/Trigger Board cir-
cuitry. The “Inputs and Outputs” of the Logic/Trigger • Remove the suspected gate connection J6 – J11
Board provide details of the required voltage levels at from the Logic/Trigger Board.
all connectors. • Connect the ohm meter negative lead to pin 1
and positive lead to pin 2 of the suspected Logic/
Begin the troubleshooting process by selecting the ap-
Trigger Board output. The meter should display a
propriate procedure. It is not necessary to sequentially
good value of 10 – 20 ohms.
perform all of them. Perform a procedure only if there
is a problem with that function. • Connect the ohm meter positive lead to pin 1 and
negative lead to pin 2 of the suspected Logic/
VERIFY SHORTED SCR Trigger Board output. The meter should display a
• Remove main input power to the starter. good value of around 200 ohms.
• Set ohm meter to Rx1 range. If the ohm meter is a • If the ohm value is lower than 5 ohms, the gate
digital model, and has a diode test scale, place the driver is shorted.
meter in the diode test mode.
• If the ohm value is greater than 500 ohms, the gate
• Connect the ohm meter from L1 to T1. If the SCR driver is open. If the values are okay, continue.
is shorted, the ohm meter will display a value less
than 5 ohms. A reading greater than 5 ohms, but • Reconnect connector J6 – J11. Reapply main in-
less than 5K ohms may indicate a leaky SCR or put power to the starter.
faulty snubber. Such SCRs and snubbers should • Connect a DC volt meter across the suspected J6-
be further evaluated. J11, pin 2 is ground. Without the starter running
• Continue with the other two phases. a voltage of 0VDC should be displayed on the
• Replace the shorted SCR Assembly. meter. With the starter running, a voltage of .55 –
2.0VDC should be displayed.
VERIFY OPEN OR SHORTED SCR GATE
• A higher voltage of around 5 – 10VDC on the J6 –
• Remove main input power to the starter. J11 connector would indicate a poorly conducting
• Set ohm meter to Rx1 range. If the ohm meter is a SCR. Replace the SCR Assembly.
digital model, and has a diode test scale, place the • A lower voltage during the running condition
meter in the diode test mode. would indicate a shorted gate on the SCR, or a
• Remove the suspected gate connection J6 – J11. bad Logic/Trigger Board. Replace the appropriate
part.
36 JOHNSON CONTROLS
FORM 160.00-O2
SECTION 8 – MAINTENANCE AND TROUBLESHOOTING
ISSUE DATE: 6/10/2011
VERIFY REAL PHASE CURRENT IMBALANCE multiply by 100. The result is the percentage
The starter cabinet contains high voltages phase imbalance for that phase. Depending on the
that can cause injury or loss of life. Ex- load of the motor a value of 1.5% can cause a cur-
treme care should be taken when working rent imbalance of 15%. If this is not the source of
on this equipment. the problem continue.
Example:
Phase A 480, Phase B 475, Phase C 482.
• Use this section to determine if the current imbal- 480 + 475 + 482 = 1437 / 3 = 479 avg.
ance is real or a reporting problem. 475 – 479 = –4 / 479 x 100 = -0.8%
• Start the chiller. • Referring to the chart below, the current imbal-
ance due to the voltage imbalance is 7.5 % at 60%
• Connect another current measuring device around load
the output wire to the motor.
• A typical motor of today may induce a current
• Compare the measured three phase currents to imbalance of up to 6%, but factory specifications
each other. allow for up to 8% before rejecting a motor. So, if
• If the currents are imbalanced, then continue. If the measured current imbalance is 13.5% or less,
they are not imbalanced, continue to section titled this is normal for the above example, and no more
“Verify False Phase Current Imbalance”. investigation is required. If this is not the source
of the problem, continue.
• While the starter is running, record the three
phases of input voltage. Typical input voltage imbalance is 1 to 1½%. Ex-
cessive input voltage imbalance is 2% or greater.
• Add the 3 values of voltage together, and divide Most often imbalances are due to unequal distribu-
by 3 to get the average voltage. Then take each tion of single phase loads within the building.
measured value, subtract the average value, and
divide this difference by the average value, and • Connect an AC voltage meter from L-1 to T-1.
NO LOAD
30
20% LOAD
40% LOAD
25 60% LOAD
80% LOAD
FULL LOAD
% CURRENT IMBALANCE
20
15
8
10
0
0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
% VOLTAGE IMBALANCE LD05247
JOHNSON CONTROLS 37
FORM 160.00-O2
SECTION 8 – MAINTENANCE AND TROUBLESHOOTING
ISSUE DATE: 6/10/2011
• After the chiller has been running for one minute, • Reconnect the J1 connector.
measure the voltage across the SCR. The voltage
• If this is not the source of the problem, continue.
should measure between .70 – 2.0VAC. The volt-
age should remain stable. If the voltage is not stable, • Start the chiller.
or is higher than 9.0VAC, there could be a problem
• Connect another current measuring device around
with the gate driver on the Logic/Trigger Board, or
the output wire to the motor.
the SCR is not latching on. In the case of the SCR
not latching on, this is typical of older starters. Ver- • Compare the three phase current from the OptiV-
ify each SCR pole by moving the meter to L-2 and iew Control Center to the three measured currents.
T-2, and L-3 and T-3. This test verifies the opera-
• Replace the CT in the phase in which the current
tion of the starter. If these voltages are correct, then
does not measure correctly.
the problem is most likely other than the starter.
REMOVING SCR ASSEMBLIES
VERIFY FALSE PHASE CURRENT
IMBALANCE Refer to the Replacement Parts List Form 160.00-RP3
for replacement SCR assembly kit part numbers.
Use this section if the current imbalance is not real, but
is a reporting problem. • Remove AC power from system. If the starter has
a circuit breaker, place it in the off position.
• Verify that the OptiView Control Center has the
correct model of starter selected. If not, verify • Drain coolant as directed in the Fill Cooling Loop
wiring of the J1 connector. Refer to the current Section.
scaling section in this form.
• Loosen the hose clamps and remove the hoses
• If this is not the source of the problem, continue. from the defective heatsink assembly.
• Remove main input power to the starter. • Place tape over the hose barbs, so that the coolant
does not leak into the cabinet of the starter.
• Set ohm meter to Rx1 range. If the ohm meter is a
digital model, and has a diode test scale, place the • Remove all electrical connections from the Logic/
meter in the diode test mode. Trigger Board. Remove Logic/Trigger Board as-
sembly by removing 4 panel mounting screws and
• Remove the J1 connector, and measure the resis-
the 6 screws holding the gate wire clamps.
tance of the three output CT’s. The resistance val-
ue will vary depending on the model of the starter. • Disconnect the thermistor wire connector for the
failed SCR (J/P16, J/P17, J/P18).
MODEL STARTER CT RESISTANCE RANGE
7L 2.4 – 4.3 OHMS • Mark and then remove the output wires to the mo-
14L 5.0 – 7.3 OHMS tor. Fold out of the way if possible.
26L 8.0 – 16.8 OHMS • Remove the current transformer mounting bracket
33L 10.7 – 22.0 OHMS by removing the four screws on the back of the
starter. Move CT assembly out of the way.
• If this is not the source of the problem, continue.
• Remove the two bolts connecting the SCR assem-
• Measure resistance across J1 pin 1-2. A resistance bly to the bus bar.
value of 3.0 ohms should be displayed on your
meter. This resistor is a 0.1% tolerance compo-
nent. If it is out of tolerance, replace the Logic/
Trigger Board. Repeat this step with J1 pin 3-4,
and J1 pin 5-6.
38 JOHNSON CONTROLS
FORM 160.00-O2
SECTION 8 – MAINTENANCE AND TROUBLESHOOTING
ISSUE DATE: 6/10/2011
COOLANT
PUMP
CONDUIT
OIL
PUMP
CONDUIT
SCR
ASSEMBLY
(1 OF 3)
RESISTOR
AND
INPUT CAPACITOR
BUS BAR ASSEMBLY
00286VIP
• Remove the four SCR/heatsink assembly mount- pad and coat with a thin film of thermal joint com-
ing nuts from the mounting studs and remove the pound (013-02880-000) before attaching the in-
entire SCR/Heatsink assembly. put bus bar. Torque the two bolts to 13‑17 ft.-lbs.
• Remove resistor and capacitor assembly from de- • On 26L and 33L models, clean the mating sur-
fective SCR assembly. Save these parts; they will faces of the SCR assembly and input bus bar with
be needed for the new SCR assembly. (Refer to fine emery cloth or ScotchbriteTM pad. Torque the
Figure 9 on page 39) two bolts to 13‑17 ft.-lbs.
• Install resistor and capacitor assembly onto the • Connect the thermistor wire connector for the 8
SCR assembly. new SCR (J/P16, J/P17, J/P18).
• Install SCR assembly into the starter and tighten • Install Logic/Trigger Board assembly by install-
the 4 mounting bolts. ing 4 panel mounting screws and the 6 screws
holding the gate wire clamps. Install all electrical
• Install the coolant hose over the hose barbs, and connections to the Logic/Trigger Board.
tighten the hose clamps (tubing must not contain
any kinks). • Fill the coolant loop as directed in the Fill Cool-
ing Loop Section in this form.
• On 7L and 14L models, it is necessary to clean
the mating surfaces of the SCR assembly and in- • The starter is now ready to be restarted.
put bus bar with fine emery cloth or ScotchbriteTM
JOHNSON CONTROLS 39
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2011 www.york.com ALL RIGHTS RESERVED
Form 160.00-O2 (611)
Issue Date: June 10, 2011
Supersedes: 160.00-O2 (200)