York VSD 270 User manual

035-27337-100
Form Number: 160.00-O4 (820)
Supersedes: 160.00-O4 (220)
Operation Manual
Issue Date: 2020-08-19
Liquid-Cooled OptiSpeed Compressor
Speed Drive
Models VSD 270, 292, 351, 385, 419, 424, 503, 608, 658, 704,
790, 868, 882, 917, 948, and 1055. Models LVD 270, 292, 351,
385, 419, 424, 503, 608, 658, 704, and 900.

2 Liquid-Cooled OptiSpeed Compressor Speed Drive

Contents
ContentsGeneral safety guidelines.............................................................................................................................. 5
Safety symbols..................................................................................................................................... 5
Changeability of this document......................................................................................................... 6
Revision notes...................................................................................................................................... 6
Associated literature........................................................................................................................... 6
Conditioned based maintenance...................................................................................................... 7
VSD models.......................................................................................................................................... 8
LVD models........................................................................................................................................ 13
General information.................................................................................................................................... 15
OptiSpeed/Harmonic filter component overview......................................................................... 15
Differences between the G and W designs.................................................................................... 17
Differences for the VSD and LVD model drives............................................................................. 17
OptiSpeed compressor drive control system overview................................................................ 17
VSD adaptive capacity control......................................................................................................... 19
OptiSpeed compressor drive details......................................................................................................... 22
System architecture.......................................................................................................................... 22
Printed circuit boards........................................................................................................................ 32
Safety shutdowns......................................................................................................................................... 34
General information.......................................................................................................................... 34
Safety shutdown messages.............................................................................................................. 35
Cycling shutdowns....................................................................................................................................... 37
General information.......................................................................................................................... 37
Cycling shutdown messages............................................................................................................ 37
Warning messages....................................................................................................................................... 42
General information.......................................................................................................................... 42
Warning messages............................................................................................................................ 42
VSD frequently asked questions................................................................................................................ 43
Unit conversion............................................................................................................................................ 45
Liquid-Cooled OptiSpeed Compressor Speed Drive 3

4 Liquid-Cooled OptiSpeed Compressor Speed Drive

General safety guidelines
Important: Read before proceeding.
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certain components or conditions including,
but not limited to: heavy objects, refrigerants, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the potential, if misused or handled improperly,
to cause bodily injury or death. It is the obligation and responsibility of rigging, installation, and
operating/service personnel to identify and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to comply with any of these requirements could
result in serious damage to the equipment and the property in which it is situated, as well as severe
personal injury or death to themselves and people at the site.
This document is intended for use by owner-authorized rigging, installation, and operating/service
personnel. It is expected that these individuals possess independent training that will enable them
to perform their assigned tasks properly and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read and understood the on-product labels, this
document and any referenced materials. This individual shall also be familiar with and comply
with all applicable industry and governmental standards and regulations pertaining to the task in
question.
Safety symbols
The following symbols are used in this document to alert the reader to specific situations:
DANGER
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.
WARNING
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.
CAUTION
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.
Note: Highlights additional information useful to the technician in completing the work being
performed properly.
5Liquid-Cooled OptiSpeed Compressor Speed Drive

WARNING
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control 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 warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
Changeability of this document
In complying with Johnson Controls’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. Johnson Controls makes no
commitment to update or provide current information automatically to the manual or product
owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson
Controls Service office or accessing the Johnson Controls Knowledge Exchange website at https://
docs.johnsoncontrols.com/chillers/.
It is the responsibility of rigging, lifting, and operating/service personnel to verify the applicability
of these documents to the equipment. If there is any question regarding the applicability of these
documents, rigging, lifting, and operating/service personnel should verify whether the equipment
has been modified and if current literature is available from the owner of the equipment prior to
performing any work on the chiller.
Revision notes
Revisions made to this document are indicated in the following table. These revisions are to
technical information, and any other changes in spelling, grammar, or formatting are not included.
Affected pages Description
7 Conditioned Based Maintenance program information added
Associated literature
Manual description Form
number
Wiring Diagrams - Field Connections YK Style F and G - LV VSD 160.54-PW6
Wiring Diagrams - OptiView Control Center YK Style G and SSS, LV VSD, MV VSD 160.75-PW6
Wiring Diagrams - OptiView Control Center YK Style G and SSS, LV VSD, MV VSD
with the LTC I/O Board 160.75-PW8
Wiring Diagrams - Field Control Modifications YK Style G 160.75-PW4
Wiring Diagrams - Field Connections YK Style H - LV VSD 160.76-PW7
Wiring Diagrams - OptiView Control Center YK Style H and SSS, LV VSD, MV VSD 160.76-PW6
Wiring Diagrams - Field Control Modifications YK Style H 160.76-PW4
Chiller Operation and Maintenance YK Style G 160.75-O1
Liquid-Cooled OptiSpeed Compressor Speed Drive6

Manual description Form
number
Operation OptiView Panel YK Style G 160.54-O1
Chiller Operation and Maintenance YK Style H 160.76-O1
Operation OptiView Panel YK Style H 160.76-O2
Conditioned based maintenance
Traditional chiller maintenance is based upon assumed and generalized conditions. In lieu of
the traditional maintenance program, a Johnson Controls YORK Conditioned Based Maintenance
(CBM) program can be substituted. This CBM service plan is built around the specific needs for
the chiller, operating conditions, and annualized impact realized by the chiller. Your local Johnson
Controls Branch can propose a customized Planned Service Agreement that leverages real time
and historical data, delivering performance reporting, corrective actions required and data enabled
guidance for optimal operation and lifecycle assurance. The program will include fault detection
diagnostics, operation code statistics, performance based algorithms and advance rules based
rationale delivered by the Johnson Controls Connected Equipment Portal.
7Liquid-Cooled OptiSpeed Compressor Speed Drive

VSD models
Nomenclature, VSD models
Figure 1: Nomenclature, VSD models
W
VSD351_RK FT-
46
Voltage Rating: 40 = 400 VAC, 60 Hz
46 = 460 VAC, 60 Hz
50 = 400 VAC, 50 Hz
58 = 575 VAC, 60 Hz
68 = 415 VAC, 50 Hz
Optional 519: Filter-Installed (FT) or Not (_)
Chiller Type: YK (K), YT (T)
Horsepower Rating: 270, 292, 351, 385, 419, 424, 503, 608
Type of Drive
(W) Asia, (_) Global Design
Retrofit Package (R), Factory Package (_)
OptiSpeed™ model part numbers, VSD
The X in the part number below indicates which type of communications is used between the
Micropanel and the OSCD: 1 = YORK Protocol, 7 = MODBUS Protocol, 8 = MODBUS with CPC, W =
Asia (W in the 4th position taking place of the first hyphen in the part number).
Table 1: VSD part numbers and descriptions
Part number
Model 60 Hz 50 Hz Description
VSD270T-40 371-02767-X21 Factory Pack, YT Base Model
VSD270K-40 371-02767-X22 Factory Pack, YK Base Model
VSD270TFT-40 371-02767-X25 Factory Pack, YT Filter Model
VSD270KFT-40 371-02767-X26 Factory Pack, YK Filter Model
VSD270RT-40 371-02767-X31 Retrofit, YT Base Model
VSD270RK-40 371-02767-X32 Retrofit, YK Base Model
VSD270RTFT-40 371-02767-X35 Retrofit, YT Filter Model
270 HP
400 VAC
VSD270RKFT-40 371-02767-X36 Retrofit, YK Filter Model
VSD292T-50 371-03700-X01 Factory Pack, YT Base Model
VSD292K-50 371-03700-X02 Factory Pack, YK Base Model
VSD292TFT-50 371-03700-X05 Factory Pack, YT Filter Model
VSD292KFT-50 371-03700-X06 Factory Pack, YK Filter Model
VSD292RT-50 371-03700-X11 Retrofit, YT Base Model
VSD292RK-50 371-03700-X12 Retrofit, YK Base Model
VSD292RTFT-50 371-03700-X15 Retrofit, YT Filter Model
VSD292RKFT-50 371-03700-X16 Retrofit, YK Filter Model
W-VSD292K-50 371W06040-X02 Factory Pack, YK Base Model
292 HP
400 VAC
W-VSD292KFT-50 371W06040-X06 Factory Pack, YK Filter Model
Liquid-Cooled OptiSpeed Compressor Speed Drive8

Table 1: VSD part numbers and descriptions
Part number
Model 60 Hz 50 Hz Description
VSD292T-68 371-03700-X21 Factory Pack, YT Base Model
VSD292K-68 371-03700-X22 Factory Pack, YK Base Model
VSD292TFT-68 371-03700-X25 Factory Pack, YT Filter Model
VSD292KFT-68 371-03700-X26 Factory Pack, YK Filter Model
VSD292RT-68 371-03700-X31 Retrofit, YT Base Model
VSD292RK-68 371-03700-X32 Retrofit, YK Base Model
VSD292RTFT-68 371-03700-X35 Retrofit, YT Filter Model
VSD292RKFT-68 371-03700-X36 Retrofit, YK Filter Model
W-VSD292K-68 371W06040-X22 Factory Pack, YK Base Model
292 HP
415 VAC
W-VSD292KFT-68 371W06040-X26 Factory Pack, YK Filter Model
VSD351T-46 371-02767-X01 Factory Pack, YT Base Model
VSD351K-46 371-02767-X02 Factory Pack, YK Base Model
VSD351TFT-46 371-02767-X05 Factory Pack, YT Filter Model
VSD351KFT-46 371-02767-X06 Factory Pack, YK Filter Model
VSD351RT-46 371-02767-X11 Retrofit, YT Base Model
VSD351RK-46 371-02767-X12 Retrofit, YK Base Model
VSD351RTFT-46 371-02767-X15 Retrofit, YT Filter Model
351 HP
460 VAC
VSD351RKFT-46 371-02767-X16 Retrofit, YK Filter Model
VSD385T-40 371-03789-X21 Factory Pack, YT Base Model
VSD385K-40 371-03789-X22 Factory Pack, YK Base Model
VSD385TFT-40 371-03789-X23 Factory Pack, YT Filter Model
VSD385KFT-40 371-03789-X24 Factory Pack, YK Filter Model
VSD385RT-40 371-03789-X31 Retrofit, YT Base Model
VSD385RK-40 371-03789-X32 Retrofit, YK Base Model
VSD385RTFT-40 371-03789-X33 Retrofit, YT Filter Model
385 HP
400 VAC
VSD385RKFT-40 371-03789-X34 Retrofit, YK Filter Model
9Liquid-Cooled OptiSpeed Compressor Speed Drive

Table 1: VSD part numbers and descriptions
Part number
Model 60 Hz 50 Hz Description
VSD419T-50 371-03789-X05 Factory Pack, YT Base Model
VSD419K-50 371-03789-X06 Factory Pack, YK Base Model
VSD419TFT-50 371-03789-X07 Factory Pack, YT Filter Model
VSD419KFT-50 371-03789-X08 Factory Pack, YK Filter Model
VSD419RT-50 371-03789-X15 Retrofit, YT Base Model
VSD419RK-50 371-03789-X16 Retrofit, YK Base Model
VSD419RTFT-50 371-03789-X17 Retrofit, YT Filter Model
VSD419RKFT-50 371-03789-X18 Retrofit, YK Filter Model
W-VSD419K-50 371W06431-X06 Factory Pack, YK Base Model
W-VSD419KFT-50 371W06431-X08 Factory Pack, YK Filter Model
W-VSD419T-50 371-05395-X05 Factory Pack, YT Base Model
W-VSD419K-50 371-05395-X06 Factory Pack, YK Base Model
W-VSD419TFT-50 371-05395-X07 Factory Pack, YT Filter Model
W-VSD419KFT-50 371-05395-X08 Factory Pack, YK Filter Model
W-VSD419RT-50 371-05395-X15 Retrofit, YT Base Model
W-VSD419RK-50 371-05395-X16 Retrofit, YK Base Model
W-VSD419RTFT-50 371-05395-X17 Retrofit, YT Filter Model
419 HP
400 VAC
W-VSD419RKFT-50 371-05395-X18 Retrofit, YK Filter Model
VSD419T-68 371-03789-X25 Factory Pack, YT Base Model
VSD419K-68 371-03789-X26 Factory Pack, YK Base Model
VSD419TFT-68 371-03789-X27 Factory Pack, YT Filter Model
VSD419KFT-68 371-03789-X28 Factory Pack, YK Filter Model
VSD419RT-68 371-03789-X35 Retrofit, YT Base Model
VSD419RK-68 371-03789-X36 Retrofit, YK Base Model
VSD419RTFT-68 371-03789-X37 Retrofit, YT Filter Model
VSD419RKFT-68 371-03789-X38 Retrofit, YK Filter Model
W-VSD419K-68 371W06431-X26 Factory Pack, YK Base Model
419 HP
415 VAC
W-VSD419KFT-68 371W06431-X28 Factory Pack, YK Filter Model
VSD424T-58 371-04881-X01 Factory Pack, YT Base Model
VSD424K-58 371-04881-X02 Factory Pack, YK Base Model
VSD424TFT-58 371-04881-X03 Factory Pack, YT Filter Model
VSD424TFK-58 371-04881-X04 Factory Pack, YK Filter Model
VSD424RT-58 371-04881-X11 Retrofit, YT Base Model
VSD424RK-58 371-04881-X12 Retrofit, YK Base Model
VSD424RTFT-58 371-04881-X13 Retrofit, YT Filter Model
424 HP
575 VAC
VSD424RTFK-58 371-04881-X14 Retrofit, YK Filter Model
Liquid-Cooled OptiSpeed Compressor Speed Drive10

Table 1: VSD part numbers and descriptions
Part number
Model 60 Hz 50 Hz Description
VSD503T-46 371-03789-X01 Factory Pack, YT Base Model
VSD503K-46 371-03789-X02 Factory Pack, YK Base Model
VSD503TFT-46 371-03789-X03 Factory Pack, YT Filter Model
VSD503TFK-46 371-03789-X04 Factory Pack, YK Filter Model
VSD503RT-46 371-03789-X11 Retrofit, YT Base Model
VSD503RK-46 371-03789-X12 Retrofit, YK Base Model
VSD503RTFT-46 371-03789-X13 Retrofit, YT Filter Model
503 HP
460 VAC
VSD503RTFK-46 371-03789-X14 Retrofit, YK Filter Model
VSD608K-40 371-06982-X22 Factory Pack, YK Base Model
VSD608KFT-40 371-06982-X24 Factory Pack, YK Filter Model
VSD608RK-40 371-06982-X32 Retrofit, YK Base Model
608 HP
380 VAC
VSD608RKFT-40 371-06982-X34 Retrofit, YK Filter Model
VSD608K-42 371-06982-X46 Factory Pack, YK Base Model
VSD608KFT-42 371-06982-X48 Factory Pack, YK Filter Model
VSD608RK-42 371-06982-X56 Retrofit, YK Base Model
608 HP
400 VAC
VSD608RKFT-42 371-06982-X58 Retrofit, YK Filter Model
VSD608T-58 371-04563-X01 Factory Pack, YT Base Model
VSD608K-58 371-04563-X02 Factory Pack, YK Base Model
VSD608TFT-58 371-04563-X03 Factory Pack, YT Filter Model
VSD608KFT-58 371-04563-X04 Factory Pack, YK Filter Model
VSD608RT-58 371-04563-X11 Retrofit, YT Base Model
VSD608RK-58 371-04563-X12 Retrofit, YK Base Model
VSD608RTFT-58 371-04563-X13 Retrofit, YT Filter Model
608 HP
575 VAC
VSD608RKFT-58 371-04563-X14 Retrofit, YK Filter Model
VSD658K-50 371-06982-X06 Factory Pack, YK Base Model
VSD658KFT-50 371-06982-X08 Factory Pack, YK Filter Model
VSD658RK-50 371-06982-X16 Retrofit, YK Base Model
VSD658RKFT-50 371-06982-X18 Retrofit, YK Filter Model
W-VSD658K-50 371W06212-X02 Factory Pack, YK Base Model
658 HP
380 VAC
W-VSD658KFT-50 371W06212-X04 Factory Pack, YK Filter Model
VSD658K-43 371-06982-X62 Factory Pack, YK Base Model
VSD658KFT-43 371-06982-X64 Factory Pack, YK Filter Model
VSD658RK-43 371-06982-X72 Retrofit, YK Base Model
658 HP
400 VAC
VSD658RKFT-43 371-06982-X74 Retrofit, YK Filter Model
VSD704K-68 371-06982-X26 Factory Pack, YK Base Model
VSD704KFT-68 371-06982-X28 Factory Pack, YK Filter Model
VSD704RK-68 371-06982-X36 Retrofit, YK Base Model
VSD704RKFT-68 371-06982-X38 Retrofit, YK Filter Model
W-VSD704K-68 371W06212-X22 Factory Pack, YK Base Model
704 HP
415 VAC
W-VSD704KFT-68 371W06212-X24 Factory Pack, YK Filter Model
11Liquid-Cooled OptiSpeed Compressor Speed Drive

Table 1: VSD part numbers and descriptions
Part number
Model 60 Hz 50 Hz Description
VSD790K-46 371-06982-X02 Factory Pack, YK Base Model
VSD790KFT-46 371-06982-X04 Factory Pack, YK Filter Model
VSD790RK-46 371-06982-X12 Retrofit, YK Base Model
790 HP
460 VAC
VSD790RKFT-46 371-06982-X14 Retrofit, YK Filter Model
VSD868K-50 371-06863-X06 Factory Pack, YK Base Model
VSD868KFT-50 371-06863-X08 Factory Pack, YK Filter Model
VSD868RK-50 371-06863-X16 Retrofit, YK Base Model
868 HP
380 VAC
VSD868RKFT-50 371-06863-X18 Retrofit, YK Filter Model
VSD882K-40 371-06863-X22 Factory Pack, YK Base Model
VSD882KFT-40 371-06863-X24 Factory Pack, YK Filter Model
VSD882RK-40 371-06863-X32 Retrofit, YK Base Model
882 HP
380 VAC
VSD882RKFT-40 371-06863-X34 Retrofit, YK Filter Model
VSD914K-43 371-06863-X62 Factory Pack, YK Base Model
VSD914KFT-43 371-06863-X64 Factory Pack, YK Filter Model
VSD914RK-43 371-06863-X72 Retrofit, YK Base Model
914 HP
400 VAC
VSD914RKFT-43 371-06863-X74 Retrofit, YK Filter Model
VSD917K-42 371-06863-X46 Factory Pack, YK Base Model
VSD917KFT-42 371-06863-X48 Factory Pack, YK Filter Model
VSD917RK-42 371-06863-X56 Retrofit, YK Base Model
917 HP
400 VAC
VSD917RKFT-42 371-06863-X58 Retrofit, YK Filter Model
VSD948K-68 371-06863-X26 Factory Pack, YK Base Model
VSD948KFT-68 371-06863-X28 Factory Pack, YK Filter Model
VSD948RK-68 371-06863-X36 Retrofit, YK Base Model
948 HP
415 VAC
VSD948RKFT-68 371-06863-X38 Retrofit, YK Filter Model
VSD1055K-46 371-06863-X02 Factory Pack, YK Base Model
VSD1055KFT-46 371-06863-X04 Factory Pack, YK Filter Model
VSD1055RK-46 371-06863-X12 Retrofit, YK Base Model
1055 HP
460 VAC
VSD1055RKFT-46 371-06863-X14 Retrofit, YK Filter Model
Liquid-Cooled OptiSpeed Compressor Speed Drive12

LVD models
Nomenclature, LVD models
Figure 2: Nomenclature, LVD models
I II III IV V VI VII VIII IX X XI XII XIII XIV
LVD 0503 G R N01 K C 30 B 06 L Z - 46 A
I - Drive Type
LVD
(historical models)
VSD
TM
HYP
II - Horsepower and Amp Rating
(4 digits fixed length)
III - Design Center/Source
G = Global Design
W = Asia Design
T = Toshiba
B = Benshaw
IV - VSD Mounting Method
X = Unit Mount (Factory Pack)
R = Remote Mount (Floor Standing)
V - Enclosure Type Rating
N01 = NEMA 1
N04 = NEMA4
N3R = NEMA 3R
I33 = IP33
*** = Not yet defined
VI - Chiller Type
H = YMC2 (YH)
K = YK
T = YT
VII - Chiller Cooling Method/VSD Cooling
Medium
C = Condenser liquid cooled / water
E = Evaporator liquid cooled / water
D = Condenser liquid cooled / glycol
F = Evaporator liquid cooled / glycol
B = Air cooled / glycol
A = Air cooled / air
R = Refrigerant / refrigerant
* = Not yet defined
VIII - Liquid DWP
15 = 150 psig
30 = 300 psig
* = Not yet defined
IX - Input Connection
D = Disconnect Switch
B = Circuit Breaker
T = Terminal Block
* = Not yet defined
X - Input Connection Rating
04 = 400 A
06 = 600 A
08 = 800 A
10 = 1000 A
12 = 1200 A
00 = None (terminal block)
* = Not yet defined
XI - Code Agency Approval
L = cUL/cETL
C = CE
G =GB
Q = Special
X = None
XII - Harmonic Mitigation
F = Filter Model
Z = Base Model
A = Active Front End Model
XIII - Input Voltage/Frequency
(Per M-527)
40 = 380/400 V 60 Hz
50 = 380/400 V 50 Hz
42 = 400 V 60 Hz
46 = 460 V 60 Hz
68 = 415 V 50 Hz
58 = 575 V 60 Hz
XIV - Product Mod Level Suffix
A = Mod Level "A"
B = Mod Level "B"
13Liquid-Cooled OptiSpeed Compressor Speed Drive

OptiSpeed™ model part numbers, LVD
The X in the part number below indicates which type of communications is used between the
Micropanel and the OSCD: 1 = YORK Protocol, 7 = MODBUS Protocol, 8 = MODBUS w/ CPC, W = Asia
(4th position taking place of the first hyphen in the part number).
Table 2: LVD part numbers and descriptions
Model number Part number Description
270 HP – 60 HZ, 380 – 400 VAC LVD0270GXN01KC30B04LZ-40A 371-06976-X22 Factory Pack, YK Chiller
270 HP – 60 HZ, 400 VAC LVD0270GXN01KC30B04LZ-42A 371-06976-X46 Factory Pack, YK Chiller (Saudi)
292 HP – 50 HZ, 400 VAC LVD0292WXI22KC30B04GZ-50A 371W06640-X02 Factory Pack, YK Chiller
292 HP – 50 HZ, 380 – 400 VAC LVD0292GXN01KC30B04LZ-50A 371-06976-X06 Factory Pack, YK Chiller
292 HP – 50 HZ, 415 VAC LVD0292WXI22KC30B04GZ-68A 371W06640-X22 Factory Pack, YK Chiller
292 HP – 50 HZ, 415 VAC LVD0292GXN01KC30B04LZ-68A 371-06976-X26 Factory Pack, YK Chiller
351 HP – 60 HZ, 460 VAC LVD0315GXN01KC30B04LZ-46A 371-06976-X02 Factory Pack, YK Chiller
385 HP – 60 HZ, 380 – 400 VAC LVD0385GXN01KC30B06LZ-40A 371-06697-X22 Factory Pack, YK Chiller
385 HP – 60 HZ, 400 VAC LVD0385GXN01KC30B06LZ-42A 371-06697-X46 Factory Pack, YK Chiller
419 HP – 50 HZ, 380 – 400 VAC LVD0419GXN01KC30B06LZ-50A 371-06697-X06 Factory Pack, YK Chiller
419 HP – 50 HZ, 400 VAC LVD0419WXI22KC30B06GZ-50A 371W06642-X06 Factory Pack, YK Chiller
419 HP – 50 HZ, 415 VAC LVD0419WXI22KC30B06GZ-68A 371W06642-X26 Factory Pack, YK Chiller
419 HP – 50 HZ, 415 VAC LVD0419GXN01KC30B06LZ-68A 371-06697-X26 Factory Pack, YK Chiller
424 HP – 60 HZ, 575 VAC LVD0424GXN01KC30B04LZ-58A 371-06976-X42 Factory Pack, YK Chiller
503 HP – 60 HZ, 460 VAC LVD0503GXN01KC30B06LZ-46A 371-06697-X02 Factory Pack, YK Chiller
608 HP – 60 HZ, 575 VAC LVD0608GXN01KC30B06LZ-58A 371-06697-X42 Factory Pack, YK Chiller
658 HP – 50 HZ, 400 VAC LVD0658WXI22KC30B10GZ-50A 371W06644-X02 Factory Pack, YK Chiller
704 HP – 50 HZ, 415 VAC LVD0704WXI22KC30B10GZ-68A 371W06644-X22 Factory Pack, YK Chiller
900 HP – 50 HZ, 400 VAC LVD0900WXI22KC30B12GZ-50A 371W06646-X02 Factory Pack, YK Chiller
900 HP – 50 HZ, 415 VAC LVD0900WXI22KC30B12GZ-68A 371W06646-X22 Factory Pack, YK Chiller
Liquid-Cooled OptiSpeed Compressor Speed Drive14

General information
This instruction is to be used in conjunction with the Operation Instructions for YORK Centrifugal
chillers furnished with an optional YORK® OptiSpeed™ Compressor Drive (OSCD).
OptiSpeed/Harmonic filter component overview
OptiSpeed compressor drive 270, 292, 351, and 424 hp (low horsepower
model)
The OSCD is a liquid cooled, transistorized, pulse- width modulation (PWM) inverter in a highly
integrated package. This package is small enough to mount directly onto the chiller motor, and
small enough to be applied in many retrofit chiller applications. The power section of the drive is
composed of four major blocks: an AC to DC rectifier section with an integrated precharge circuit, a
DC bus filter section, a three-phase DC to AC inverter section and an output suppression network.
An electronic circuit breaker with ground fault sensing connects the AC line to an AC line inductor
and then to the DC converter. The line inductor will limit the amount of fault current so that the
electronic circuit breaker is sufficient for protecting the OSCD. Input fuses to the OSCD are no
longer needed. The following description of operation is specific for the 351 hp OSCD unless
otherwise noted.
The AC to DC converter uses three Silicon Controlled Rectifiers (SCRs) and three diodes. One SCR
and one diode are contained in each module. Three modules are required to converter the three-
phase input AC voltage into DC voltage. The modules are mounted on the bot- tom of the liquid
cooled heatsink.
The use of the SCRs in the converter permits precharge of the DC bus capacitors when the chiller
enters the prelube cycle. It also provides a fast disconnect from the AC line when the chiller
enters the coastdown cycle. At this time, the OSCD is turned off, the SCRs in the converter are no
longer turned on and remain in a turned off condition until the next precharge cycle. The DC bus
capacitors will start to discharge through the bleeder resistors. When the chiller enters the pre-lube
cycle, the OSCD is commanded to precharge and the SCRs are gradually turned on to slowly charge
the DC bus capacitors. This is called the precharge period, which last for 20 seconds. At this time the
SCRs are fully turned on. The SCR Trigger board provides the turn on commands for the SCRs. The
OSCD Logic board provides the command to the SCR trigger board when to precharge.
WARNING
Although many of these parts are similar to the parts used in previous Variable Speed Drive (VSD)
designs, these parts are only compatible with drives having the base part numbers included on
the cover of this form. Failure to use the correct parts may cause major damage to these and other
components in the drive.
For example, the VSD logic board 031-02077-000 used in this drive is not compatible with 031-01433-000
logic board used in previous designs. A new VSD logic board was designed in 2006. The part number
of the new board is 031-02506-002. The part number of the new board for the 575 VAC application
is 031-02506-003. The software is not interchangeable between the 575 VAC version and all other
applications. Also the software is not interchangeable be- tween the 031-01433, 031-02077, or the
031-02506 boards.
The DC Bus filter section of the drive consists of one basic component, a series of electrolytic
filter capacitors. The capacitors provide a large energy reservoir for use by the DC to AC inverter
section of the OSCD. The capacitors are contained in the OSCD Power Unit. “Bleeder” resistors are
15Liquid-Cooled OptiSpeed Compressor Speed Drive

mounted on the side of the Power Unit to provide a discharge path for the stored energy in the
capacitors.
The DC to AC inverter section of the OSCD serves to convert the DC voltage to AC voltage at the
proper magnitude and frequency as commanded by the OSCD Logic board. The inverter section is
actually composed of one power unit. This power unit contains one very fast switching transistor
module mounted on the same liquid cooled heatsink as the converter modules, the DC Bus
capacitors, and an OSCD Gate Driver board. The gate driver board provides the turn on and turn
off commands to the output transistors. The OSCD Logic board determines when the turn on and
turn off commands should occur. The gate driver board is mounted directly on top of the transistor
module, and it is held in place with mounting screws and soldered to the transistor module.
The OSCD output suppression network is composed of a series of capacitors and resistors. The job
of the suppressor network is to increase the time it takes for the output voltage to switch as seen
by the motor, and reduce the peak voltage applied to the motor windings. This network protects
the compressor motor from problems commonly associated with PWM motor drives.
Other sensors and boards are used to provide safe operation of the OSCD. The transistor module
and heatsink have thermistors mounted on them to provide temperature information to the OSCD
logic board. These sensors protect the OSCD from over temperature conditions. A Bus Voltage
Isolator board is used to ensure that the DC bus capacitors are properly charged. Three output
current transformers protect the OSCD and motor from over current conditions.
OSCD 385, 419, 503, 608, 658, 704, 790, 868, 882, 914, 917, 948, and 1055 hp
(high horsepower model)
The high horsepower models' OSCDs function in the same manner as the low horsepower models,
and have the same basic components. The power requirements of these high horsepower drives
require more capacitors in the DC Bus and 3-output transistor sections are needed. One section is
used for each output phase. Each transistor module within the output transistor section contains a
thermistor, which is connected to the OSCD logic board. The transistor gate driver board is mount-
ed on top of the transistor section in the same manner as the low horsepower model, but it only
contains two transistor drivers. The modules and gate driver boards are not interchangeable
between the various models.
Harmonic filter option
The VSD model of OSCD system may also include an optional harmonic filter and high frequency
trap designed to meet the IEEE Std 519, IEEE Recommended Practices and Requirements for Harmonic
Control in Electrical Power Systems. The harmonic filter is offered as a method to improve the input
current wave- form drawn by the OSCD from the AC line. In this way, it reduces the possibility of
causing electrical interference with other sensitive electronic equipment connected to the same
power source. An additional benefit of the optional harmonic filter is that it will correct the system
power factor to nearly unity.
The power section of the Harmonic Filter is composed of three major blocks: a precharge section, a
three-phase inductor, and a Filter Power Unit.
The precharge section contains precharge resistors, a precharge contactor, and a supply contactor.
The pre-charge network serves two purposes, to slowly charge the DC bus capacitors associated
with the Filter Power Unit, and to provide a means of disconnecting the filter power unit from the
AC line. When the chiller is turned off, both contactors are de-energized and the filter power unit is
disconnected from the AC line. When the chiller starts to run, the precharge resistors are switched
into the circuit by the precharge contactor for a fixed time period of 5 seconds. This permits the
filter capacitors in the filter power unit to slowly charge. After the 5-second time period, the supply
contactor is energized and the precharge contactor is de-energized, permitting the filter power
unit to completely charge. Three power fuses connect the filter power components to the AC line.
Very fast semiconductor power fuses are used to quickly disconnect the transistor module from the
power source if a catastrophic failure were to occur on the DC bus of the filter power unit.
Liquid-Cooled OptiSpeed Compressor Speed Drive16

The three-phase inductor provides some impedance for the filter to “work against”. It effectively
limits the rate of change in current at the input to the filter to a reason- able level.
The Filter Power Unit is the most complicated power component in the optional filter. Its purpose
is to generate the harmonic currents required by the OSCD’s AC-to-DC converter so that these
harmonic currents are not drawn from the AC line. The Filter Power Unit is identical to the OSCD's
Power Unit in the 351 hp drive, except for two fewer capacitors in the filter capacitor “bank”, and
a smaller transistor module and modified gate driver board. The Harmonic Filter Gate Driver
board provides turn on and turn off commands as determined by the Harmonic Filter Logic board.
“Bleeder” resistors are mounted on the side of the Filter Power Unit to provide a discharge path for
the DC bus capacitors.
Other sensors and boards are used to provide safe operation of the harmonic filter. The transistor
module contains a temperature sensor that provides temperature information back to the Filter
Logic Board. This sensor protects the filter transistor module from over temperature conditions.
A Bus Isolator board is used to ensure that the DC bus capacitors are properly charged and the
voltage is balanced. Two output current sensors are used to protect the filter against an over
current or an overload condition. Input current transformers sense the input current drawn by the
OSCD’s AC to DC converter. The Line Voltage Isolation board provides AC line voltage information
to the Harmonic Filter Logic board. This information is used to determine the proper bus voltage
value.
The “trap” filter is standard on all OSCD's that contain an optional Harmonic Filter. The “trap” filter
is composed of a series of capacitors, inductors, and resistors. The “trap” filter is used to reduce the
effects of the PWM switching frequency of the filter on the power source.
Differences between the G and W designs
The drive model number nomenclature has two different letters for the design center of the drive.
The G for the design center is a drive that is designed to the UL and CE requirements. The W for the
design center is a drive that is designed to standards that govern products built for the Asia market.
The way the drive functions, protects itself, and the motor are the same for both designs. The W
design takes advantage of local components, and local manufacturing. The cooling system is the
area where most of the changes occur and only effect the 50 Hz application. The W design solves
the problem of reduce cooling because of 50 Hz power by using a large cooling fan and a different
cooling pump. The cooling fan and pump require a 230 VAC 50 Hz source. This higher power source
allows the fan and pump to provide the same amount of cooling as the 60 Hz application. The
230 VAC source is provided by an additional voltage tap from the control transformer. This new
transformer provides the voltage required for the 230 VAC and 120 VAC components.
Differences for the VSD and LVD model drives
The VSD model drives are designed so that the harmonic filter system can be included in the
drive enclosure. The VSD model also contains the control wiring, additional cooling capacity, and
precharge resistors for the harmonic filter system, regardless if the harmonic filter system is
installed or not. This process allowed for an easier method to retrofit the harmonic filter system
later if the customer desired. The LVD model does not contain any support for the harmonic filter
system. The enclosure size is reduced, and the harmonic filter cannot be added as an option later.
The function of the drive is identical between the two designs.
OptiSpeed compressor drive control system overview
The OSCD control system can be connected to a Microcomputer Control Center or to an OptiView
Control Center. Regardless of which control center is used each component performs the same
function.
17Liquid-Cooled OptiSpeed Compressor Speed Drive

The OSCD control system is composed of various components located within both the Control
Center and the OSCD. In this way, the Control Center integrates with the OSCD. The OSCD system
uses various microprocessors, which are linked together through a network of communications
links.
The Control Center before 2005
The Control Center contains two boards that act upon OSCD related information, the Microboard
and the Adaptive Capacity Control board (ACC). The ACC board performs two major functions in the
OSCD control system:
• To act as a gateway for information flow between the Control Center and the OSCD
• To determine the optimum operating speed for maximum chiller system efficiency
The ACC board acts as an information gateway for all data flowing between the OSCD and the
Control Center. The ACC board has a communication link to the OSCD logic board, and one
communication link from the optional Harmonic Filter logic board. When the ACC board receives
the information, the information is passed onto the Control Center by a software communication
link. The Microcomputer Control Center communicates in a parallel fashion through two ribbon
cables connecting the ACC board to the Microboard. The OptiView™ Control Center communicates
through communications port through a bidirectional serial port through a three-wire cable that
connects the ACC board to the Microboard.
To achieve the most efficient operation of a centrifugal compressor, the speed of the compressor
must be reduced to match the lift or head of the load. This lift or head is determined by the
evaporator and condenser refrigerant pressures. However, if the compressor speed is reduced
too much, the refrigerant gas will flow backwards through the compressor wheel causing the
compressor to surge, which is an undesirable and extremely inefficient operating condition. As
a result, one particular optimum operating speed exists (on the edge of surge) for a given head,
which provides the optimum system efficiency.
The compressor’s inlet guide vanes, which are used in fixed speed applications to control the
amount of refrigerant gas flowing through the compressor, are controlled together with the
compressor speed on an OSCD chiller system to obtain the required chilled liquid temperature
while simultaneously requiring minimum power from the AC line.
The ACC board automatically generates its own “Adaptive”three-dimensional surge surface map
while the chiller system is in operation. This “Adaptive” operation is accomplished through the
use of a patented surge detection algorithm. The novel surge detection system uses pressure
information obtained from the chiller’s two pressure transducers or the OSCD’s instantaneous
power output to determine if the system is in surge. The adaptive system permits construction of
a customized compressor map for each individual chiller system. The benefits of this new adaptive
system include the following:
• A customized compressor map for each chiller that eliminates inefficient operation due to the
safety margin built into the previous designs to compensate for compressor manufacturing
tolerances
• The ability to update the system’s surge surface as the unit ages
• Automatic updating of the compressor map if changes in refrigerant are implemented at a
later date
The Control Center beginning in 2005
A major change in the control system took place in 2005. Several redesigns took place in the
OptiView panel and the OSCD. The redesign replaced microprocessors that were becoming
obsolete. This was a time to take advantage of new components that were now available. An
additional communications port was added so that the communications between the microboard
Liquid-Cooled OptiSpeed Compressor Speed Drive18

and the OSCD logic board is faster. In the changes to the microboard the function of the Adaptive
Capacity Board was placed into the microboard, and the ACC board was longer needed in new
production. The new microboard is also compatible with the older designs microboards used in the
OptiView panel. The new OSCD logic also added this new communication port, but also retained all
of the functions required to still communicate with the ACC board.
OptiSpeed and optional harmonic filter logic control boards
Within the enclosure of the VSD model drive, the OSCD logic board and optional Harmonic Filter
logic board are interconnected by a 16-position ribbon cable. This cable provides power for the
Filter logic board and a method of communications between the two boards.
The OSCD Logic board performs numerous functions, control of the OSCD’s cooling fans and
pumps, when to precharge the bus capacitors, and generates the PWM.
The OSCD Logic board also determines shutdown conditions by monitoring the three phases of
motor current, heatsink temperature, baseplate temperature, internal ambient temperature, and
the DC bus voltage.
The optional Harmonic Filter logic board determines when to precharge the harmonic filter power
unit, when to switch the transistors in the harmonic filter power unit, and collects data to determine
power calculations. This board also uses this data to determine shutdown conditions.
Microcomputer control panel VSD related keypad functions
Refer to 160.00-M4 for related keypad functions. Some of the displayed data in this form is different
from the 160.00-M1. Under the Options Key – the following changes will be displayed:
• VSD PHASE A INVERTER HEATSINK TEMP = °F.
• VSD PHASE B INVERTER HEATSINK TEMP = °F.
• VSD PHASE C INVERTER HEATSINK TEMP = °F.
These three temperature values are replaced with:
• VSD BASEPLATE TEMP = °F
For the low horsepower model drives. The high horsepower model drives will display three phases
of Baseplate temperature. When the Filter is present, the following data will change from:
• FILTER HEATSINK TEMP = °F.
This temperature data will now be called:
• FILTER BASEPLATE TEMP = °F.
The names for the above data were changed because the temperature sensor is now inside the
transistor module instead of the chill plate where the transistor modules are mounted. This new
sensor gives a better indication of true temperature of the power electronics.
OptiView control panel VSD functions
Refer to the specific OptiView™ Control Panel operations manual for detailed information. All of the
OSCD related information is contained under the Motor and Compressor Screens.
VSD adaptive capacity control
The YORK OSCD uses a different approach to speed reduction compared to earlier variable
speed products. There is no longer a pre-programmed surge map – the YORK® adaptive system
experiments with the speed and vanes to find the optimum speed for any given condition. It does
not always encounter a surge in the process, but when it does, the Adaptive Capacity Control (ACC)
19Liquid-Cooled OptiSpeed Compressor Speed Drive

stores the conditions surrounding the surge into memory, so that it can avoid the stored operating
point anytime in the future.
Early versions of the ACC software required that the drive always start and run up to full speed. ACC
software starting with version C.ACC.01.04 applies anew slow ramp up of the drive speed. This new
software lowers the peak current demand from the drive during start up, saves additional energy,
and reduces the possibility of the chiller running in a stall condition.
The new software will quickly ramp the compressor speed up to 1/2 speed, and then it takes 5
minutes to ramp up to full speed. During this slow ramp up period the vanes will open to meet
the cooling demand. If the leaving chilled liquid temperature is within +0.5 or lower of the leaving
chilled liquid temperature setpoint, then the drive speed will stop increasing the RPM of the
compressor motor, and start to search for a surge map point. On extremely hot days the chiller
may surge during the slow ramp period. The new software has a method to limit the surging. If two
surges were to occur during the slow ramp period, then the speed of the drive will increase to full
speed.
Now that the ACC function is provided by the microboard in the OptiView panel future control
changes will be covered by the operation manual for the chiller model of interest. All versions of
software require two conditions to be met for speed reduction to occur. These two conditions are:
Setpoint requirements
The leaving chilled liquid temperature must be within +0.5°F or lower from the leaving chilled liquid
temperature setpoint. A programmable value is now available through the OptiView panel on
software versions C.OPT.01.21.307 for the YK chiller. This programmable value is not available on
the YT chiller. Speed reduction will not occur until the leaving chilled liquid temperature reaches
this range.
Stability requirements
The leaving chilled liquid temperature must be stable. Lack of stability will be indicative of the
vanes hunting, the leaving chilled liquid temperature varying, and the green LED on the ACC will be
on. Once the above conditions are met, the ACC may begin to lower the speed of the compressor
motor 1/10 of a hertz at a time. As the ACC lowers the speed, the leaving chilled liquid temperature
will begin to creep up. As this occurs, the control center will begin to open the vanes slightly, just
enough to maintain the leaving chilled liquid temperature within +/- 0.5°F of the leaving chilled
liquid temperature setpoint. The ACC will continue to lower speed, with the leaving chilled liquid
temperature control in turn driving the vanes to a more open position. This process will continue
until one of three following situations occur. This setting is no longer available after software
version C.OPT.01.21.307 for the YK chiller.
Full open vane operation
Once the vanes reach the full open position, the ACC knows it can no longer reduce speed and
maintain the leaving chilled liquid temperature setpoint. The ACC will maintain operation at this
point, with the vanes full open, and the speed at the last point reached when the vanes hit 100%. If
there is an increase in load while at this point, the ACC will increase speed until the vanes are closed
to 95% of open. The ACC will then be allowed to continue to reduce speed again.
Effects of surge
If in the process of reducing speed and opening vanes the compressor should surge, the ACC will
boost the speed up by 0.8 Hz. The ACC will store in memory a value that represents the ratio of
condenser pressure to evaporator pressure, the vane position, and the speed of the drive. The ratio
of condenser pressure to evaporator pressure is displayed as Delta P/P on the Control Panel.
The ACC will then know not to reduce speed this low again, if the same delta pressure, and the vane
position conditions are encounter again in the future. As the chiller encounters various conditions,
which result in surge, it will store more points, and eventually this storing of points creates a “Surge
Liquid-Cooled OptiSpeed Compressor Speed Drive20