160.00-O2

OPERATIONLIQUIDCOOLEDSOLIDSTATESTARTERNewReleaseForm160.00-O2(200)MODELSSSS7L-B,14L-B,26L-B,33L-B7LK-B,14LK-B,26LK-B,33LK-B(STYLEB)NOTEUNLESSOTHERWISENOTED,INFORMATIONINTHISINSTRUCTIONISAPPLICABLETOALLSTYLESTARTERSOFTHESAMESIZE.EXAMPLE:26L-BAND26LK-B00282VIPYORKINTERNATIONAL2Thisequipmentisarelativelycomplicatedapparatus.Duringinstallation,operation,maintenanceorservice,individualsmaybeexposedtocertaincomponentsorconditionsincluding,butnotlimitedto:refrigerants,oils,materialsunderpressure,rotatingcomponents,andbothhighandlowvoltage.Eachoftheseitemshasthepo-tential,ifmisusedorhandledimproperly,tocausebodilyinjuryordeath.Itistheobligationandresponsibilityofoperating/servicepersonneltoidentifyandrecognizetheseinherenthazards,protectthemselves,andproceedsafelyincompletingtheirtasks.Failuretocomplywithanyoftheserequirementscouldresultinseriousdam-agetotheequipmentandthepropertyinwhichitisIMPORTANT!READBEFOREPROCEEDING!GENERALSAFETYGUIDELINESsituated,aswellasseverepersonalinjuryordeathtothemselvesandpeopleatthesite.Thisdocumentisintendedforusebyowner-authorizedoperating/servicepersonnel.Itisexpectedthatthisindi-vidualpossessesindependenttrainingthatwillenablethemtoperformtheirassignedtasksproperlyandsafely.Itisessentialthat,priortoperforminganytaskonthisequipment,thisindividualshallhavereadandunderstoodthisdocumentandanyreferencedmaterials.Thisindi-vidualshallalsobefamiliarwithandcomplywithallapplicablegovernmentalstandardsandregulationsper-tainingtothetaskinquestion.SAFETYSYMBOLSThefollowingsymbolsareusedinthisdocumenttoalertthereadertoareasofpotentialhazard:CAUTIONidentifiesahazardwhichcouldleadtodamagetothemachine,damagetootherequipmentand/oren-vironmentalpollution.Usuallyanin-structionwillbegiven,togetherwithabriefexplanation.NOTEisusedtohighlightadditionalinformationwhichmaybehelpfultoyou.DANGERindicatesanimminentlyhazardoussituationwhich,ifnotavoided,willresultindeathorseri-ousinjury.WARNINGindicatesapotentiallyhazardoussituationwhich,ifnotavoided,couldresultindeathorseri-ousinjury.Externalwiring,unlessspecifiedasanoptionalconnectioninthemanufacturer’sproductline,isNOTtobeconnectedinsidethemicropanelcabinet.Devicessuchasrelays,switches,transducersandcontrolsmayNOTbeinstalledinsidethemicropanel.NOexternalwiringisallowedtoberunthroughthemicropanel.AllwiringmustbeinaccordancewithYORK’spublishedspecificationsandmustbeperformedONLYbyqualifiedYORKpersonnel.YORKwillnotberesponsiblefordamages/problemsresultingfromimproperconnectionstothecontrolsorapplicationofimpropercontrolsignals.Failuretofollowthiswillvoidthemanufacturer’swarrantyandcauseseriousdamagetopropertyorinjurytopersons.FORM160.00-O23YORKINTERNATIONALTABLEOFCONTENTSSTYLE“B”LIQUIDCOOLEDSOLIDSTATESTARTERGENERALINFORMATION...................5ReferenceInstructions.....................................................................................................................5Style“B”LiquidCooledSolidStateStarterVariations....................................................................5Style“B”LiquidCooledSolidStateStarterOverview....................................................................6SECTION1THEORYOFOPERATION...........................................................................................7General.............................................................................................................................................7SystemMicroprocessors.................................................................................................................7SolidStateStarterCoolingLoop.....................................................................................................9ElectricalConditions.......................................................................................................................10MotorProtection............................................................................................................................10SECTION2SYSTEMARCHITECTURE........................................................................................10SECTION3LOGIC/TRIGGERBOARD........................................................................................12GeneralInformation........................................................................................................................12CurrentScaling...............................................................................................................................12Logic/TriggerBoardIndicatorLED’s.............................................................................................13RelayFunctions..............................................................................................................................13Logic/TriggerBoardInputsAndOutputs......................................................................................13SECTION4SAFETYSHUTDOWNS.............................................................................................16GeneralInformation........................................................................................................................16105%MotorCurrentOverload.......................................................................................................16HighTemperature...........................................................................................................................16HighInstantaneousCurrent...........................................................................................................16OpenSCR........................................................................................................................................17OutputCurrentImbalance...............................................................................................................17PhaseRotation................................................................................................................................17ShortedSCR....................................................................................................................................18SECTION5CYCLINGSHUTDOWNS..........................................................................................18GeneralInformation........................................................................................................................18HighSupplyLineVoltage...............................................................................................................18InitializationFailed..........................................................................................................................19InvalidCurrentScale.......................................................................................................................19LogicBoardPowerSupply.............................................................................................................19LogicBoardProcessor....................................................................................................................19LowPhaseTemperature..................................................................................................................20LowSupplyLineVoltage................................................................................................................20PhaseLockedLoop........................................................................................................................20PhaseLoss......................................................................................................................................21PowerFault.....................................................................................................................................21RunRelay.......................................................................................................................................21SerialCommunications....................................................................................................................22StopContactsOpen........................................................................................................................22SECTION6STARTINHIBITS.......................................................................................................22HighTemperature...........................................................................................................................22SECTION7STARTUPINSTRUCTIONS......................................................................................24Start-UpChecklist...........................................................................................................................24FillCoolingLoop............................................................................................................................24SECTION8TROUBLESHOOTINGPROCEDURES....................................................................25GeneralInformation........................................................................................................................25VerifyShortedSCR.........................................................................................................................25VerifyOpenorShortedSCRGate...................................................................................................25VerifyGateDriverOutput...............................................................................................................25VerifyRealPhaseCurrentImbalance..............................................................................................26VerifyFalsePhaseCurrentImbalance.............................................................................................27RemovingSCRAssemblies............................................................................................................27InstallingSCRAssemblies.............................................................................................................28YORKINTERNATIONAL4LISTOFFIGURESFIG.1–LIQUIDCOOLEDSOLIDSTATESTARTER-FRONTVIEW,EXTERIOR...........................6FIG.2–LIQUIDCOOLEDSOLIDSTATESTARTER-BASICBLOCKDIAGRAM..........................7FIG.3–LIQUIDCOOLEDSOLIDSTATESTARTER-REARVIEW,EXTERIOR.............................8FIG.4–LIQUIDCOOLEDSOLIDSTATESTARTER-INTERIOR,CONNECTIONSECTIONFUSESANDLOGICTRIGGERBOARD..............................................................................11FIG.5–LIQUIDCOOLEDSOLIDSTATESTARTER-INTERIOR,POWERSECTION...................11FIG.6–LIQUIDCOOLEDSOLIDSTATESTARTER-LOGIC/TRIGGERBOARDDETAIL............13FIG.7–LOGIC/TRIGGERBOARDPINLOCATIONDIAGRAM....................................................15FIG.8–CURRENTIMBALANCEDUETOVOLTAGEIMBALANCE............................................26FIG.9–LIQUIDCOOLEDSOLIDSTATESTARTER-POWERCOMPONENTS............................27LISTOFTABLESTABLE1–CTRATIO............................................................................................................................12TABLE2–CURRENTCAPABILITY....................................................................................................12TABLE3–HIGHSUPPLYLINEVOLTAGE...........................................................................................18TABLE4–LOWSUPPLYLINEVOLTAGE...........................................................................................20TABLE5–PHASELOSS......................................................................................................................21TABLE6–LIQUIDCOOLEDSOLIDSTATESTARTERTHERMISTORCHARACTERISTICS..........23FORM160.00-O25YORKINTERNATIONALSTYLE“B”LIQUIDCOOLEDSOLIDSTATESTARTERGENERALINFORMATIONREFERENCEINSTRUCTIONSOperation(Unit)ModelYT,StyleJ(Centrifugal)Form160.55-O1ModelYK,StyleE(Centrifugal)Form160.54-O1ModelYS,StyleE(ScrewChiller)Form160.80-NOM1Operation(OptiViewControlCenter)ModelYT,StyleJ(Centrifugal)Form160.55-O1ModelYK,StyleE(Centrifugal)Form160.54-O1ModelYS,StyleE(ScrewChiller)Form160.80-O1Service(OptiViewControlCenter)ModelYT,StyleJ(Centrifugal)Form160.55-M1ModelYK,StyleE(Centrifugal)Form160.54-M1ModelYS,StyleE(ScrewChiller)Form160.80-M1WiringDiagram(OptiViewControlCenter)ModelYT,StyleJ(Centrifugal)Form160.55-PW2ModelYK,StyleE(Centrifugal)Form160.54-PW8ModelYS,StyleE(ScrewChiller)Form160.80-PW2WiringFieldConnections(SolidStateStarter)ModelYT,StyleJ(Centrifugal)Form160.55-PW5ModelYK,StyleE(Centrifugal)Form160.54-PW5ModelYS,StyleE(ScrewChiller)Form160.80-PW4ReplacementPartsList(SolidStateStarter)Form160.00-RP3TheNewStyle“B”LiquidCooledSolidStateStarterisalsoavailablewithadisconnectswitchoracircuitbreaker.Consultthesalesinformationforadditionalpartnumbersforthosemodels.STYLE“B”LIQUIDCOOLEDSOLIDSTATESTARTERVARIATIONSMODELLineVoltageApplication(VAC)PartNumberforaStarterWithLugKit7L-40380371-02506-1027L-46440/460/480371-02506-1037L-58550/575/600371-02506-1047L-50380/400/41550Hz371-02506-10514L-17200/208371-02506-10614L-28220/230/240371-02506-10714L-40380371-02506-10814L-46440/460/480371-02506-10914L-58550/575/600371-02506-11014L-50380/400/41550Hz371-02506-11126L-17200/208371-02507-10226L-28220/230/240371-02507-10326L-46440/460/480371-02507-10426L-40380371-02507-10526L-58550/575/600371-02507-10626L-50380/400/41550Hz371-02507-10733L-17200/208371-02507-10833L-28220/230/240371-02507-10933L-40380371-02507-11033L-46440/460/480371-02507-11133L-50380/400/41550Hz371-02507-112YORKINTERNATIONAL6STYLE“B”LIQUIDCOOLEDSOLIDSTATESTARTEROVERVIEWTheStyle“B”LiquidCooledSolidStateStarterisastateoftheart,softstartforYORKcompressormo-tors.NewfeaturesincludeacombinedLogic/TriggerBoard,improveddatacollection,bettergeneratorop-eration,andeasierset-up.TheStyle“B”LiquidCooledSolidStateStarteristobeappliedonlytotheYORKOptiViewControlCenter.Thisinstructionisadescriptionoftheoperation,start-upandtroubleshootingoftheStyle“B”YORKLiquidCooledSolidStateStarter.Itshouldbereadthoroughlybeforeservicingthisproduct.DuetotheintegrationoftheSolidStateStarterwiththeYORKOptiViewCon-trolCenter,anunderstandingoftheOptiViewControlCenterisnecessary.Therefore,thisdocumentshouldbeusedwithreferencedinstructionsonpage5.FIG.1–LIQUIDCOOLEDSOLIDSTATESTARTER–FRONTVIEW,EXTERIOR00283VIPOPTIONALCIRCUITBREAKERCONDUITCONNECTIONTOOPTIVIEWCONTROLCENTERLOCKANDKEYSCOOLANTPUMP1.5KVACONTROLPOWERTRANSFORMERHIGHHATFOROPTIONALDISCONNECTSWITCHANDCIRCUITBREAKERINLETCONDENSERWATERCONNECTIONTOHEATEXCHANGERFORM160.00-O27YORKINTERNATIONALTTSCRASSY.TTSCRASSY.TTSCRASSY.OAOBOCCURRENTTRANSFORMERSCONTROLPOWERXFMRLOGIC/TRIGGERBOARDMOTORCURRENT115VACCONTROLPOWERTOOPTIVIEWCONTROLCENTERCOOLANTPUMPPOWERSUPPLYI/OBOARDMICROBOARDSTARTERINITIATEDSHUTDOWNSERIALCOMMUNICATIONSLINKOPTIVIEWCONTROLCENTERHEATSINKTEMP.COMPRESSORMOTORSECTION1–THEORYOFOPERATIONGENERAL(RefertoFig.2)TheStyle‘B’LiquidCooledSolidStateStarterpro-videsasoftcontinuous-currentstartforthecompres-sormotor.Duringthestartingsequence,theinrushmo-torcurrentislimitedtotheprogrammedvalueofthestartingcurrent,byreducingthevoltageappliedtothemotor.Thisreductioninvoltageisaccomplishedwhenthesiliconcontrolledrectifiers(SCRs)areturningonina“phase-back”techniqueduringmotoracceleration.TheTriggerportionoftheLogic/TriggerBoardpro-videsthefiring(Turn-ON)pulsestotheSCRsbaseduponacontrolvoltage(VCONorDelayangle)pro-videdbytheLogicportionoftheLogic/TriggerBoardlocatedintheSolidStateStartercabinet.Afterthemotorhasacceleratedtosynchronousspeed,theSCRsareturnedfullontoconductthefullAClinevoltagetothemotor.TheLogic/TriggerBoardprovidessafetyfunctionstoprotectthecompressormotorandthestarterfrommanydifferentconditions,suchashighandlowAClinevolt-ageproblems,highmotorcurrent,andpossibleSCRfailure.Inordertoreducesizeofthestarter,thecoolingtotheSCRassembliesisprovidedbyawater-to-waterheatexchangerbetweenthechillercondenserwaterloopandthecoolantintheclosedloop.Theheatexchangerlengthhasbeenreducedandisnowmountedonthestarteritself.Toreducethelengthoftheheatexchanger,thediameterofthetubehasbeenincreased.SYSTEMMICROPROCESSORSThesystemmicroprocessorshaveback-upprotectionincasetheyfailtofunction.Awatchdogcircuitisused,inwhich,thesystemmicroprocessorwillstrobeanout-putataregulartimeinterval.Iftheoutputstrobeismissing,theLogic/TriggerBoardwillsafelyshutdownthechiller.Anotherback-upcircuitrequiresthattheLiquidCooledSolidStateStarterreceiveahardwareFIG.2–LIQUIDCOOLEDSOLIDSTATESTARTER,BASICBLOCKDIAGRAMLD052461YORKINTERNATIONAL8andsoftwaresignalfromtheOptiViewControlCenter,forthechillertobestarted.Ifthetwosignalsarenotreceivedwithinacertainperiodoftime,ashutdownwilloccur.Themainsystemmicroprocessorperformsmanyfunc-tions.ItprovidestheserialcommunicationslinkbetweentheLogic/TriggerBoard,andtheMicroBoardintheOptiViewControlCenter.Itdeterminesthepropercur-rentscalingforthesizeofstarter,andinterrogatestheRUN/STOPsignalfromtheOptiViewControlCenter.ThisprocessoralsointerrogatesfeedbacksignalstodetermineOpenandShortedSCR,PhaseLoss,PhaseRotation,MotorOverload,HighInstantaneousCurrent,HighLineVoltage,andLowLineVoltageshutdowns.TheVCONsignalisgeneratedbythemainsystemmicroprocessor.Itisadigitalsignalplacedonthedatabus.Thisprocessorcomparesthestartingcurrentvalue,programmedattheOptiViewControlCenter,withthecurrentfeedbackfromthethreeoutputcurrenttrans-formers.AnewvalueofVCONisgeneratedeverylinecycle.Thissignalisthensenttotheprogrammablelogicdevice(PLD).ThePLDdeterminestheproperfiringorderfortheSCRstomaintaintheprogrammedstartingcurrentvalue.Asthespeedofthemotorap-proachessynchronousspeedoutputcurrentdropsoff,theVCONvalueincreases,andthePLDturnstheSCRsfullon.TheoutputofthePLDissenttoadigitaldriverchipandthentosixopticalcouplers,oneforeachSCR.TheopticalcouplersarethefirststageofthetriggerportionoftheLogic/TriggerBoard.Theyisolatethehighpowercircuitfromthelowpowercircuit.ThepowerforthehighpowercircuitissuppliedfromtheJ5connector.Thetriggersectionismadeupofsixoutputdrivers,oneforeachSCR.Eachoutputdriverhasadedicatedtransformer,thatstepsdowntheincomingvoltage,andprovidesisolationbetweeneachoutputdriver.Adigitalsignalprocessor(DSP)isusedformanytim-ingandcalculationfunctions.RootMeanSquare(RMS)calculationsrequirethatinputlinevoltageandoutputcurrentvaluesbecalculatedonacycle-by-cyclebasis.ThesecalculationsareusedtodisplaytheRMSvoltageandcurrentforeachphase,kW,andkWhontheOptiViewControlCenter.TheDSPisalsousedtoin-terpretthefeedbacksignalsfromthethermistorsmountedontheSCR’sassemblies.Allofthesevaluesareplacedonthedatabusforthemainsystemmicro-processortogeneratefaults,ifrequired,andtosenddataontotheOptiViewControlCenterviatheserialcommunicationlink.FIG.3–LIQUIDCOOLEDSOLIDSTATESTARTER–REARVIEW,EXTERIORPIPEPLUGWATERRESERVOIRWATERPUMPDRAINCAPHEATEXCHANGER00284VIPTheoryofOperationFORM160.00-O29YORKINTERNATIONALSOLIDSTATESTARTERCOOLINGLOOP(RefertoFig3)TheSCRsintheLiquidCooledSolidStateStartergen-erateheatduringnormalrunningconditionsandbecomeveryhotduringstart-upofthechiller.Thisheatisgen-eratedbythefactthatallofthecurrentflowingtothemotorisconductedthroughtheSCRs.TheSCRsareveryreliable,buttheydohaveaslightresistancevaluewhentheyareturnedon.Theresistance,alongwiththeloadcurrentofthemotor,generatestheheat.Theheatmustbedissipated,ortheSCRswillfailfromanoverheatingcondition.Twomethodsarecommonlyusedtodissipatetheheat.Thefirstmethod,whichwasemployedonoldersolidstatestarterswasforcedaircooling.Thismethodworkswell,butrequiresalargercabinetandtheadditionofmanyfans.Thesecondmethodfordissipatingtheheatistoemployawatercoolingsystemsimilartothatusedinautomobiles.ThecoolingsystemfortheLiquidCooledSolidStateStarterisdifferentfromthesysteminanautomobile.Inautomobiles,heatistransferredtotheair,butthestartertransfersheattothecondenserwater.Condenserwaterisusedtocoolthestarterformanyreasons.One,thecondenserwaterwillalwaysbeavail-ablesinceitispartofthechillersystem.Thecoolingisfreesincethecondenserwaterwillbecooledinthecool