VARIABLE SPEED OIL PUMP DRIVE

FOR STYLE “E” YK CHILLER WITH

STYLE “P” COMPRESSOR
SERVICE INSTRUCTIONS New Release Form 160.00-M3 (601)

VARIABLE SPEED OIL PUMP DRIVE FOR STYLE “E” YK CHILLER WITH
STYLE “P” COMPRESSOR

00579VIP
 IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES

This equipment is a relatively complicated apparatus. situated, as well as severe personal injury or death to
During installation, operation, maintenance or service, themselves and people at the site.
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, oils, This document is intended for use by owner-authorized
materials under pressure, rotating components, and both operating/service personnel. It is expected that this indi-
high and low voltage. Each of these items has the po- vidual possesses independent training that will enable
tential, if misused or handled improperly, to cause bodily them to perform their assigned tasks properly and safely.
injury or death. It is the obligation and responsibility of It is essential that, prior to performing any task on this
operating/service personnel to identify and recognize equipment, this individual shall have read and understood
these inherent hazards, protect themselves, and proceed this document and any referenced materials. This indi-
safely in completing their tasks. Failure to comply with vidual shall also be familiar with and comply with all
any of these requirements could result in serious dam- applicable governmental standards and regulations per-
age to the equipment and the property in which it is taining to the task in question.

SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:

DANGER indicates an imminently CAUTION identifies a hazard which

hazardous situation which, if not could lead to damage to the machine,
avoided, will result in death or seri- damage to other equipment and/or en-
ous injury. vironmental pollution. Usually an in-
struction will be given, together with
a brief explanation.

WARNING indicates a potentially NOTE is used to highlight additional

hazardous situation which, if not information which may be helpful to
avoided, could result in death or seri- you.
ous injury.

External wiring, unless specified as an optional connection in the manufacturer’s product

line, is NOT to be connected inside the micro panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the micro panel. NO external wiring
is allowed to be run through the micro panel. All wiring must be in accordance with YORK’s
published specifications and must be performed ONLY by qualified YORK personnel. YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will void the
manufacturer’s warranty and cause serious damage to property or injury to persons.

2 YORK INTERNATIONAL
 FORM 160.00-M3

TABLE OF CONTENTS

Page

VSD Oil Pump General Information ................................................................................................................. 3

Reference Instructions ....................................................................................................................................... 3
VSD Oil Pump Ratings ...................................................................................................................................... 3
VSD Oil Pump Drive Overview ........................................................................................................................ 3
VSD Oil Pump Drive Detail Information ......................................................................................................... 3
VSD Oil Pump Drive Operation ........................................................................................................................ 4
OptiView Control Center Operation .................................................................................................................. 5
Automatic Speed Control ................................................................................................................................... 5
Manual Speed Control ....................................................................................................................................... 7
Oil Pump Drive Status LEDs ............................................................................................................................ 8
VSOP Drive Okay Relay .................................................................................................................................. 8
Standby Lubrication ........................................................................................................................................... 8
Safety Shutdowns ................................................................................................................................................. 9
Oil – Variable Speed Pump – Setpoint not Achieved ........................................................................................ 9
Oil – Variable Speed Pump – Drive Contacts Open ......................................................................................... 9
Fault Indications by the VSOP Drive ............................................................................................................... 9
Inverter Gate Driver Fault ................................................................................................................................. 9
Overload Fault ................................................................................................................................................. 10
Low DC Link Voltage Fault ............................................................................................................................. 10
Over Temperature Fault .................................................................................................................................. 11
Trouble Shooting Guide .................................................................................................................................... 11
Drive Replacement Instructions .................................................................................................................... 13
Most Frequently Asked Questions ............................................................................................................... 14
Service Parts List ............................................................................................................................................. 15

YORK INTERNATIONAL 3
 VSD OIL PUMP GENERAL INFORMATION

REFERENCE INSTRUCTIONS

Operation (Unit) Wiring Diagram Field Connections

Model YK, Style “E” Chiller, Style “P” Compressor Model YK, Style “E” Chiller, Style “P” Compressor
(Form: 160.54-O1) Electro-Mechanical Starter
(Form: 160.54-PW11)
Operation (OptiView Control Center)
Model YK, Style “E” Chiller, Style “P” Compressor Style “B” Solid State Starter
(Form: 160.54-O1) (Form: 160.54-PW12)
Variable Speed Drive
Service (OptiView Control Center) (Form: 160.54-PW13)
Model YK, Style “E” Chiller, Style “P” Compressor
(Form: 160.54-M1)

Wiring Diagram (OptiView Control Center)

Model YK, Style “E” Chiller, Style “P” Compressor
Electro-Mechanical Starter
(Form: 160.54-PW8)
Style “B” Solid State Starter
(Form: 160.54-PW9)
Variable Speed Drive
(Form: 160.54-PW10)

TABLE 1 – VSD OIL PUMP RATINGS

INPUT VOLTAGE VSOP DRIVE MAXIMUM INPUT MAXIMUM OUTPUT

RANGE (Vrms) PART NUMBER CURRENT (Arms) CURRENT (Arms)
200/208 60 Hz 031-02044-000 6.1 11.0
220/230/240 60 Hz 031-02044-000 5.6 11.0
380 60 Hz 031-02044-000 3.3 11.0
440/460/480 60 Hz 031-02044-000 2.8 11.0
575/600 60 Hz 031-02044-000 2.2 11.0
380/400/415 50 Hz 031-02044-000 3.3 11.0

VSD OIL PUMP DRIVE OVERVIEW

The new YORK Variable Speed Oil Pump Drive The VSOP drive is now being installed on Style “E” YK
(VSOP drive) for Style “E” YK chillers with a “P” com- chillers with a “P” compressor. The VSOP drive will
pressor is an air cooled, microprocessor controlled, replace the mechanical valve system used in the past on
PWM inverter utilizing Insulated Gate Bipolar Transis- other chillers to regulate oil pressure. This new system
tors (IGBT). The VSOP drive has the same four major will improve bearing lubrication by providing a higher oil
components that most AC motor drives have, pre-charge, pressure during the pre-lube cycle, and provide a method
input rectifiers, DC bus, and the inverter. The one ma- of regulating oil pressure to a specific programmed value
jor difference is that the VSOP drive is controlling a 2- during the run time of the compressor.
phase motor. The VSOP drive is not repairable, but is
simply replaced if it has failed.

4 YORK INTERNATIONAL
 FORM 160.00-M3

VSD OIL PUMP DRIVE DETAIL INFORMATION

VSD OIL PUMP DRIVE OPERATION this drive uses 3. The reason for 3, is that the bus voltage
for this drive can exceed the voltage rating for 2 capaci-
The pre-charge of the VSOP drive takes place as soon tors. The higher voltage rating gives the VSOP drive the
as input power is applied. Instead of using a contactor ability to have a wide input voltage range. This is why only
and resistor combination used in larger drives, this drive one drive is being used with an input voltage range of
uses two thermistors for pre-charge. The thermistor is 208VAC to 600VAC.
a device that varies resistance, as it becomes hot or
cold. When input power is applied, the thermistors are The output inverter section is made up of six switches.
at room temperature and have a high resistance. This These switches are insulated gate bipolar transistors (IGBT).
high resistance limits the inrush current required to IGBTs are very fast switches used in power electronics.
charge up the DC bus capacitors. While the drive is The IGBT gives the drive the ability to vary the output
running, the thermistors will remain hot and the low re- voltage and frequency with a constant DC bus voltage
sistance allows the drive to run normally. Without the stored in the bus capacitors. In this case the oil pump mo-
pre-charge operation, the DC bus capacitors would re- tor is rated for 120VAC. The bus voltage will vary based
quire such a large inrush of current that the input power on the different input voltage supply. At 208VAC input
fuses and possibly the input rectifiers could fail. voltage the bus voltage will be approximately 294VDC,
and with a 575VAC input voltage the bus voltage will be
DURING NORMAL RUNNING approximately 813VDC. The reason that the 120VAC
CONDITIONS THE THERMISTORS motor can be run with such a high bus voltage is the IGBT
BECOME VERY HOT. PERSONAL switching duty cycle (being the time that the switch is on
INJURY MAY RESULT. (REFER TO or off). The duty cycle will vary based on the bus voltage
FIG. 1) value. At the low bus voltage the IGBTs will be turn on for
a longer period of time, and with a high bus voltage the
IGBTs will be turn on for a shorter period of time.
The input rectifiers are used to convert the AC input volt-
age into a DC voltage, which is stored in the DC bus ca-
As already stated the drive is capable of using a wide
pacitors. The input rectifier for this drive is made up of six
input range of voltage. This wide range of input voltage
diodes. Since diodes are used the DC bus voltage is al-
is automatically addressed in the power section of the
ways present whenever input power is applied. As
drive. The control circuitry power supply uses an input
with many small drives the input diodes are integrated into
transformer to step-down the input voltage to a level
one power module with the output inverter.
that can be easily regulated. This voltage needs to be
somewhat constant so that the voltage regulator in the
The DC bus is basically made up of capacitors. Typically,
control circuitry power supply will not over heat. Jump-
the bus is made up of an even number of capacitors, but
ers are used to connect the winding of the transformer

EPROM
GREEN LED

TBI VOLTAGE RED LED

SCALING

TB3 LOGIC
SIGNALS
THERMISTORS

TB2 INPUT
POWER T1 - T3
OUTPUT WIRES
00577VIP
FIG. 1 – LOCATION OF THERMISTORS AND TERMINAL BLOCKS

YORK INTERNATIONAL 5
in either a parallel or series configuration to provide a operates the VSOP drive over the same range to main-
somewhat constant AC voltage to the control circuitry tain the oil pressure to the programmed OIL PRES-
power supply. The jumper configuration is shown be- SURE SETPOINT (20 to 45 PSID).
low. Refer to Fig. 1 for the location of TB1.
After the compressor has been running for 15 seconds,
TABLE 1 – JUMPER CONFIGURATION FOR TB1 the TARGET OIL PRESSURE becomes the OIL
PRESSURE SETPOINT (20 to 45 PSID) that has been
Nominal Line Jumper J1 Jumper J2 Jumper J3 programmed by the Service Technician using the proce-
Voltage (VAC) Between Between Between dure stated in Form 160.54-M1. The Microboard then
50 & 60 Hz TB1-1 & TB1-3 TB1-2 & TB1-4 TB1-2 & TB1-3 applies a speed command to the VSOP drive that changes
200, 208, 220, 240 ON ON OFF the output frequency of the VSOP drive as required to
380, 400, 415, achieve the “OIL PRESSURE SETPOINT.” The pro-
OFF OFF ON
440, 480, 575 grammed OIL PRESSURE SETPOINT is the oil pres-
sure for the remainder of “SYSTEM RUN” and through
OPTIVIEW CONTROL CENTER OPERATION “SYSTEM COASTDOWN.”

The OptiView Control Center maintains desired system During oil pump operation, the actual oil pressure and
oil pressure by controlling the output frequency of the commanded frequency of the VSOP drive can be
theVSOP drive and thus the speed of the oil pump. The monitored on the OIL SUMP SCREEN. Refer to Form
Microboard applies a speed command to the VSOP drive 160.54-O1 for details about the OIL SUMP SCREEN.
to control the output frequency. The speed command is
in the form of a Pulse Width Modulation (PWM) signal
as explained later. Refer to Fig. 2 for the wiring inter- AUTOMATIC SPEED CONTROL
face between the OptiView Control Center and the
VSOP drive. During the pre-lube period and the first 15 The Microboard controls the VSOP drive output fre-
seconds of compressor run, the software in the quency by applying a Pulse Width Modulation (PWM)
Microboard starts the VSOP drive at 45 Hz, and then speed command signal to the VSOP drive (Fig. 3). The
operates the VSOP drive over a range of 25 Hz to 60 signal is applied every 0.7 seconds. Within the 0.7 sec-
Hz to maintain the oil pressure at 45 PSID, or the TAR- ond period, the duration of time that the signal is “low”
GET OIL PRESSURE. Thereafter, the Microboard

TB3
I/O
BOARD 1

TB3

70
J1 6

OIL VARIABLE SPEED PUMP -

DRIVE CONTACTS OPEN LINE
70 1

J19 6
J20
DRIVE OKAY RELAY
1 SPEED COMMAND PWM OPEN ON FAULT

2 +12VDC +V OIL
MICROBOARD 3
START / STOP EN PUMP
VSD

LD04718

FIG. 2 – OIL PUMP VSD - INTERFACE

6 YORK INTERNATIONAL
 FORM 160.00-M3

(0VDC), determines the VSD output frequency between is divided by .3 to provide a CONTROL PERIOD VALUE
25 to 60 Hz. If the signal remains “high” (+12VDC) for of (1- 9). This value is multiplied by 0.5 Hz to provide
the entire 0.7 second period, it is commanding the VSOP greater frequency change to more quickly adjust the oil
drive’s output frequency to 25 Hz. If the signal is low pressure. If the error is > ± 0.5 PSID & < ± 6 PSID, the
for the entire 0.7 second period, it is commanding the output frequency is increased or decreased 0.5 Hz. At the
VSOP drive’s output frequency to 60 Hz. Frequencies end of each “CONTROL PERIOD”, the actual oil pres-
between these extremes are achieved by driving the sure is compared to the “PROGRAMMED OIL PRES-
signal low for a proportionate amount of time within the SURE” and the Microboard changes the speed command
0.7 second period. For example, if the signal is low for as required per the following:
50% (0.35 seconds) of the 0.7 second period, it would
command the VSOP drive to operate at an output fre- If actual oil pressure is:
quency that is halfway between 25 and 60 Hz, or 42.5 a. >setpoint + 0.5 PSID) & <(setpoint + 6 PSID), de-
Hz. The resolution or smallest increment of change is crease output frequency 0.5 Hz.
0.01 seconds. This allows the output frequency to be b. >(setpoint + 6 PSID), decrease output frequency
changed in 0.5 Hz steps. The formula provided in Fig. 3 0.5 Hz x Control Period Value.
could be used to calculate the output frequency for a
given PWM signal. c. <(setpoint – 0.5 PSID) & >(setpoint – 6 PSID),
increase output frequency 0.5 Hz.
0.7 SEC
d. <(setpoint – 6 PSID), increase output frequency
+12 VDC OFF 0.5 Hz x Control Period Value.
0 VDC ON 25.0 Hz

+12 VDC OFF

0.17 SEC
0 VDC ON 33.5 Hz

OFF
ON 0.35 SEC
42.5 Hz

OFF
0.52 SEC
ON 51.0 Hz

OFF
ON 60.0 Hz

+12 VDC "OFF TIME"

0VDC "ON TIME"

OUTPUT FREQUENCY IN HZ = (ON TIME IN SECONDS / 0.02) + 25

SMALLEST INCREMENT OF CHANGE = 0.010 SEC; 0.5 Hz

LD04377
LD06916

FIG. 3 – PULSE WIDTH MODULATION (PWM)

SPEED CONTROL SIGNAL VOLTAGE MANUAL SPEED CONTROL
MEASURED TO GROUND
The VSOP drive speed can be manually controlled us-
The entire VSOP drive run time is divided into “OIL ing the RAISE, LOWER, SET or AUTO keys on the
PRESSURE CONTROL PERIODS.” They run con- OIL SUMP SCREEN. Access Level for SERVICE is
secutively and continuously; when the first one ends, required for this function. This features is available dur-
the next one begins. This repeats until the oil pump is ing manual oil pump operation, and while the compres-
shutdown. The duration of the periods are determined sor is running, but this feature is not available during the
by the “CONTROL PERIOD,” programmed by the pre-lube operation.
Service Technician using instructions stated in Form
160.54-M1. This setpoint is programmed in increments When the chiller is not running the VSOP drive can be
of 0.3 seconds over the range of 0.3 to 2.7 seconds, by turned on with the “MANUAL OIL PUMP” key on
programming the actual value. The “CONTROL PE- the OIL SUMP SCREEN. When this key is pressed, a
RIOD” also determines the magnitude of output fre- timer will appear on the same screen. This timer will
quency correction when the error between the actual indicate the amount of time left that the VSOP drive
oil pressure and the “PROGRAMMED OIL PRES- will continue to run before automatically turning off. The
SURE” is > ± 6 PSID. The “CONTROL PERIOD” maximum time is 10 minutes. The “RAISE” and
YORK INTERNATIONAL 7
“LOWER” keys can be used to increase or decrease will indicate that the VSOP drive has faulted since
the VSOP drive’s output frequency over the range of the power was last applied, and it has restarted.
25 Hz to 60 Hz. Each time the “RAISE” key is pressed, The fault conditions are explained under the Fault
the frequency is increased 0.5 Hz. Each time the Indications section of this form.
“LOWER” key is pressed, the frequency is decreased • A flashing RED LED will indicate that the VSOP drive
0.5 Hz. If the “AUTO” key is pressed, automatic op- is in a faulted condition. The fault conditions are ex-
eration as described previously is resumed. plained under the Fault Indications section of this form.

A special feature allows the VSOP drive to output a spe- STATUS

cific pre-determined frequency. This permits service to LEDs
analyze the oil pressure at various oil pump speeds. This
frequency is programmed when the “SET” key is pressed.

During manual and automatic operation, the OIL SUMP

SCREEN can be used to monitor the VSOP drive’s
commanded output frequency and system oil pressures.

Manual oil pump speed control can be confirmed on the

OIL SUMP SCREEN. View the “VARIABLE SPEED
OIL PUMP CONTROL MODE” for the mode of op- 00578VIP

eration. The text will change from “AUTO” to

“MANUAL” when the “RAISE”, “LOWER”, or “SET” FIG. 4 – LOCATION OF STATUS LEDs ON
keys on the OIL SUMP SCREEN are pressed. The CONTROL BOARD
text will change from “MANUAL” to “AUTO” when
the “AUTO” key is pressed. VSOP Drive Okay Relay

When the chiller is running the manual speed is con- The VSOP drive is equipped with a set of normally open
trolled in the same manner as when the chiller is not contacts. These contacts are open when the VSOP drive
running. Press the “RAISE”, “LOWER”, or “SET” keys is in a faulted condition. These contacts are driven
on the OIL SUMP SCREEN and the “VARIABLE closed when the VSOP drive condition is okay. The
SPEED OIL PUMP CONTROL MODE” text will contacts are connected between TB3-70 and TB3-1.
change from “AUTO” to “MANUAL.” The text will When the contacts are open a voltage of 115VAC will
change from “MANUAL” to “AUTO” when the be measured across these two terminal connections, and
“AUTO” key is pressed. the chiller will initiate a Cycling Shutdown. The follow-
ing message will appear on System Details line of the
Oil Pump Drive Status LEDs display. “OIL – VARIABLE SPEED PUMP -
DRIVE CONTACTS OPEN.” This message will ap-
The VSOP drive has a drive status LED, and a fault pear, and the contacts will remain open as long as the
LED. The drive status LED is located on the upper fault is still present. Refer to the fault conditions below
right corner of the control board, and it is noted as for detailed information about the faults.
GREEN. The fault LED is located just below the drive
status LED, and it is noted as RED. The panel door for Standby Lubrication
the VSOP drive must be removed to view these LEDs.
The state and frequency at which the RED LED will To maintain oil seal integrity while the chiller is shut-
flash will determine the fault of the VSOP drive. If down, the oil pump is turned on for 2 minutes every 24
power is removed the fault condition is no longer dis- hours if the chiller has not run in the past 24 hours.
played. The conditions of the LEDs are as follows: While the oil pump is running, the message “WARN-
ING – SEAL LUBRICATION IN PROCESS” is
• A constant GREEN LED will indicate that the displayed. The operating oil pressure will be the pro-
VSOP drive is in a running condition. grammed OIL PRESSURE SETPOINT, programmed
• A constant RED LED will indicate that the VSOP by the Service Technician. This feature will be inhibited
drive is in a stopped condition with no faults present. if the chiller enters the prelube cycle, or if the oil pres-
• If none of the LED’s are lit at all, the input power sure is to low. If the oil pressure is too low the following
has been removed, or VSOP drive has failed. message is displayed “WARNING – STANDBY
• A constant GREEN LED and a flashing RED LED, LUBE – LOW OIL PRESSURE.”
8 YORK INTERNATIONAL
 FORM 160.00-M3

To prevent oil pump damage due to low oil level, an oil indicate that the lubrication cycle will not be performed
pressure fault has been created to function during the although a Safety message will appear to indicate the
Standby Lubrication Cycle. This fault will terminate the oil pressure transducer will be out of range. The verifi-
Standby Lubrication Cycle, if at least 15 PSID of oil cation of correct pressure assures that standby lubrica-
pressure is not achieved within 30 seconds of turning on tion cycles will not be performed when the chiller is
the oil pump, or if the oil pressure drops below 15 PSID opened to atmospheric pressure, or until the chiller has
after the first 30 seconds of operation. This fault is iden- been charged with refrigerant and chiller commission-
tified when the message “WARNING – STANDBY ing has been completed.
LUBE – LOW OIL PRESSURE” is displayed. The
next standby lube cycle will occur only after the warn- These standby lubrication cycles are enabled or disabled
ing has been manually cleared, or by starting the chiller. by the Service Technician using the procedure stated in
Form 160.54-M1. It is recommended that the standby
Standby lubrication cycles will not be performed if ei- lubrication be enabled on chillers that remain shutdown
ther oil pressure transducer is out of range (HOP < 6.8 for periods of 24 hours or greater.
PSIG, LOP < 0 PSIG). No message will be displayed to

SAFETY SHUTDOWNS

Oil – Variable Speed Pump – Setpoint Not Achieved One solution is a change in the software for the
OptiView Control Center that will cause the oil pump
If either of the following conditions occur, a Safety shut-
drive to accelerate to 45 Hz on start, and then regulate
down is initiated and the message “OIL – VARIABLE
the speed of the drive to the oil pressure requirement.
SPEED PUMP – SETPOINT NOT ACHIEVED”
This software should already be installed.
is displayed on the System Details line of the display.
The second solution is to change the control period.
a. If the oil pressure is less than 25.0 PSID for 5 con- Lowering the value of the control period will allow the
tinuous seconds during the last 10 seconds of the
oil pump drive’s output frequency to change more quickly
compressor pre-lube or during the first 15 seconds
of SYSTEM RUN.
in response to the changing oil pressure. This adjust-
ment is important when the chiller compressor first starts
to spin. The oil pressure will drop since the oil can more
b. If the oil pressure is less than the programmed OIL freely move in a rotating bearing.
PRESSURE SETPOINT and the speed command to
the VSOP drive is at 60 Hz for 5 continuous seconds,
The “OIL – VARIABLE SPEED PUMP –
anytime after the first 30 seconds of SYSTEM RUN.
SETPOINT NOT ACHIEVED” safety check is not
Typically, this fault occurs during the prelube cycle or performed during MANUAL SPEED control.
during the automatic seal lubrication cycle. The reason
Oil – Variable Speed Pump – Drive Contacts Open
for the fault is that the cool oil is saturated with refriger-
ant. Oil that is saturated with refrigerant is much thin- In an effort to have a VSOP drive that is as reliable as
ner then oil that has the refrigerant boiled off. Since, the possible, the VSOP drive can only generate 4 faults.
oil is thinner it is more difficult to build oil pressure in the Although this fault is a Cycling shutdown for the chiller,
system. This cool oil is generally not the oil in the sump, commonly the chiller will also shutdown on a Low Oil
but the oil that is laying in the rest of the oil lubrication Pressure Shutdown. The Low Oil Pressure Shut-
system, which cannot be heated by the oil heater mounted down is a Safety shutdown, and it will require a manual
in the sump. reset of the chiller.

YORK INTERNATIONAL 9
 FAULT INDICATIONS BY THE VSOP DRIVE

Inverter Gate Driver Fault Overload Fault

In order for the VSOP drive to be compatible with a
This fault is generated by 2 different conditions. The wide range of input line voltages, the overload fault is
first condition is the power supply voltage at the output determined by calculating the average power transferred
gate driver. If this voltage is not high enough, then the from the DC bus to the oil pump motor. If this value
output switch will not turn on properly. This will cause a exceeds 1757 watts then a shutdown will occur. Also, if
great amount of heat, possibly causing the output switch the DC bus current exceeds 8 amps., then the VSOP
to fail. The second condition, is a high amount of cur- drive will shutdown in 10 seconds. The current flowing
rent flowing out of the DC bus. This fault is auto re- to the pump motor can be verified by measuring the
settable, since the condition is cleared when the VSOP current in the motor leads. With a two-phase motor the
drive turns itself off. The drive will turn back on and try maximum current flowing in each phase is different.
to start again. If this fault occurs 3 times within 1 minute, The red output wire is the main winding, and it’s 100%
the drive will lockout. After the VSOP drive is locked rating is 7.0 amps. The blue output wire is auxiliary wind-
out, it may be restarted by placing the COMPRESSOR ing, and it’s 100% rating is 10.0 amps. The black output
SWITCH in the STOP/RESET position, and then in the wire is common wire, and it’s 100% rating is 11.0 amps.
START position. When these values exceed 105% of the rated current
value then the overload timer will start. The overload
Indications for This Fault timer is variable based, on the amount of current that is
The RED LED will blink on once and then off for 5 flowing.
seconds. This sequence will repeat until a new fault
occurs, or power has been removed and reapplied. Indications for This Fault
The RED LED will blink on 2 times and then off for 5
Possible Problems
seconds. This sequence will repeat until a new fault
• The input supply voltage may not be within specification. occurs, or power has been removed and reapplied.
• A component failure on the VSOP drive control board.
• Shorted output switch on the VSOP drive. Possible Problems
• Short from the output of the VSOP drive to ground, • Dirty oil filter.
through the output insulator or the oil pump motor. • Dirty oil causing the oil pump to bind up.
• Shorted oil pump motor, phase-to-phase. • Blockage in the oil lines.

Possible Solutions Possible Solutions

• Verify input voltage to the VSOP drive. • Verify that the oil filter is clean.
• Verify that the oil filter is clean, and that there are no • Verify that the oil in the chiller is clean and does not
oil blockages. contain any slag from the welding process. Tempo-
rarily switch the Main and Auxiliary wires from the
• Verify the jumper position on the TB1 terminal block. VSOP drive and the motor. This will cause the oil
• Verify that the oil pump motor is not locked into po- pump motor to reverse direction, and possibly re-
sition. Temporarily switch the Main and Auxiliary move any slag from the oil pump gears. Properly,
wires from the VSOP drive and the motor. This will reconnect the motor wires.
cause the oil pump motor to reverse direction, and • Verify that the oil pump motor is free to rotate.
possible remove any slag from the oil pump gears.
Properly, reconnect the motor wires. Low DC Link Voltage Fault:
• Verify that the VSOP drive is not shorted.
This fault is generated when the DC bus voltage does
• Verify that the oil pump motor is not shorted phase-
to-phase, or phase- to-ground.
not reach 170VDC within 3 seconds of power being
applied, or the DC bus voltage drops below 170VDC
after the Bus voltage has reached a level higher than
170VDC.

10 YORK INTERNATIONAL
 FORM 160.00-M3

Indications for This Fault Possible Problems

The RED LED will blink on 3 times and then off for 5 • Ambient temperature of the chiller room is above
seconds. This sequence will repeat until a new fault oc- 104°F (40°C).
curs, or power has been removed and reapplied. • The heatsink for the VSOP drive is dirty.
• The mounting screws for the output power device
Possible Problems are not properly torqued.
• Input voltage range outside the specification of the • Blockage in the oil lines.
VSOP drive. • The oil is too hot.
• Input voltage variation due to power factor correction
capacitors. Possible Solution
• Reduce the ambient temperature of the chiller room.
Possible Solutions • Clean the heatsink of the VSOP drive.
• Provide the proper input voltage for the VSOP drive. • Properly torque the mounting screws of the output
power device.
Over Temperature Fault • Verify that the oil temperature is not exceeding 180°F
This fault is generated when the base plate temperature (82°C).
of the output power device is greater than 255°F
(124°C). The temperature sensor is part of the output
power device. The drive will attempt to restart when
the base plate temperature is below 250°F (121°C).

Indications for This Fault

The RED LED will blink on 4 times and then off for 5
seconds. This sequence will repeat until a new fault
occurs, or power has been removed and reapplied.

YORK INTERNATIONAL 11
 TROUBLE SHOOTING GUIDE

Problem Action Required Solution

Blown Input Fuses, or the 1. Remove input wires L1-L3 from the VSOP Drive, 1a. If input is shorted, replace VSOP drive.
status LEDs are not lit. measure resistance, input phase to phase 1b. If input is not shorted, replace L1-L3 and continue
on the VSOP drive. to the next step.
2. Remove wires T1-T3, measure resistance, output 2a. If output is shorted, replace VSOP drive.
phase to phase on the VSOP drive. 2b. If output is not shorted, replace T1-T3, and replace
the blown input fuses.
2c. If the LEDs still do not light, then the LEDs have
failed. Replace the VSOP drive.
System Details on the OptiView Panel 1. Refer to Fault Indications by the VSOP Drive in the 1a. Correct for any of the fault conditions in the
reads Oil – Variable Speed Pump – previous section. previous section.
Drive Contacts Open, and the fault
RED LED is flashing on the VSOP drive.
System Details on the OptiView Panel 1. Measure the voltage between TB3-1 on the VSOP 1a. If 0VAC is measured, verify wiring of TB3-1 TB6-1
reads Oil – Variable Speed Pump – drive and Ground. in the OptiView Panel. For details refer to the proper
Drive Contacts Open, but the fault Wiring Diagram.
RED LED is constantly lit on the 1b. If 115VAC is measured continue to the next step.
VSOP drive. 2. Measure voltage between TB3-4 on the I/O board 2a. If 0VAC is measured, verify wiring between
and Ground. terminalTB3-70 on the VSOP and the I/O board.
Replace wire if required.
2b. If wiring is okay, the relay on the VSOP drive has
failed. Replace the VSOP drive.
2c. If 115VAC is measured, then verify operation of the
I/O board and the Microboard.
Start the VSOP drive, but the VSOP 1. Measure voltage between TB3-1 on the VSOP drive 1a. If 0VDC is displayed, verify wiring from TB3-1 to the
drive will not start and the fault and Ground on the Microboard. Microboard.
RED LED is constantly lit. 1b. If 12VDC is measured continue to the next step.
2. Manually start the VSOP drive from the OptiView Panel. 2a. If 12VDC is displayed, verify wiring from TB3-2 to
Measure voltage between TB3-2 on the VSOP drive the Microboard.
and Ground. 2b. If 0VDC is measured continue to the next step.
3. Temporarily disconnect the oil heater. Remove the wire 3a. If VSOP drive starts verify the J20 connector for
connected to J20-3 in the Microboard, and connect that broken solder joint or loose connector.
wire to Ground on the Microboard. 3b. If VSOP drive does not start replace VSOP drive.
Also reconnect the oil heater.
The VSOP drive will run but the 1. None 1a. Verify wiring between VSOP drive, and Microboard.
Oil pressure will not regulate to the 1b. If wiring is okay, continue to the next step.
setpoint in automatic mode. 2. Temporarily disconnect the oil heater. Connect the Run 2a. The oil pressure should be maintained at a minimum
signal to ground. Remove J20-1 and connect it to J20-2 low pressure.
on the Microboard. 2b. If the oil pressure starts to increase over time, then
replace the oil pump drive. Reconnect the oil heater.
The status GREEN LED is flashing. 1. Verify wiring between the VSOP drive and the
Microboard.
VSOP drive is running, but oil 1. Verify that the Main and Auxiliary wires are properly
pressure is not increasing or has connected to the oil pump motor.
remained 0 PSID.

12 YORK INTERNATIONAL
 FORM 160.00-M3

DRIVE REPLACEMENT INSTRUCTIONS

1. Remove power from the chiller at the main power 8. Clean the heatsink with a rag and rubbing alcohol.
disconnect. 9. On the replacement drive verify that the TB1 jump-
2. Wait 5 minutes for the DC bus voltage to decay to a ers are properly configured for your application. Refer
safe level, and the thermistors to cool off. to Table 1.
3. Remove the cover to the VSOP drive. The screws 10. Apply a thin coating of Heatsink grease (provide
are captive. with replacement drive) to the bottom of the power
4. Take note of all wiring connected to the VSOP drive. module.
5. Remove all wiring from the VSOP drive. 11. Replace the VSOP drive and install the hardware.
6. Remove the nut securing the control transformer, The 2 screws that hold the power module to the
and the 2 nuts at the top two corners of the VSOP heatsink should be torqued to 24-28 In-Lbs.
drive control board. Remove the 2 screws holding 12. Rewire the VSOP drive using Fig. 4 below.
the power module to the heatsink. 13. Install the cover for the VSOP drive.
7. Carefully, remove the power module from the 14. Reapply power to the chiller at the main power dis-
heatsink. Do not nick or scratch the heatsink. connect.

LD06915

FIG. 4 – SYSTEM WIRING DIAGRAM

YORK INTERNATIONAL 13
 MOST FREQUENTLY ASKED QUESTIONS

1. Why doesn’t the rotation of the motor change full voltage is applied to the motor the SCRs are fully
when I change the input wiring to the VSOP turned on. The VSOP drive is the same as a Variable
drive? Speed Drive. This type of drive employs an input stage,
The VSOP drive converts the input line voltage into a an energy storage stage, and an output stage. The
DC bus voltage, and then converts the DC bus volt- input stage converts the AC input into a DC supply
age back into an AC voltage with a varying frequency. by rectifying the input line voltage. The DC supply is
So, the output section of the drive is isolated from stored in the energy storage stage, within capacitor
the input section of the drive by the capacitor bank. bank. The stored energy is then converted into a vary-
ing voltage and frequency in the output stage. The
2. How is oil pressure regulated?
output stage uses very fast switches that switch with
A differential oil pressure setpoint is programmed a constant frequency (of about 2 kHz) but with a vary-
through the OptiView panel. This setpoint is then ing duty cycle. The varying duty cycle allows the out-
used to regulate the oil pressure. The speed of the put to vary in frequency and voltage.
oil pump motor will increase if the oil pressure is
5. Can the VSOP drive be bypassed and the oil
less than the setpoint by 0.5 PSID. Also, the speed
pump motor powered directly across the line?
of the oil pump motor will decrease if the oil pres-
sure is greater than the setpoint by 0.5 PSID. No, the oil pump motor is a 2-phase motor with a
voltage rating of 120VAC. Connecting this motor is
3. On a 50 Hz installation how can the VSOP drive
the line voltage will burn it up, and it will not rotate.
still run at 60 Hz?
6. Can I read the VSOP output frequency with a
Normal operation of a motor requires that the increase
hand held meter?
in frequency and the increase in voltage occur at the
same rate. This is called a linear volts/Hz curve. If Yes, but the meter reading will not be correct. The
the supply voltage for 50 Hz is the same as 60 Hz, output frequency of the VSOP drive is actually sev-
then the drive can develop enough voltage to supply eral kHz. This frequency is what is called the carrier
a 60 Hz motor. The gating of the output power de- frequency. The motor acts like a filter to the carrier
vices determines the output frequency not the input frequency and the fundamental frequency or 60 Hz
frequency to the VSOP drive. is what is left. The hand held meter will detect the
carrier frequency, but not the fundamental frequency.
4. What are the differences between the Solid
Start Starter (SSS) and a VSOP drive? 7. Why does the VSOP drive fault when it is not
running?
The SSS reduces the amplitude of the voltage ap-
plied to the motor during start-up, by gradually turn- The line voltage is always applied to the input of the
ing on SCRs connected to the input line. Inrush cur- VSOP drive. Since this is the case, the voltage faults
rent is reduced since the voltage applied to the mo- must be active to protect the VSOP drive and the oil
tor is reduced. This method of controlling a motor pump motor.
has no effect on the frequency of the voltage. When

14 YORK INTERNATIONAL
 FORM 160.00-M3

SERVICE PARTS LIST

Description Part Number

VSOP Drive with Thermal Grease 371-03704-001
VSOP Drive EPROM 031-02059-001
Input Fuses with an EM-Starter or a Liquid Cooled Solid State Starter
200, 208, 220, 230, 240 Volts 025-25584-000 (FNQ-15)
380, 400, 415, 440, 460, 480 Volts 025-25515-000 (FNQ-7)
550, 575, 600 Volts 025-27971-000 (KTK-10)
Input Fuses with a VSD Compressor Drive 025-25515-000 (FNQ-7)

YORK INTERNATIONAL 15
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by York International Corporation 2001 www.york.com ALL RIGHTS RESERVED
Form 160.00-M3 (601)
New Release