Johnson Controls York AYK550 User manual

AYK 550
AIR MODULATORS
Supersedes: 100.42-01 (604) Form: 100.42-01 (506)
USER’S MANUAL
User’s Manual
AYK550-UH HVAC DRIVES (1...150HP)





!""#
$… %
• Safety
• Installation
• Start-Up
• Diagnostics
• Maintenance
• Technical Data
&%'*&"#
(Fieldbus Adapters, I/O Extension Modules etc., manuals
delivered with optional equipment)
!+&,,/,223 (typical title)
• Installation
• Programming
•Faulttracing
• Technical data
BACnet is a registered trademark of ASHRAE.
CANopen is a registered trademark of CAN in Automation
e.V.
ControlNet is a registered trademark of ControlNet International.
DeviceNet is a registered trademark of Open DeviceNet Vendor Association.
DRIVECOM is a registered trademark of DRIVECOM User Organization.
Ethernet is a registered trademark of Xerox Corp.
Interbus is a registered trademark of Interbus Club.
LonWorks is a registered trademark of Echelon Corp.
Metasys is a registered trademark of Johnson Controls Inc.
Modbus and Modbus Plus are registered trademarks of Schneider Automation Inc.
Profibus is a registered trademark of Profibus Trade Org.
Profibus-DP is a registered trademark of Siemens AG.
© 2004 YORK All Rights Reserved.

AYK550-UH User’s Manual
Table of Contents
Table of Contents
Safety
Use of Warnings and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation
Installation Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-Up
HVAC Control Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Application Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
YORK Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Serial Communication – EFB
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Mechanical and Electrical Installation – EFB . . . . . . . . . . . . . . . . . . . . . . . . . 142
Communication Set-up – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Activate Drive Control Functions – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Feedback from the Drive – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Diagnostics – EFB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Modbus Protocol Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
YORK Drives Profile Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
N2 Protocol Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
FLN Protocol Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
BACnet Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Serial Communication – FBA
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Mechanical and Electrical Installation – FBA . . . . . . . . . . . . . . . . . . . . . . . . . 193
Communication Set-up – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Activate Drive Control Functions – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Feedback from the Drive – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Diagnostics – FBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
YORK Drives Profile Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Generic Profile Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Diagnostics
Diagnostic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Correcting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Correcting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

AYK550-UH User’s Manual
Table of Contents
Maintenance
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Main Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Technical Data
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Degrees of Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Liability Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Appendix A
Factory-Mounted Solution and AHU VFDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
Appendix B
Field-Mounted Ship Loose Air Mods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1
Mechanical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1
Appendix C
Quick Start-Up Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1
Analog Input Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2
RS485 Interface Termination for Serial Communication . . . . . . . . . . . . . . . . . .C2
Customer Control Terminal Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2
Typical Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3
IGBT Test Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4
Inverter Component Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4
Inverter Diodes and IGBT Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4

AYK550-UH User’s Manual
Table of Contents
Appendix D
Solution AHU Drawing #205662. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1
#205648 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2
#205647 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
#205651 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
#205649 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
#205653 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6
#205663 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7
#205652 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8
#205650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9
#205654 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10
#205633 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11
Appendix E
Solution Dimensions
AYK550 Frame Size Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1
Base Drive (OO Option) Outside Dimensions . . . . . . . . . . . . . . . . . . . . . . . E2
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2
Base Drive w/Fused Disconnects (AO Option) Dimensions & Weights . . . . E3
Field Mounted Shipped Loose AirMods
Base Drive, 2 Contactor, Drive Input Service Disconnect Switch,
Main Fused Disconnect Switch (CM Option) Enclosure
Drawings & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4
Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E5
Outside Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6
Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E7
Appendix F
YORK Solution XTO VFD Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1
Index

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YORK, A Johnson Controls Company 
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678'9?,,,2@,=+4,,2,7
,,24,9/,=2@@32>
678'99,W@+=9979,@,>#['=9=,[2
7FF>
678*4,93?;342,7,?2WB@2=?,
3Q\@Z!!]B2\3\F\@Z!2!^>#
37@27F37Q=,+>
2,8 For more technical information, contact the factory or your local YORK sales
representative.


 YORK, A Johnson Controls Company
246732,
'9,?2,+244,+,=,2,92792,,9@_
• Notes draw attention to a particular condition or fact, or give information on a
subject.
• Warnings caution you about conditions which can result in serious injury or death
and/or damage to the equipment. They also tell you how to avoid the danger. The
warning symbols are used as follows:
722,7?7?249792,7?9=9==9+=
:+3`23@7,2,9<@,>
?7?;2,=23,2B2,9,9,92=3;+
=,=,+B?9=9=,9+=:+3`23@7,2,9<@,

 
YORK, A Johnson Controls Company 
*,,2
Study these installation instructions carefully before proceeding. \,22;
,9?73,=,2@+=@4=,2229Z3>
678J42+2;73[#4,+[27>
*,,2\2?9,
The installation of the AYK550 adjustable speed AC drive follows the outline below.
The steps must be carried out in the order shown. At the right of each step are
references to the detailed information needed for the correct installation of the unit.
'W #
%!%! for installation "Preparing for Installation" on page 4.
%!%! the Mounting Location "Prepare the Mounting Location" on page 7.
!&the front cover "Remove Front Cover" on page 7.
&'the drive "Mount the Drive" on page 8.
*#'"" wiring "Install the Wiring" on page 8.
 installation "Check Installation" on page 13.
!*#'"" the cover "Re-install Cover" on page 13.
%%"power "Apply Power" on page 14.
#'!'% "Note! For drives with bypass, if motor is running in
reverse switch incoming power lines at input disconnect."
on page 14.


 YORK, A Johnson Controls Company
%742*,,2
"4,7,9
Lift the drive only by the metal
chassis.
=W ,9
1. Unpack the drive.
2. Check for any damage and
notify the shipper immediately
if damaged components are
found.
3. Check the contents against
the order and the shipping label to verify that all parts have been received.
*3,4=,2
!"
To determine the type of drive you are installing, refer to either:
• Serial number label attached on upper part of the chokeplate between the
mounting holes.
• Type code label attached on the heat sink – on the right side of the unit cover.
IP2040
#>2>
cc]
dFQgd

*F
%
8.8 A
4
3~ 380...480 V
#>2>
cc]
dFQgd
*,
*
4
&,,F
*F
4F
2,2%
48...63 Hz
8.8 A
3~ 380...480 V
3~ 0...U1V
8.8 A
0...500 Hz
4

 
YORK, A Johnson Controls Company 
#$%&
Use the following chart to interpret the type code found on either label.
'(&)*+
The chart in "Ratings" on page 221 lists technical specifications, and identifies the
drive’s frame size – significant, since some instructions in this document, vary,
depending on the drive’s frame size. To read the Ratings table, you need the “Output
current rating” entry from the type code (see above). Also, when using the Ratings
tables, note that there are two tables based on the drive’s “Voltage rating”.
2,22@,;,+
The motor, drive, and supply power must be compatible:
2,2
#=4=,2 4+ !4=
Motor type 3-phase induction motor –
Nominal current Motor value is within this
range: 0.15…1.5 * I2N
(I2N = normal use current)
• Type code label on drive, entry for Output I2N,
or
• Type code on drive and rating table in
"Technical Data" on page 225.
Nominal frequency 10…500 Hz –
Voltage range Motor is compatible with
the AYK550 voltage range.
208…240 V (for AYK550-UH-XXXX-2) or
380…480 V (for AYK550-UHXXXX4)
500...600 V (for AYK550)
Insulation 500...600 V drives: Either
the motor complies with
NEMA MG1 Part 31, or a
du/dt filter is used between
the motor and drive.
For AYK550
Bh23=,
See Ratings chart for details
4 = 380…480 VAC
UH = Setup and parts specific to US installation and NEMA compliance
2 = 208…240 VAC
2,=,272=4=
&,,=,,7
2,7,7
01 = Setup and parts specific to IEC installation and compliance
=22,=,2=
6 = 500…600 VAC
No specification = IP 21 / UL type 1
AYK550-UH-08A8-4+...